engine LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Engine - I6 3.2L Petrol - Engine
Removal
Special T ool(s)
205-857Remover, Halfs haft
General Equipment
Powert rai n Jack
• NOTE: In t hi s procedure t he engi ne and t rans mis s ion are removed t oget her.
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
2.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - I6 3.2L Pet rol (501-05 Int eri or Trim andOrnament ati on, Removal and Ins tal lat ion).
3.
Remove t he plenum box acces s panel.
Refer t o: Plenum Chamber (412-01 Cl imat e Control, Removal andInst all at ion).
4.
Remove t he bat t ery t ray.
Refer t o: Bat t ery Tray (414-01 Bat tery, Mount ing and Cables ,Removal and Ins tall ati on).
5.
Remove t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -I6 3.2L Pet rol, Removal and Ins t al lat ion).
6.
Drai n t he cool ant .
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03AEngine Cooli ng - I6 3.2L Petrol, General Procedures).
7.
Remove t he s tart er mot or.
Refer t o: Start er Motor (303-06A Starti ng Sys t em - I6 3.2L Pet rol ,Removal and Ins tall ati on).
8.
Remove t he cat alyti c convert ers .
Refer t o: Cat alyt ic Converter (309-00A Exhaus t Syst em - I6 3.2LPetrol, Removal and Ins tall ati on).
9.Remove t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2LPetrol, Removal and Ins tall ati on).
10.Remove t he front subframe as s embly.
Refer t o: Front Subframe (502-00 Uni -Body, Subframe and Mount ing
11.

Di sconnect t he engi ne wiring harnes s .33.
LH s i de: Releas e 4 engine compartment ground cables .34.
Releas e t he cl ip and di s connect t he purge l ine.35.

Support the engi ne.
General Equi pment: Powert rai n Jack
39.
40. W ARNING: Make sure t hat new nut s arei ns t alled.
Remove t he LH engine mount bracket .
40.
Remove t he LH engine mount.41.

RH si de: Rel eas e t he engine mount .42.
W it h ass i st ance, careful ly remove the engi ne andt rans mis s ion.43.

Publi s hed: 11-May-2011
Engine - I6 3.2L Petrol - Engine
Installation
General Equipment Powert rai n Jack W it h ass i st ance, careful ly i nst all t he engi ne and
t rans mis s ion.
General Equi pment: Powert rai n Jack 1.
RH si de: Ins tall t he engine mount .
T orque: 80 Nm 2.
Inst all t he LH engine mount.
T orque: 175 Nm 3.
Inst all t he bracket .
T orque: M12 80 Nm M8
25 Nm 4.
Remove t he engi ne s upport .
5.
Connect t he bulkhead heat er hos es.
6.
7. CAUTIONS: Make s ure that t he component is cl ean, free of foreign
mat eri al and l ubricant. Make s ure that new bolt s are ins t al led.
Inst all t he dri ves haft .
7.

