LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Auxiliary Climate Control - Fuel Fired Booster Heater
Des cript ion and Operat ion
COMPONENT LOCATION - VEHICLES WITHOUT FFBH REMOTE CONTROL
ItemPart NumberDescription1-Automat ic Temperat ure Cont rol (ATC) modul e
2-Fuel Fi red Boos ter Heater (FFBH)
3-Auxili ary coolant pump4-Ambi ent ai r temperat ure s ens or
5-Auxili ary fuel pump
COMPONENT LOCATION - VEHICLES FROM 2009MY WITH FFBH REMOTE CONTROL

ItemPart NumberDescription
1-Automat ic Temperat ure Cont rol (ATC) modul e2-Fuel Fi red Boos ter Heater (FFBH)
3-Auxili ary coolant pump
4-Ambi ent ai r temperat ure s ens or5-Auxili ary fuel pump
6-FFBH Recei ver
7-FFBH antenna mat chi ng unit
OVERVIEW
The Fuel fired Boos t er Heat er (FFBH) is rated at 5 kW and compensat es for t he rel ativel y low coolant t emperaturesinherent i n the di esel engine. The uni t is locat ed behind t he Right Hand (RH) front fender s plas h s hield and heat s enginecool ant downs tream of t he heat er core.
Operat ion of t he FFBH is controlled by the Aut omati c Temperature Control (ATC) module via the medi um s peed ControllerArea Net work (CAN) bus . Operati on of the FFBH i s influenced by:
Ambient air t emperat ureEngi ne cool ant temperat ure.
The FFBH wil l operate i f the ambient air t emperature is lower than 5 °C (41 °F) and s top if ambient t emperature reaches 8°C (46 °F). Operat ion of t he FFBH may als o be inhibit ed if t he fuel l evel drops below a predet ermi ned level .
Remote Operation - Vehicles from 2009MY
On vehicles from 2009MY the FFBH has remote operati on. The remote sys tem includes t he addi ti on of a FFBH receiver,

FFBH antenna mat chi ng uni t and a remote hands et for operati on of the s ys tem. The FFBH unit remains as previ ous l y fi tt edbut has upgraded s oftware. The Engine Cont rol Modul e (ECM) als o has a s oft ware cal ibrat ion upgrade. The ins trumentclus ter mes s age cent er di spl ays FFBH mes s ages when required.
AUTOMATIC TEMPERATURE CONTROL MODULE
The ATC module is mount ed in the center cons ole and is i ntegral wi th the control panel. The module works i n conjunct ionwit h t he ECM t o control al l aspects of heati ng, venti lat ion, and Air Condit ioning (A/C).For addit ional informat ion, refer t o: Cont rol Component s (412-01 Cli mat e Cont rol , Descripti on and Operat ion).
AUXILIARY FUEL PUMP
ItemPart NumberDescription
1-Fuel li ne connect or2-Non return valve
3-Solenoid coi l
4-Pl unger5-Fi lt er i nsert
6-Fuel li ne connect or
7-O-ring s eal8-Spring
9-Pi st on
10-Bus hThe auxi li ary fuel pump is mount ed on the RH s ide of t he fuel t ank and regulates t he fuel s upply t o t he FFBH. The pump isa s elf primi ng, s olenoid operat ed plunger pump, controll ed by a Puls e W idt h Modulation (PW M) s ignal from t he cont rolmodule i n t he FFBH. W hen the pump is de-energized, i t provides a pos it ive s hut-off of t he fuel s uppl y.

