LAND ROVER FRELANDER 2 2006 Repair Manual

For addit ional informat ion, refer t o: Specificati ons (307-01 Aut omati c Trans mis s ion/Transaxle, Speci fi cat ions ).
Manual Transmission
Every 10 years or 150,000 miles (240,000 km): Renew manual t rans mi ss ion fl ui d.
For addit ional informat ion, refer t o: Specificati ons (308-00 Manual Trans mis s ion/Transaxle and Clutch - General
Informat ion, Speci ficat ions).
Power Transfer Unit
Every 10 years or 150,000 miles (240,000 km): Renew power t rans fer unit oi l. For addi ti onal informat ion, refer to:
(308-07B Transfer Case)
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D (Removal and
Ins tal lat ion),
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D (Removal and
Ins tal lat ion).
Differential Assembly - Rear
Every 10 years or 150,000 miles (240,000 km): Renew rear different ial oil .
For addit ional informat ion, refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial, Specifi cat ions ).
Suspension and Body Mountings Check for free play i n all s us pens ion and body mounti ng rubbers . Check condit ion of s uspens ion rubber boots and gait ers .
Fuel System
Check fuel sys tem pipes , hos es and unions for chafi ng, l eaks and corros ion. Electrical Harnesses
Check al l el ect ri cal harnes s es for chafing. Oil/Fluid Leaks
Check for oil/fluid leaks . Power Steering
Check power s teering rod bal l joi nt fixi ngs , gait ers and condi ti on of bal l joi nt s an d dus t covers .Check power s teering pipes , hos es and unions for chafi ng, leaks and corros ion.
Exhaust System
Check exhaust s ys tem for l eaks , securi ty and damage. Clutch
1. Check clut ch pipes and unions for chafi ng, l eaks and corrosi on.
Fault Lamp(s) If fault l amp(s ) are ill uminat ed, t est the as s oci at ed s yst em us i ng Land Rover approv ed di agnos ti c equipment and
report findi ngs . Road Test
Carry out road t est of vehicle.
For addit ional informat ion, refer t o: Road/Roller Tes ti ng (100-00 General Informati on, Des cri pt ion and Operati on).
General
Endors e Service Record. Report any unus ual features of vehi cl e condi ti on and any addi ti onal work required.
Vehicles Operating Under Arduous Conditions
Recommended s ervi ce interval s for vehicles operat ing under arduous condit ions are de t ail ed below.
Braking System CAUTION:
When vehicles are operating under arduous conditions, the following service items mu st be carried
out every 3 months or 3,750 miles (6,000 km).
Ins pect front brake pads for wear.

Ins pect rear pads for wear.
Check brake cal ipers for s igns of fl ui d l eaks .
Check brake dis cs for condi ti on.
Check al l brake boos t er and brake s ys t em pipes and hos es for condi ti on, chafi ng and
leaks.Clean road wheel hub s pigot s and appl y greas e, Land Rover Part Number RY L 105020 t o
t he wheel mat ing surface
of each s pigot . Brake Fluid Replacement
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 2 Years or 30,000 miles (48,000 km).
Replace brake fluid. Road Wheel Speed Sensors
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 3 months or 3,750 miles (6,000 km).
Ins pect the road wheel s peed s ens or harness es for damage. Engine Oil and Filter
• CAUTIO NS:
When vehicles are operating under arduous conditions, the following service item mus t be carried out every 3
months or 3,750 miles (6,000 km).
Vehicles operating on high sulphur content fuel - above 0.7%, the oil and filter cha nge period MUST NOT
exceed 3 months or 3,750 miles (6,000 km).
Vehicles operating on moderate sulphur content fuel - 0.3 to 0.7%, the oil and filte r change period MUST NOT
exceed 6 months or 7,500 miles (12,000 km).
Renew engi ne oil and fil ter. Air Filtering
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 12 months or 15,000 miles (24,000 km).
Replace the ai r fi lt er el ement.
For addit ional informat ion, refer t o: Air Cl eaner (303-12A Int ake Ai r Dis t ri but ion and Fi lt ering - I6 3.2L Petrol ,
Removal and Inst all ati on). Accessory Drive Belt
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 5 years or 75,000 miles (120,000 km).
Replace the access ory drive bel t. For addi ti onal informat ion, refer to: Acces s ory Drive Belt (303-05A Acces s ory Drive
- I6 3.2L Pet rol, Removal and Ins tal lat ion). Camshaft Timing Belt, Tensioner and Pulley
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 4 years or 60,000 miles (96,000 km).
Replace the cams haft t iming belt , tens ioner and pul ley.
For addit ional informat ion, refer t o: Timi ng Belt (303-01B Engi ne - TD4 2.2L Dies el, Removal and Inst all ati on).
Radiator/Charge Air Cooler and Cooling Fan
CAUTION:
When vehicles are operating under arduous conditions, the following items must be ca rried out.
Vis uall y check t he radiat or/charge air cool er for ext ernal obst ruct ions, check cooli ng fan bl ades for damage.Remove any debris from t he charge air cool er us i ng a l ow pres s ure hos e.
Continuous Use In Severe Off-Road Conditions
CAUTION:
After 50 miles (80 km) continuous use in severe off-road conditions i.e. w ading, dee p mud and
abrasive grit/slurry, the following items must be cleaned and inspected.