Secure t he A/C and power s t eering l ines .
24.
Inst all t he A/C compress or.
T orque: 25 Nm 25.
Inst all t he A/C compress or, upper s upport bracket.
T orque: M10 45 Nm M8
25 Nm M6
10 Nm 26.
Inst all t he A/C compress or, l ower support bracket.
T orque: 25 Nm 27.
Connect t he brake boost er vacuum hos e.
28.
Connect t he ECM elect rical connectors .
29.
Inst all t he s tart er mot or.
Refer t o: Start er Motor (303-06A Starti ng Sys t em - I6 3.2L Pet rol ,
Removal and Ins tall ati on).
30.
Remove t he front subframe as s embly.
Refer t o: Front Subframe (502-00 Uni -Body, Subframe and Mount ing
Syst em, Removal and Ins tall ati on).
31.
Inst all t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01B Engine - TD4 2.2L
Di es el, Removal and Ins tal lat ion).
32.
Remove t he cat alyti c convert ers .
Refer t o: Cat alyt ic Converter (309-00A Exhaus t Syst em - I6 3.2L
Petrol, Removal and Ins tall ati on).
33.
Refi ll and bleed t he cool ing s ys tem.
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03A
Engine Cooli ng - I6 3.2L Petrol, General Procedures).
34.
Inst all t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12B Intake Ai r Dis tribut ion and Fil tering -
TD4 2.2L Dies el, Removal and Inst all ati on).
35.
Remove t he bat t ery t ray.
Refer t o: Bat t ery Tray (414-01 Bat tery, Mount ing and Cables ,
Removal and Ins tall ati on).
36.
Remove t he plenum box acces s panel.
Refer t o: Plenum Chamber (412-01 Cl imat e Control, Removal and
Inst all at ion).
37.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel -
Lubricants, Fluids, Sealers and AdhesivesDescriptionDescription and part number.
‘T’ joi nts - ladder frame to engi ne blocks ealantThree bond TB 1215J
Oi l pan to bl ock s ealantThree bond TB 1215J
Cams haft l adder s eal antLocti te 518 (8510302)
Engine Oi lSAE 5W -30 oils conforming to Ford W SS-M2C13B specificat ion or ACEA A1 orB1
C apacities
ItemCapacity (liters/pints/US quarts)
Dry fi ll i ncludi ng fi lt er6.5/11.4/6.7Service fil l5.9/10.4/6.2
Amount of oil required t o bri ng level from t he lower t o t he upper mark on t he dips tick1.5/2.6/1.6
C ylinder Head Gasket Selection
Piston ProtusionT hickness of Compressed GasketNumber of holes at ' a'Number of holes at 'b'0.55 to 0.60 mm1.25 ± 0.04 mm11
0.61 to 0.65 mm1.30 ± 0.04 mm22
0.66 to 0.70 mm1.35 ± 0.04 mm330.71 to 0.75 mm1.40 ± 0.04 mm44
'a' and 'b' = Thi ckness identi fi cat ion
General Specification
ItemSpecificationType2.2 l it re, i nl ine 4, t urbocharged and int ercool ed dies el engine, t win overheadcamshaft , 4 valves per cyl inder
Cyli nder arrangementInl ine 4Cyli nder numberi ngNo.1 from gearbox end
Bore - nominal85.0 mm (3.346 i n)
St roke96.0 mm (3.779 i n)Capaci ty2179 cm³ (132.9 in³)
Firing order1 - 3 - 4 - 2
Compres s ion rati o16.6:1Di recti on of rotat ionClockwi s e viewed at FEAD
Maximum permi s sable cyl inder headwarp0.03mm (0.00118 i n)
Maximum pow er
All markets except Bel gi um118 kW (160 ps ) @ 4000rpmBelgi um s peci fi cat ion110 kW (150 ps ) @ 4000rpm
Maximum t orque400 Nm (295 l b-ft ) @ 2000rpm
Engine oil pressure*:At 1750 rev/min1.6 bar/160 kPa/23 l b/i n²
At 4000 rev/min3.1 bar/310 kPa/45 l b/i n²
Balance shaft to crankshaftclearance**:
Mi ni mum0.01mm
Maximum0.07mm* Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometres) must be carried out. Do notattempt to attain normal engine operating temperature by allowing the engine to idle.
**If the backlash betw een the balance shaft and crankshaft is less than 0.01 mm or greater than 0.07 mm then thebalance shaft assembly must be replaced.
Torque SpecificationsDescriptionNmlb-ft
Acces s ory drive belt i dler bol t4835
Acces s ory drive belt t ensi oner bolt4835Camshaft pulley bolt
St age 12015
St age 260°60°Cams haft t imi ng belt cover bolt s65
Cams haft t imi ng chai n t ens ioner bolt s75
Crankshaft pulley bolt:St age 17052
St age 260°60°
Cranks haft rear s eal retai ner pl at e97Coolant outl et el bow97
Cyli nder head bolt sAA
Di ps t ick t ube bol t107Engine i ns ulat or lower11081
Engine i ns ulat or lower heat s hiel d107
Engine i ns ulat or lower li nk bracket s11081Engine i ns ulat or upper11081

DescriptionNmlb-ft
Engine mount bracket LH:
M8*2518M12*8059
Engine mount bracket RH:
M12*8059M14*175129
Engine mount LH bolt175129
Engine mount RH bol ts8059Flywheel bol tsAA
Fuel i njector wi ri ng harness bol t107
Fuel fil ter bracket bol ts2518Intake manifold runner control (IMRC) act uat or bol t107
Intake manifold adaptor and t hrot tl e hous i ng bol t65
Intake manifold bol ts97Lifti ng bracket s107
Oi l cooler brackets107
Oi l cooler t o cyl inder block bol ts2015Oi l fil ler t ube97
Oi l pan drain pl ug2015
Oi l pan bol ts97Oil pan extension panel:
St age 1107
St age 21612Oil pump bolts:97
St age 175
St age 297Oi l separat or bol ts75
Oi l level s ensor86
Pis t on cool ing jet bol t107Timing belt t ensi oner bolt2518
Timing belt i dler pulley bol t6044
Timing belt rear cover64Valve cover bol ts107
Vacuum pump bolt s97
* New nuts/bolts must be fitted
A = refer to procedure for correct torque sequence