The s olenoi d coil of the auxil iary fuel pump i s ins tal led around a hous ing which cont ains a pl unger and pis t on. The pi st onlocates i n a bus h, and a s pri ng is i nst all ed on t he pis ton bet ween the bus h and t he plunger. A fil ter i nsert and a fuel l ineconnector are ins tal led i n the inlet end of t he hous ing. A non return valve and a fuel line connect or are i nst all ed in the fueloutl et end of t he housi ng.
W hi le t he s olenoid coil i s de-energized, the spring holds t he pis t on and plunger i n t he clos ed pos i ti on at the i nlet end oft he hous ing. An O-ri ng s eal on the pl unger provides a fuel ti ght s eal bet ween t he plunger and t he filt er ins ert , prevent ingany fl ow t hrough t he pump. W hen the sol enoi d coi l is energi zed, t he pis ton and pl unger move t owards t he outl et end oft he hous ing, unti l the pl unger cont act s t he bush; fuel i s t hen drawn i n t hrough the i nlet connecti on and fi lt er. The i ni ti almovement of t he pis t on als o clos es t rans verse dril li ngs in t he bus h and is olat es the pumpi ng chamber at t he out let end oft he hous ing. Subsequent movement of t he pis ton then forces fuel from t he pumping chamber through t he non return val veand int o t he li ne to the fuel fi red boost er heat er. W hen the s olenoid de-energizes , the s pri ng moves the pi s ton andplunger back t owards t he cl osed pos it ion. As t he pis t on and plunger move towards t he clos ed posi ti on, fuel fl ows pas t t heplunger and through t he annul ar gaps and t rans vers e holes i n t he bus h t o replenis h the pumping chamber.
FUEL FIRED BOOSTER HEATER (FFBH)
The FFBH is ins tall ed in the coolant s uppl y li ne to the heat er as s embly and i s located behind the RH front fender s plas hs hield. Two el ect ri cal connectors connect the FFBH t o t he vehi cl e wi ri ng.
The FFBH compris es t he fol lowing:
A combus ti on air fanA burner housi ngA heat exchangerAn air i nlet hose and mufflerAn exhaus t pipe and mufflerA control modul e.
Sect ioned View of Typi cal Fuel Fired Boost er Heater

ItemPart NumberDescription
1-Combus t ion ai r fan2-Cool ant out let
3-Cool ant inlet
4-Burner ins ert5-Heat exchanger
6-Temperature s ens or
7-Exhaus t8-Fuel i nl et
9-Evaporat or
10-Air i nl et
Combustion Air Fan
The combus t ion ai r fan regul at es t he fl ow of air i nto t he FFBH t o s upport combus ti on of the fuel suppli ed by t he auxi liaryfuel pump. It i s als o us ed t o purge and cool the FFBH.
Burner Housing
The burner hous ing cont ai ns the burner i nsert and als o i ncorporat es connecti ons for t he exhaus t pipe, the coolant inl etfrom the auxil iary coolant pump and t he cool ant out let t o t he vehi cl e heater.
The burner ins ert i ncorporat es t he fuel combus t ion chamber, an evaporator and a gl ow pin and fl ame s ens or. Fuel from t heauxi li ary fuel pump is s uppl ied t o a vent uri, where it evaporat es and ent ers t he combust ion chamber to mix wit h air fromt he combus ti on air fan. The gl ow pin and fl ame s ens or provides t he igni ti on source for t he fuel:air mi xture and, oncecombus t ion i s es tabli shed, monit ors t he flame.
Heat Exchang er
The heat exchanger t ransfers heat generated by combus ti on t o the coolant . Two s ens ors are i nst all ed in t he heatexchanger cas ing t o provide the control modul e wi th i nput s of Engine Coolant Temperature (ECT). The cont rol module us est he temperat ure inputs t o control s ys tem operati on.
Air Inlet Hose and Muffler
A canis ter t ype muffler i s included in the ai r inlet s upply l ine. The muffler reduces the noi se caus ed by inducti on roar.
Exhaust Pipe and Muffler
The exhaus t pipe and muffl er di rects exhaus t combus ti on gases t o at mos phere below t he front RH wheel arch. Exhaus tvapor may be vi s ible when the FFBH i s running, dependi ng on atmos pheri c condit ions .
Control Module
The cont rol module cont rols and moni tors operati on of the FFBH sys tem. An int ernal flow of ai r from t he combust ion ai r fanvent il ates t he cont rol module to prevent i t overheat ing.

