engine LAND ROVER FRELANDER 2 2006 Repair Manual

Remove t he LH engine mount.40.
RH si de: Rel eas e t he engine mount .41.
W it h ass i st ance, careful ly remove the engi ne andt rans mis s ion.42.

Publi s hed: 11-May-2011
Engine - TD4 2.2L Diesel - 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 clutch flui d hose.
6.
Connect t he bulkhead heat er hos es.
7.
8. CAUTIONS: Make s ure that t he component is cl ean, free of foreign
mat eri al and l ubricant.
8.

22. CAUTION: A new O-ring s eal is t o be ins tall ed.
Connect t he high-press ure power s t eering l ine t o t he power st eeri ng
pump.
T orque: 24 Nm 22.
Secure t he power s t eering hi gh-pres s ure l ine.
T orque: 10 Nm 23.
Inst all t he gear s elector cables .
24.
Connect t he brake boost er vacuum hos e.
25.
Connect t he ECM elect rical connectors .
26.
Inst all t he int ake ai r duct .
27.
Inst all t he charge air cool er inlet pipe.
T orque: 10 Nm 28.
Inst all t he front subframe.
Refer t o: Front Subframe (502-00 Uni -Body, Subframe and Mount ing
Syst em, Removal and Ins tall ati on).
29.
Inst all t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2L
Petrol, Removal and Ins tall ati on).
30.
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).
31.
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 (303-03B
Engine Cooli ng - TD4 2.2L Di esel , General Procedures ).
32.
Inst all 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).
33.
Inst all 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).
34.
Inst all t he plenum chamber access panel.
Refer t o: Plenum Chamber (412-01 Cl imat e Control, Removal and
Inst all at ion).
35.

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Anti -freezeTexaco Ext ended Li fe Coolant (XLC) or any glycol bas ed anti -freezecontaini ng no met hanol wit h only Organic Acid Technology (O AT) corrosi oni nhi bit ors
Anti -freeze concentrati on - W i ll provi de frostprot ect ion to -40°C (-40°F)50%
Speci fi c gravit y of cool ant at 20°C (68°F), t oprot ect agains t fros t down to -40°C (-40°F)1.068
Amount of anti-freeze to use for 50%concentration:4.0 li ters
C apacitiesItemCapacity (liters/pints/US quarts)
Cooli ng sys t em capacit y8.0/14.0/8.5
General Specification
ItemSpecificationCooling fan:
St andard fi t - Single fan500W
Hot cli mate - Twin fan750WCooli ng sys t em t ypePress uris ed, t hermos t at icall y cont rol led wi th remot e header t ank
Expans ion tankSeeber wit h i nt egrat ed level s ens or
Radiat orVal eo 28mm core wit h i ntegrat ed drain cock and repl aceable lower pinThermos t atW ax element
St arts to open90° C
Full y open100° C
Torque Specifications
DescriptionNmlb-ftCoolant expans ion t ank bol t107
Coolant pump bolt s1713
Coolant pump pull ey bol ts107Radiat or bolt s65
Radiat or drain pl ug76
Thermos t at hous ing bolt s107W at er inlet pi pe bol ts1713
W at er inlet pi pe drain nipple75
W at er out let t o bl ock bolt107

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Engine Cooling
Des cript ion and Operat ion
COMPONENT LOCATION
OVERVIEW
Becaus e of it s powerful engine, s ophi s ti cat ed transmis si on and t racti on s ys t em; the vehicle in the mos t demandingcondi ti ons will need t o cont inuall y dis s ipate as much as 120 kW of heat t o atmos phere. To compound the s i tuati on t hi st ypi call y occurs at low speeds when t here i s ins ufficient air being forced t hrough the radiat or t o ai d the cooli ng s ys t em.W i th thi s in mind and consi dering that t he majorit y of vehi cl es rarel y need to dis s ipate more t han 10 kW of heat , thecool ing s ys tem has been s peciall y devel oped t o cope wit h t he s everit y of off-road dri vi ng and variable ext remes of cl imat e.
The cool ing s ys tem functi ons us ing the cros s -flow pri ncipl e. The coolant is routed from t he cool ant pump int o the engi neblock on t he exhaus t s ide of t he engi ne and leaves the engine bl ock at t he rear edge, vi a t he t hermos tat housi ng, on theint ake si de.
The t hermos tat is a wax t hermos tat . The cool ant t emperat ure s ensor i s located i n t he thermost at hous i ng.
The cool ant i s pumped from the coolant pump t o t he engi ne through 2 connecti ons . After pass ing through t he engine,s ome of t he coolant exit s t he engi ne block at the rear edge of t he exhaus t s ide t o be routed t hrough t he pass engercompartment el ement and onwards to the coolant pump.