The parking brake.
The acces sory dri ve belt .
Vehicles used in dusty or field conditions or d eep wading:
More frequent att enti on to the ai r cl eaner wi ll be requi red. Fuel Filter
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 3 months or 3,750 miles (6,000 km).
Drai n wat er from t he fuel fi lt er. Poor Fuel Quality
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 3 months or 3,750 miles (6,000 km).
W here vehi cl es are us ed i n t hes e areas , t he fuel fi lt er may require drai ning at more frequent i nterval s.Additional Items That May Require Attention
1. Every 6 years: It i s recommended t hat al l brake fl uid hydrauli c s eal s are replaced.
• NOTE: This i s in addi ti on to the maintenance requirement that fl exi ble brake hos es MUST be replaced at thi s s ervice
int erval.

Publ is hed: 08-Dec-2011
Suspension System - General Information -
C oil Spring SuspensionItemSpecification
FrontFront: - Convent ional coi l spring wi th a t win tube damper and a high s t res s s tabi lizer bar
RearRear: - Convent ional coil s pri ng wit h a twi n t ube damper and a hi gh s tress st abil izer bar
Wheel Alignment Specification (All Markets) - Front• NOTE: All figures are wi th vehicle at 'Showroom' ri de height - ful l flui ds, full tank of fuel , no occupants /l uggage, ti resinflat ed to normal pres sures
ItemLeft-handRight-handT otal/Balance
CamberNominalT oleranceNominalT oleranceNominalT oleranceDeci mal degrees-0.50°± 0.75°-0.50°± 0.75°0°± 0.75°
Degrees/mi nut es-30'± 45'-30'± 45'0'± 45'
MinimumMaximumMinimumMaximumMinimumMaximumDeci mal degrees-1.25°0.25°-1.25°0.25°-0.75°0.75°
Degrees/mi nut es-1°.15'15'-1°.15'15'-45'45'
CastorNominalT oleranceNominalT oleranceNominalT oleranceDeci mal degrees3.25°± 0.75°3.25°±0.75°0°± 0.75°
Degrees/mi nut es3°15'± 45'3°15'± 45'0'± 45'
MinimumMaximumMinimumMaximumMinimumMaximumDeci mal degrees2.50°4°2.50°4°-0.75°0.75°
Degrees/mi nut es2°30'4°2°30'4°-45'45'
T oeNominalT oleranceNominalT oleranceNominalT olerance
Deci mal degrees0.10°±0.10°0.10°±0.10°0.20°± 0.20°Degrees/mi nut es6'±6'6'±6'12'± 12'
MinimumMaximumMinimumMaximumMinimumMaximum
Deci mal degrees0°0.20°0°0.20°0°0.40°Degrees/mi nut es0'12'0'12'0'24'
Wheel Alignment Specification (All Markets) - Rear• NOTE: All figures are wi th vehicle at 'Showroom' ri de height - ful l flui ds, full tank of fuel , no occupants /l uggage, ti resinflat ed to normal pres sures
ItemLeft-handRight-handT otal/BalanceT hrust Angle
CamberNominalT oleranceNominalT olerance
Deci mal degrees-1.95°± 0.75°-1.95°± 0.75°Degrees /mi nut es-1°57'± 45'-1°57'± 45'
MinimumMaximumMinimumMaximum
Deci mal degrees-2.70°-1.20°-2.70°-1.20°Degrees /mi nut es-2°42'-1°12'-2°42'-1°12'
T oeNominalT oleranceNominalT oleranceNominalT oleranceNominalT olerance
Deci mal degrees0.17°± 0.14°0.17°± 0.14°0.33°± 0.20°0°± 0.14°Degrees /mi nut es10'± 8'10'± 8'20'± 12'0'± 8'
MinimumMaximumMinimumMaximumMinimumMaximumMinimumMaximum
Deci mal degrees0.03°0.31°0.03°0.31°0.13°0.53°-0.14°0.14°Degrees /mi nut es2'18'2'18'8'32'-8'8'
Vehicle Ride Height• NOTE: All figures are wi th vehicle at 'Kerbs ide' (curbs ide) ride height - ful l fl uids , full t ank of fuel, no occupants /luggage,t ires infl ated t o normal press ures
• NOTE: Ride hei ght i s meas ured vert icall y from wheel cent er to unders i de of wheel arch
Descriptionmminch
Front490.7 ± 1219.32 ± 0.47
Rear504.6 ± 1219.87 ± 0.47