The cont rol module is powered by a permanent feed from the Bat t ery Junct ion Box (BJB), and communi cat es wi th t he ATCmodule over the medium speed Controller Area Network (CAN) bus .
AUXILIARY COOLANT PUMP
The auxi li ary coolant pump is mount ed on t he heater cas i ng and is us ed t o as si s t coolant flow through t he FFBH and t heheat er core.
The auxi li ary coolant pump runs conti nuous ly whi le the FFBH i s act ive. W hen t he FFBH is inact ive, cool ant flow is reli ant ont he engi ne cool ant pump. Operat ion of t he auxi li ary cool ant pump is controll ed by a power feed di rect from t he cont rolmodule wit hi n t he FFBH.
Stop/Start Vehicles - From 2010 MY
Duri ng a St op/Start cycle when the engine i s s hutdown and consequent ly the engine-driven coolant pump is st ati onary, thedesi red s et cabi n t emperature cannot be mai ntai ned for a prol onged period, especially in col d ambient t emperatures . Tocount eract this an auxi li ary electric coolant -pump, cont rol led by t he ECM (engi ne cont rol module), has been i ntegrat ed int ot he cooli ng s yst em t o mai ntai n the coolant flow t hrough t he cabi n’s heater core. This s upporti ng circulat ion prolongs thes et temperat ure set ti ng in the cabin and accordingly prevent s an earl y engi ne res t art .
On vehicles fit ted wit h a Fuel Fi red Boos ter Heat er (FFBH) t he addit ional auxil iary cool ant pump is not ins t al led. In it splace t he FFBH auxi liary cool ant pump is ut il ized t o circulat e t he cool ant i n an engine s hutdown s i tuati on. The pump isact ivat ed via t he FFBH by t he CJB (central junct ion box).For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
AMBIENT AIR TEMPERATURE SENSOR

The ambient air t emperat ure s ensor i s a Negati ve Temperature Co-effi ci ent (NTC) thermis t or, and is mount ed in the LeftHand (LH) door mi rror. The s ens or is connect ed t o the Engi ne Cont rol Module (ECM) which t rans mit s an ambi ent ai rt emperature val ue over t he high speed CAN bus . This value i s rel ayed to the ATC modul e by t he Cent ral Junct ion Box (CJB)over t he medium s peed CAN bus.For addit ional informat ion, refer t o: Cont rol Component s (412-01 Cli mat e Cont rol , Descripti on and Operat ion).
REMOTE CONTROL COMPONENTS - VEHICLES FROM 2009MY WITH FFBH REMOTE
CONTROL
The addi ti on of remot e control retai ns the FFBH component s fit ted t o pre 2009MY vehicl es wit h t he addi ti on of thefol lowing components :
FFBH wit h upgraded s oft ware and cali brat ionFFBH remot e handsetFFBH remot e receiverRecei ver power, communicati on and antenna harnes sesAntenna mat chi ng unit harnes s to connect recei ver co-axial cable t o exis t ing DAB antenna in s ide window.
FFBH Remote Handset
ItemPart NumberDescription
1-On butt on2-Off butt on
3-LED operat ion indicator
4-Ant ennaThe remot e handset al lows t he dri ver t o remotely act ivate the FFBH wi thout entering t he vehi cl e. The hands et has a rangeof at leas t 100 m (328 ft ) i n free s pace, alt hough t his di s tance may be decreas ed depending on t he l ocat ion of obst acl ess uch as bui ldings . The hands et is powered by a 3.3 vol t CR1/3N replaceable bat t ery whi ch can be access ed by removi ng acover from the rear of t he hands et . The bat tery li fe in t he remote hands et is approximat ely 300 FFBH cycl es. One cycle i sdefi ned as a hands et butt on pres s fol lowed by 30-minut e burn t ime wi th flas hing LED feedback.
The remot e handset has a green Light Emit ti ng Diode (LED) to indicate the FFBH i s act ive. W hen t he 'O N' but ton i spres s ed on t he hands et for more t han 2 s econds, t he LED wi ll il lumi nat e for 2 s econds . Aft er t he 2 s econd period haspass ed, the LED wil l i ll uminate for 50 ms every 2 s econds for up to the 30 minut e on t ime of t he FFBH. The LED wil l onl ys top flas hing i f the 'OFF' but ton i s pres s ed or the 30 minute on t imer has elaps ed.
Remote Hands et LED Indi cat or Functi onal it y
The LED il lumi nat es i n different ways t o alert the driver to the various s tat es of the FFBH remote control sys t em asfol lows :
Illumi nates green for 2 s econds when t he ON but ton has been press ed t o s how t hat t he receiver unit hass uccess fully recei ved the hands et on request . The FFBH may now s t art operat ing providi ng that fuel l evel , bat teryvolt age and coolant t emperature variabl es are wi thi n li mit s .Flas hes green for 50 ms every 2 s econds t o i ndi cat e t hat the FFBH may be act ive.Illumi nates red for 2 seconds when the OFF but ton has been pres s ed t o s how t hat t he receiver unit has s uccess fullyreceived t he hands et off reques t. The FFBH s hould t hen s top operat ing.Flas hes green or red for 2 s econds when pres s ing t he ON or OFF but t ons t o i ndi cat e that the s i gnal was notreceived by t he FFBH receiverIllumi nates orange before changi ng to green or red to s how t hat remot e hands et batt ery vol tage i s lowFlas hes orange for 5 s econds t o s how t hat si gnal was not received by t he FFBH and t hat t he remote hands etbatt ery requi res replacement .
Remote Hands et Pairi ng
Each remot e hands et mus t be 'paired' t o t he receiver t o enabl e communicati ons . Each hands et has a unique identi fi cat ionnumber whi ch is st ored by t he receiver. The recei ver can s t ore up 3 hands et identi ficat ion numbers . If a fourth hands et ispaired to the recei ver, the recei ver wi ll repl ace the first pai red handset number wit h t hat for t he fourt h handset i n t hereceiver memory. Subsequentl y, t he first paired hands et wi ll no l onger be paired and wil l not be recognis ed by t he receiver.
The fol lowing procedure det ail s t he pai ri ng process :
Remove fus e FA5 from the Rear Junct ion Box (RJB)W ai t for a minimum of 5 s econdsReplace fus e t o pos it ion FA5 i n the RJBW i thi n 5 s econds of repl aci ng the fus e (and res toring t he receiver power s upply), pres s and hol d the remot e