ItemPart NumberDescription
1-Engine2-Thermost at
3-Cabin heat er core
4-By-pas s5-Radiat or
6-Vent uri exi t
7-Trans mi s si on oil cool er8-Coolant pump
9-Coolant expans ion tank
10-Engine oi l cooler
PRINCIPLES OF OPERATION
At idl e, and l ow out door t emperatures (l ower t han -10°C (14°F)) the engi ne's idle s peed i ncreas es from approxi mat el y 650rpm t o approximat el y 750 rpm. Thi s is to increase the coolant flow t hrough t he pass enger compart ment element, whi ch, i nt urn, makes it pos si ble t o i ncreas e t he heat in t he pas senger compartment . The coolant pump i s dri ven by the powers teeri ng pump t hrough a flange.
Coolant Flow - Closed Thermostat
Coolant leaves the engine bl ock vi a t he 2 circui ts at t he rear edge on t he int ake side of the engi ne.
The cool ant i s rout ed from one of t he circui ts to t he engine's oi l cooler and onwards t o t he cool ant pump.Coolant is routed from the ot her ci rcuit t o a 'by-pass ' circui t where t here i s a valve. The val ve is cl osed at engines peeds up t o approximat ely 1500 rpm. At approximat el y 1500 rpm, the valve opens and cool ant pas s es through t hecircuit . By keepi ng t he val ve clos ed at low engine speeds, a suffi ci ent flow is guarant eed through the pas sengercompartment el ement to obt ain a good cl imat e (suffi ci ent heat) in t he pass enger compart ment .

Coolant Flow - Open Thermostat
W hen t he t hermos tat opens, coolant is al so rout ed to the radiatorThe radi at or has an inl et on the Ri ght Hand (RH) s ide and 2 out let s on t he left-hand si deThe great er volume of cooled coolant is routed at the radi ator's l ower out let t o the coolant pumpAt t he upper outl et some of the coolant is routed t o t he automat ic t rans mi ss i on's oil cool er. Before t he coolantreaches the oi l cooler, it pas ses a 'choke' circuit t hrough t he radi at or wit h a lower (s lower) fl ow t han other cool ant s .This provi des opt imum cool ing of t he cool ant before i t reaches the oi l cooler, whi ch in turn, provi des effect ivecool ing of t he transmis s ion oil . The cool ant i s rout ed from t he oil cooler onwards to t he cool ant pump.
Bleeding
The engi ne has 2 bl eed ci rcuit s connected t o t he expans ion t ank. One is l ocat ed on the radiat or and the ot her on thecyl inder head.
Radiator and Cooling Fan(s)
The radi at or, whi ch di s si pat es heat from t he engine cool ant and engi ne mount ed oil cooler, i s manufactured from a 27 mmalumi num mat ri x wit h hi gh-pres s ure i nject ion molded end t anks .
ItemPart NumberDescription
A-Col d t o mi ld cli mat e radiat orB-Hot cl imat e radi at or
Dependant on cli mate condit ions t here are 2 s peci fi cat ions of radiat or fan avail abl e:
Cold t o mild cl imat es : a s ingle fan unit des igned around a 500W mot orHot climat es : a t win fan unit feat ures t wo motors del iveri ng a t otal of 750W
Common t o bot h fan types are:
Electric mot ors wit h brus hesThe Engi ne Control Module (ECM) controls t he fan speed via Pul s e W i dth Modulat ion (PW M) s i gnal s to the El ect ronicFan Cont rol Module (EFCM)The fan speed i s cont rol led at 4 l evel s:- Run-on occurs i n 3 s t ages (i.e. depres s ing the fan s peed)- The engine cool ing fan i s act ivated a cert ai n t ime aft er t he engine has been s wit ched off to prot ect vari ousengi ne component s from overheati ng- The t ime the fan is act ivated and the s peed of the fan i s dependent on the coolant t emperature and thedri ver's driving s t yle (engi ne load) when t he engi ne is swi tched off- The hott er the engine and the hot ter t he load, the hi gher t he fan speed and t he longer run-on ti me. The