Publi s hed: 11-May-2011
Suspension System - General Information - Suspension System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the sus pens i on sys t em, refer t o t he rel evant Des cript ion and Operat ion s ecti on in theworks hop manual . REFER to:
Front Sus pensi on (204-01 Front Sus pensi on, Des cri pti on and Operati on),Rear Sus pens ion (204-02 Rear Suspens ion, Descri pti on and Operat ion),Ride and Handli ng Opti mizati on (204-06 Ride and Handli ng Opti mizat ion, Descri pti on and Operat ion).
Inspection and Verification
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of damage.2.
Visual InspectionMechanical
Damaged t iresW heel bearing(s)Loose or damaged front or rear s uspens ion component sLoose, damaged or mis s ing s us pens ion fas tener(s )Incorrect spring(s ) i ns t alledDamaged or s aggi ng spring(s )Damaged or leaking s hock abs orber(s )Damaged or leaking s t rut (s )W orn or damaged s us pensi on bushi ng(s )Loose, worn or damaged s t eering sys tem componentsDamaged axle component s
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep.3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart.4.
Symptom Chart
SymptomPossible CauseAction
CrabbingIncorrect rear thrus t angleFront or rear s uspens ioncomponent sDrive axle damaged
CHECK t he rear toe adjust ment.REFER to: Speci fi cat ions (204-00 Suspens ion Syst em - GeneralInformat ion, Specificati ons) /Four-W heel Al ignment (204-00 Sus pens i on Sys t em - GeneralInformat ion, General Procedures ).INSPECT t he front and rear s us pensi on s yst ems . REPAIR orINSTALL new s us pens ion component s as neces s ary. INSTALL a newrear dri ve axl e/di fferenti al as necess ary
Drift/Pul lUnequal t ire pres s ureIncorrect wheel ali gnmentTiresUnevenl y loaded oroverloaded vehi cleDamaged s teeri ngcomponent sBrake drag
CHECK and ADJUST the t ire pres s ures . INSPECT t he ti re forexces si ve wear.REFER to: Speci fi cat ions (204-04 W heels and Ti res , Specificati ons ).CHECK and ADJUST the wheel ali gnment .REFER to: Four-W heel Al ignment (204-00 Sus pensi on Syst em -General Informat ion, General Procedures ).CHECK and ADJUST the t ire pres s ures . INSPECT t he ti re forexces si ve wear.REFER to: Speci fi cat ions (204-04 W heels and Ti res , Specificati ons ).NOTIFY the cus tomer of incorrect vehicle l oadi ng. CHECK thes teeri ng s ys t em.REFER to: St eering Sys tem (211-00 St eeri ng Sys t em - GeneralInformat ion, Diagnosi s and Test ing).CHECK t he brakes .REFER to: Brake Sys tem (206-00 Brake Syst em - GeneralInformat ion, Diagnosi s and Test ing).Front Bott omi ng orRidi ng LowCoil s pri ngsCHECK t he ri de hei ght. INSTALL new springs as neces s ary.REFER to: Spri ng (204-01 Front Sus pensi on, Removal andIns t al lat ion) /Rear Shock Absorber (204-02 Rear Sus pensi on, Removal andIns t al lat ion).
Incorrect Ti re W earIncorrect ti re press ure(rapid center rib or i nnerand outer edge wear)Exces s ive front or rear toe(rapid inner or out er edgewear)Exces s ive negat ive orposi ti ve camber (rapi dinner or out er edge wear)Tires out of bal ance (ti rescupped or dis hed)
CHECK and ADJUST the t ire pres s ure. INSPECT t he t ire forexces si ve wear.REFER to: Speci fi cat ions (204-04 W heels and Ti res , Specificati ons ).CHECK and ADJUST the wheel ali gnment .REFER to: Four-W heel Al ignment (204-00 Sus pensi on Syst em -General Informat ion, General Procedures ).BALANCE the wheels /ti res

