engine LAND ROVER FRELANDER 2 2006 Repair Manual

22. CAUTION: The O-ri ng s eal i s to be reus ed
unles s damaged.
• NOTE: Make s ure the fuel pump drive remains capti ve
when removi ng t he fuel pump.
22. 23.
24.
NOTE: The engine is now i n t he SAFE pos i ti on.
Remove the cranks haft t imi ng t ool .
Spec i al T ool(s ): 303-1270 Rotat e t he cranks haft t hrough 90 degrees .24.
Retract and lock the cams haft drive chai n t ens i oner.
25.

26.
NOTE: Dis card t he gasket .
26.
Installation 1. CAUTION: Make s ure that the mati ng faces are
clean and free of foreign materi al.
Apply a cont inuous bead of s ealant to one s urface.
Refer t o: Specificati ons (303-01B Engine - TD4 2.2L
Di es el, Specifi cat ions ).
1. Temporarily ins tall t he cams haft pulley and t he pull ey
t imi ng pin
Speci al Tool (s ): 303-1277 2.

3. CAUTION: Lubricat e the bearing s urfaces wi th
clean engine oi l.
• NOTE: Inst all a new gas ket. Inst all and li ghtl y ti ght en bolt s i n s equence
i llus t rated. Tight en the bol ts i n t he s equence il lus trated.
T orque: 10 Nm 3.
Releas e t he chai n tens ioner
4.
Rotat e t he crankshaft and ins tall t he crankshaft ti ming t ool.
Speci al Tool (s ): 303-1270 5.
Remove t he camshaft pul ley.
6.
Secure t he EGR cool er. Inst all t he nut s , bol ts and washers, do not
t ighten at t his st age. Tight en the nut s in the sequence s hown.
T orque: 6 Nm Tight en the bol t in t he s equence s hown.
T orque: 10 Nm 7.
8. CAUTIONS: Ext reme cl eanli ness must be exerci sed when handli ng t hi s
component . Make s ure that t he mat ing faces are clean and free of foreign
mat eri al . Make s ure that t he s eal i s correctl y l ocated.
Inst all t he fuel pump.
T orque: 22 Nm 8.
Connect t he fuel s hut off electrical connect or.
9.
10. W ARNING: Before i nst all ing t he component s, ens ure t he
area around the joint faces and connect ions are cl ean.
Connect t he fuel pump feed and ret urn connect ors .
10.
11. CAUTIONS:
11.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Camshafts
Removal and Inst all ati on
Removal
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).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he val ve cover.
Refer t o: Val ve Cover (303-01B Engine - TD4 2.2L Dies el, Removal
and Inst all at ion).
3. 4.
Installation 1.
CAUTIONS: Make s ure that t he mat ing faces are clean and
free of foreign mat eri al. Lubri cat e t he bearing s urfaces wit h clean engine
oil .
Inst all t he camshaft s wi th the t iming chain and
t ens i oner. Al ign t he chain t iming l inks wit h t he t imi ng
marks on the cams haft s procket as shown.
1.
Tight en the tens ioner bol ts .
T orque: 7 Nm 2.
Inst all t he val ve cover.
Refer t o: Val ve Cover (303-01B Engine - TD4 2.2L Dies el, Removal
and Inst all at ion).
3.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Camshaft Seal
Removal and Inst all ati on
Special T ool(s)
205-053Ret ai ner, Drive Flange
205-053-04Adapter, Dri ve Fl ange
303-1276Inst all er, Cams haft Seal
303-935Remover, Cams haft Seal
Removal
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 ti ming bel t.
Refer t o: Timi ng Belt (303-01B Engi ne - TD4 2.2L Dies el , Removaland Inst all at ion).
3.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Timing Belt
Removal and Inst all ati on
Special T ool(s) 303-1270
Ti ming Pi n, Cranks haft 303-1272
Locki ng Tool , Flywheel 303-1277
Ti ming Pi n, Cams haft
Removal
• NOTE: The t imi ng and locking t ool s are ins tal led t o all ow t he ti mi ng cover to be r emoved. All t ool s mus t be left ins tal led
t o all ow t he ti ming cover ins tall ati on procedure t o be fol lowed.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e and s upport t he vehi cl e. 2.
Refer t o: Timi ng Cover (303-01B Engi ne - TD4 2.2L Dies el , Removal
and Inst all at ion).
3.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Exhaust Manifold
Removal and Inst all ati on
Removal
W ARNING: Observe due care when worki ng near a hot exhaust s ys tem.
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 exhaus t gas recirculat ion (EGR) cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi neEmi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
2.
Remove t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculateFil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removaland Inst all at ion).
3.
4. NOTE: Make s ure t hat al l openings are s eal ed.4.
5.

T orque:
24 Nm
Inst all t he turbocharger s upport bracket , but do not fully
t ighten at t his st age. Tight en the support bracket to turbocharger bol t.
T orque: 24 Nm Tight en the support bracket to cyli nder bl ock bolt s .
T orque: 24 Nm 4.
5. CAUTIONS: Make s ure that t he area around the component i s clean and
free of foreign mat eri al. Make s ure that new s eali ng washers are ins tall ed.
Connect t he turbocharger oil feed line.
T orque: 24 Nm 5.
Inst all t he turbocharger outl et pi pe.
T orque: 25 Nm 6.
Inst all t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculate Fil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removal
and Inst all at ion).
7.
Inst all t he EGR cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi ne
Emi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
8.
Check and top-up the engine oi l.
9.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - Cylinder Head
Removal and Inst all ati on
Removal
• NOTE: The valve cover and cylinder head is machined as an ass embly and cannot be serviced s eparately.
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).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he exhaus t manifol d.
Refer t o: Exhaus t Mani fol d (303-01B Engi ne - TD4 2.2L Di esel ,Removal and Ins tall ati on).
3.
Remove t he camshaft s .
Refer t o: Camshafts (303-01B Engine - TD4 2.2L Dies el, Removaland Inst all at ion).
4.
Remove t he thermost at.
Refer t o: Thermos tat (303-03B Engi ne Cool ing - TD4 2.2L Di es el,Removal and Ins tall ati on).
5.
Remove t he RH engine mount .
Refer t o: Engi ne Mount RH (303-01B Engi ne - TD4 2.2L Di esel ,Removal and Ins tall ati on).
6.
7.

16.
Installation Inst all t he li ft ing brackets and ti ght en t he bol ts .
T orque: 10 Nm 1.
2. CAUTION: Only use a plas ti c s craper t o clean
off t he old gas ket.
Clean and i nspect the cyli nder head and cylinder block.
2. Check cyli nder head face for dis torti on, acros s t he
cent er and from corner t o corner.
Refer t o: Specificati ons (303-01B Engine - TD4 2.2L
Di es el, Specifi cat ions ).
3.
If neces sary, s elect t he correct thi cknes s cyl inder head gas ket .
Refer t o: Cyl inder Head Gasket Selecti on - TD4 2.2L Di esel (303-00
Engine Sys tem - General Informati on, General Procedures ).
4.
5. CAUTIONS: Make s ure that t he mat ing faces are clean and free of foreign
mat eri al . Make s ure the locat ing dowels are i nst all ed correctl y.
5.