hands et OFF butt onConfirmat ion of s ucces sful pai ri ng is di spl ayed by t he remote hands et LED ill uminat ing i n a red col or for 2 s econds .
• NOTE: The pairing proces s rel ies on t he FFBH receiver havi ng the power s uppl y removed and t hen t he power s upplyre-ins tat ed. The fus e met hod is t he easi est method but it can al so be achi eved by bat tery dis connect ion or removal of t heharnes s connect or from t he receiver unit .
Receiver
The receiver is l ocat ed in the LH si de of the luggage compart ment . The recei ver i s mounted on an int egral bracket which i nt urn i s att ached t o t he audio s ys tem bracket whi ch locat es t he High Definit ion (HD) radi o receiver.
The receiver is connect ed to the ant enna on the LH s ide wi ndow wit h a co-axi al cable. Radi o Frequency (RF) s ignals fromt he remot e hands et are received by t he ant enna and pas s ed via the ant enna matching unit and co-axial cable t o t hereceiver. The recei ver proces ses t he s ignals and t rans mi ts appropriate mes sages t o the FFBH on a dedicated bus .
Antenna and Antenna Matching Unit
Antenna Mat chi ng Unit
The FFBH antenna is locat ed i n the LH rear s ide wi ndow and us es the s ame ant enna el ements as us ed by t he audio Di git al

Audio Broadcast (DAB) s yst em.
Sit uat ed above the DAB antenna unit , behi nd the headli ni ng, is an ant enna matching unit . A flying lead from this uni tconnects di rectl y t o a s t ud on the gl ass ant enna. The recei ver unit connect s to the matching unit vi a a co-axial cabl e.
The glas s mounted ant enna recei ves RF transmit ted s i gnals from t he remot e handset and t rans mi ts t hem, via t hemat chi ng uni t and co-axial cable, t o t he FFBH receiver.
CONTROL DIAGRAM - VEHICLES WITHOUT FFBH REMOTE CONTROL
• NOTE: A = Hardwi red; D = High speed CAN bus ; N = Medium s peed CAN bus
ItemPart NumberDescription

1-Batt ery
2-Fuse 17, BJB
3-Fuse 27, CJB4-ATC module
5-CJB
6-Engi ne Control Module (ECM)7-Ambient air t emperat ure s ensor
8-Auxi li ary coolant pump
9-Auxi li ary fuel pump10-Fuel fired boos t er heat er
11-Fuse 32, BJB
CONTROL DIAGRAM - VEHICLES FROM 2009MY WITH FFBH REMOTE CONTROL
• NOTE: A = Hardwi red; D = High speed CAN bus ; F = RF Trans mis s ion; N = Medium s peed CAN bus; T = Co-axi al; AA =W ebas to 'W ' bus