Publi s hed: 11-May-2011
Suspension System - General Information - Four-Wheel Alignment
General Procedures
Check the geomet ry s peci fi cat ions .
Refer t o: Specificati ons (204-00 Sus pens i on Sys t em - GeneralInformat ion, Speci fi cat ions ).
1.
Check the t ie rod ends , sus pens i on joi nt s , wheel beari ngs andwheels and t ires for damage, wear and free pl ay.2.
Check and adjust t ire pres s ures .3.
Pos it ion t he vehi cl e on a cal ibrat ed, l evel , vehicl e li ft .4.
Releas e t he vehi cl e parking brake.5.
Us ing onl y four wheel al ignment equi pment approved by Land Rover,check and adjus t t he wheel al ignment.6.
7. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
7.
Adjus t t he rear t oe.
T orque: 175 Nm
8.
Repeat t he rear t oe meas urement.9.
Ali gn t he s teeri ng to s trai ght ahead.10.
Adjus t t he front toe.
T orque: 55 Nm
11.

Check, and i f necess ary, repeat t he wheel al ignment procedure unti lt he correct values are obt ained.12.
Us ing t he Land Rover approved diagnost ic sys tem, cali brat e thes teering angle s ens or.13.

Publi s hed: 11-May-2011
Front Suspension -
C oil Spring SuspensionItemSpecification
FrontConvent ional coil s pri ng wi th a twi n t ube damper and a high s tres s s tabil izer bar
Road Spring Identification
Part NumberSpecificationIsolator
LR 001131Green/Y ell ow/Orange.LR 001145
Torque SpecificationsDescriptionNmlb-ft
Damper locknut *8059
Front subframe crossbrace:M10*4533
M16*140 + 240°103 + 240°
Front s ubframe t o body bol ts *140 + 240°103 + 240°Front ride height s ens or107
Halfs haft to hub bol t*45 + 80°33 + 80°
Lower cont rol arm front bol t140 + 45°104 + 45°Lower cont rol arm rear nut and bol t175129
Lower cont rol arm taper ball joi nt locknut *10074
Spri ng and damper as s embly t op mounti ng nuts3022St abi lizer bar cl amp bolt s175129
St abi lizer bar li nk nut s *6044
W heel knuckle to damper clamp bol t11081* New nuts/bolts must be fitted