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Engine
Des cript ion and Operat ion
EXTERNAL VIEW
OVERVIEW
• NOTE: Freelander 2 feat ures a new TD4 dies el engine. This TD4 di esel engine i s not previousl y us ed by Land Rover, andmus t not be mis t aken for the Td4 di esel engine us ed wi th t he previ ous Freel ander model.
The new TD4 di es el engi ne may al so be referred to, and appear i n t ext as t he 2.2L Duratorq-TDCi (DW ) engi ne.
The TD4 dies el engi ne is a 2.2 l it er in-line 4 cyl inder as s embly, compri si ng a Double O verhead Cams haft (DOHC)arrangement t hat operat es 4 valves per cyl inder. The valves are operat ed by roller-type fi nger rockers and hydraul ic l as hadjus ters. Ai r and dies el fuel are deli vered to the cyli nders wit h an el ect ronic cont roll ed Vari abl e Geometry Turbine (VGT)t urbocharger, and Bos ch Generati on 3 common rail fuel s ys tem.
Engi ne operati on is monit ored, and opt imum performance is achieved wi th an electronic engi ne management s ys tem andBosch Engine Cont rol Module (ECM).
The engi ne is a compact unit t hat occupies mi nimal s pace, and is des igned t o reduce produced levels of Nois e, Vibrat ionand Hars hness (NVH). The reduced engine si ze allows the vehicle to achieve high level s of pedes t ri an protect ion, and meett he st andards for hi gh-s peed cras h performance.
Engi ne cons t ructi on is formed wit h a preci s ion machined, cas t-alumi num all oy cyl inder head and a lami nat ed met al gas ket,

s ecurel y bolt ed to the top of a machined cas t-iron cyl inder block. The cylinder head provides t he locati on for t he 16 valves(4 per combus ti on chamber), valve operat ing gear, cams haft s and ti ming gear, fuel inject ors and glow plugs. Dril li ngs andgalleries are formed wi thi n the cyli nder head t o provide lubri cat ing oi l and coolant fl ow.
The cyl inder head is formed wit h the cams haft l ower bearing cap cas t ings , and is enclos ed by a mat ing s t ructural cams haftcover wi th s eali ng gasket. The cams haft cover i s formed wi th the cams haft upper beari ng cap cas t ings , intake ai r fil li ngt racts , and port s for t he cyl inder head cover, crankcas e venti lat ion component s.
An 'L' s haped cyli nder head cover enclos es the s t ructural cams haft cover openings, and i ncorporates t he Posi ti ve Crankcas eVenti lati on Valve (PCV), s afet y val ve and crankcas e vent il ati on connecti ons .
An acous t ic engine cover i s i ns t alled above t he engi ne, and compris es a polypropylene foam layer adhered to theunders ide of a t hermo-plas ti c cover. The cover i s t uned t o abs orb and reduce engine produced nois e t o accept abl e NVHlevels . A hole formed in the rear Left-hand (LH) s ide of t he engine cover provi des the l ocat ion for the engine oi l fil ler cap.
The cyl inder block provides t he locat ion for t he cranks haft and beari ngs , oil cooling jet s, reci procat ing component s , and thecount er-bal ance s haft hous ing. Galleries and drill ings are formed in the cyli nder block for lubri cat ing oi l and coolant fl ow. Acount er-bal ance s haft hous ing i s bolt ed to the unders ide of t he cylinder block and is gear dri ven by the cranks haft . Thecount er-bal ance s haft as s embly reduces engine NVH to provi de a s moot h power out put .
An aluminum oi l pan hous ing and a pres sed st eel oi l pan are s ecured t o t he bot t om of t he cyl inder bl ock. The oil panhous i ng is s ealed and bol ted di rectl y to the cyli nder block. The oil pan is sealed wit h li qui d s ealant and att ached t o t he oilpan hous i ng to provide t he lubricat ion sys tem res ervoir. The lubricat ion sys tem oil pump i s l ocated ins ide t he oil pan andis bol ted t o t he unders ide of t he cyl inder bl ock. The oil pump is chain driven by t he cranks haft .
Engi ne cool ing i s achi eved wit h a pres s uri zed water-cool ant sys tem. An engi ne dri ven coolant pump dis t ri but es t he cool antt hrough gal leries in the cyli nder head and block.
Engi ne produced emis s ions comply wi th European Commis s ion Di recti ve (EUCD) St age 4 legis l at ive requirement s . Theli mit ing of res ul tant emi ss i on pol lut ant s i s acheived by us e of an exhaus t s yst em cat alyti c convert er, an opt ional Di eselPart iculate Filt er (DPF), advanced el ect ronic engine management cont rol , PCV, and Exhaus t Gas Recircul at ion (EGR)s ys t em.
ENGINE STRUCTURE