Publi s hed: 11-May-2011
Front Suspension - Front Suspension
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription1-Right Hand (RH) s pring and damper as sembl y
2-St abi lizer bar li nk
3-St abi lizer bar4-Left Hand (LH) spring and damper as sembl y
5-W heel knuckle
6-Hub and beari ng ass embl y7-Lower cont rol arm
8-Subframe
OVERVIEW
The front sus pensi on feat ures long t ravel McPherson st rut s t o opti mize on and off road performance.
The s uspens ion component s are mount ed on a subframe. The s ubframe is mount ed on 4 bus hes which have differi ngcompres si on rat es t o absorb lat eral and longit udi nal l oadi ng. Thi s provides a rigi d plat form for front s us pens ion corneringloads , front al impact abs orpt ion and al so provides a t owing poi nt for off-road recovery.
SPRING AND DAMPER

ItemPart NumberDescription
1-Boot2-Bolt s - Top mount (3 off)
3-Upper t op mount plat e
4-Lower t op mount plat e5-Bump was her
6-Top mount bearing
7-Spring is olator8-Spring
9-Spring Is olat or
10-Damper body11-Spring seat
12-Damper pi s ton rod
13-Locknut14-Spring ai d
The s pring and damper as s embl y i s a t win tube des ign wi th the convent ional coil s pring located on a welded s pri ng s eat ont he damper t ube. The l ower end of t he damper body l ocat es in the wheel knuckle whi ch is cl amped wit h a bolt .
The damper funct ions by rest ricti ng the flow of hydraul ic fluid through internal gall eri es wit hin t he damper. The damper rodmoves axi all y wit hin t he damper, i ts movement l imi ted by the flow of flui d t hrough the gal leri es, provi di ng damping ofundul ati ons i n t he t errai n. The damper rod is s ealed at i ts exi t poi nt from t he damper body t o mai ntain the flui d wit hin theunit and t o prevent the i ngres s of dirt and mois ture. The seal als o i ncorporat es a wiper to keep t he rod cl ean.
The damper rod i s located t hrough a central hol e in the top mount as sembl y. The rod i s threaded at i ts out er end. As elf-locking nut s ecures the t op mount t o t he damper rod. A s pring ai d i s fi tt ed t o t he damper rod t o prevent the t opmount cont act ing t he t op of the damper duri ng ful l s us pens ion compress ion and al s o as si st s t he s uspens ion t une. A bootis fi tt ed between t he damper body and t he t op mount and protects the damper pis t on rod from damage.
The coi l s pring fit t ed differs wit h vehi cl e s peci fi cat ion. Each s pring i s col our coded to identi fy i ts rat ing and fit mentrequirements .
The coi l s pring i s l ocated in a spring s eat which i s an int egral part of the damper body and cont ains a spring i sol at or. Thedesi gn of the spring s eat prevent s t he s pring rotat ing. The s pring has a li near rate compres s ion and i s i ncli ned to count ercorneri ng forces . The oppos it e end of t he coi l spring i s als o l ocat ed in a s pring isolator whi ch is fit ted i n t he t op mountas sembl y. Bot h s pri ng is olat ors are made from rubber and prevent any nois e produced during damper and s pri ngcompres si on/extens ion from bei ng t rans mit ted to t he vehicle body.
The t op mount is fit ted wit h a t op mount bearing whi ch is l ocat ed between t he 2 t op mount plat es and the damper rod. As elf locking nut s ecures the damper rod to the t op mount. The t op mount bearing reduces s t eering resi s tance bypreventi ng the s pring from 'wi ndi ng' up when t he s teering i n t urned. The t op mount att aches t o a st rengt hened t urret ont he chas s is wi th 3 int egral st uds and s elf-locking nut s.
Two brackets are welded t o t he damper body. One bracket provides for t he att achment of t he s tabil izer li nk. The s econdbracket provi des for t he att achment of t he brake hose and wheel s peed s ens or cabl e. This bracket als o pos it ively locat est he damper i nto t he wheel knuckle and i ts locat ion i s cri ti cal t o cont rol li ng the vehicle trim height.