maximum t ime of run-on i s 360 s econdsThe EFCM can, by modul at ing the PW M control s i gnal, i nform t he ECM about the fan's st at us and any faul ts .
PW M cont rol of the fan mot or provides variabl e cont rol of fan speed t o ensure mi nimum fan noi se and reduced energycons umpt ion when fan operati on is required. The cont rol module is mount ed above the wade wat er ent ry li nesFor addit ional informat ion, refer t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol ,Des cript ion and Operat ion).
The cool ant expansi on tank provi des an expans ion volume and permit s eas y in-s ervice bleeding of t he cool ing s ys tem.Coolant level s ens ing i s precis e t o provide early warning i n t he event of low cool ant l evel . To prevent i ntrusi on int o t heexpans ion t ank's cas i ng, whi ch could be a potent ial leak path, a magnet ic float wi thin the t ank act ivat es a s wit ch locatedouts ide the t ank.

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Engine Cooling
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the cooli ng s ys t em, refer t o t he rel evant Des cript ion and Operat ion secti on in the workshopmanual.REFER to: Engine Cooli ng (303-03A Engi ne Cool ing - I6 3.2L Pet rol , Descri pti on and Operat ion).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual InspectionMechanicalElectrical
Coolant leaksCoolant expans ion t ankElectric fanRadiat or
FuseW i ri ng harnessLoos e or corroded connect or(s )Engi ne Coolant Temperature (ECT) s ensor
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 ep3.
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, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseActionCoolant los sHosesHose connect ionsRadi atorCool ant pumpHeat er coreGasketsEngi ne cas t ing cracksEngi ne block core plugs
GO t o Pinpoint Test A.
Engine overheati ngEngi ne cool ant (level/condit ion)Thermos tatFan motorFan motor fus es and/or circui tsECT s ens orEngi ne cont rol module (ECM)Fan speed module
GO t o Pinpoint Test B.
Engine not reaching normal operat ing t emperat ureThermos tatElect ric fanFan speed module
GO t o Pinpoint Test C.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve ext rainformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces, and wi th a current cali brati on cert ifi cat e. W hen t est ing res is tance, al ways take t he res is t ance of t he DMM leadsint o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
DT CDescriptionPossible CauseAction
P011600Engine coolant temperature s ens or 1circui t range/performanceEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: hi ghCheck t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l a

1
2
DT CDescriptionPossible CauseAction
res is t anceEngi ne cool ant t emperat ure(ECT) s ens or fai lure
new s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011621Engine coolant temperature s ens or 1circui t range/performance - s ignalampl it ude les s than minimum
Engi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o groundEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: openci rcuitEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011622Engine coolant temperature s ens or 1circui t range/performance - s ignalampl it ude greater t han maxi mum
Engi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o powerEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011700Engine coolant temperature s ens or 1circui t lowEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o groundEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: openci rcuitEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011800Engine coolant temperature s ens or 1circui t highEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o powerEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: openci rcuitEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P012500Insuffi ci ent coolant t emperature forclos ed-l oop fuel cont rolDamaged/Faul ty coolantthermost atCool ing fan faul tEngi ne cool ant t emperat ures ens or ci rcuit : highres is t anceEngi ne cool ant t emperat ures ens or fai lure
Check t he cool ing s ys tem operati on.Rect ify as neces s ary. Check for DTCsindicati ng a coolant temperat ures ens or fault .
P012800Coolant t hermos tat (coolantt emperat ure below thermost atregul ati ng temperat ure)
Damaged/Faul ty coolantthermost atCool ing fan faul tEngi ne cool ant t emperat ures ens or ci rcuit : highres is t anceEngi ne cool ant t emperat ures ens or fai lure
Check t he cool ing s ys tem operati on.Rect ify as neces s ary. Check for DTCsindicati ng a coolant temperat ures ens or fault .
P145C68Fan s yst em component errorCool ing fan cont rol moduletemperat ure fail ureNo acti on neces sary. Code forinformat ion only.
P145D68Fan s yst em component error BCool ing fan cont rol modulehigh t emperature i ndi cat ionNo acti on neces sary. Code forinformat ion only.
Pinpoint Tests
PINPOINT TEST A : LOSS OF COOLANT
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
A1: VISUAL INSPECT IONVis ually ins pect for l oss of coolant .
Carry out a s ys t em press ure tes t. See component t es ts i n t his s ecti on.
Is the engine cooli ng sys t em l eaking?YesRect ify t he leak as i ndi cat ed by t he tes t res ult . Top-up and fil l t he cooling sys tem t o the correctlevel wit h t he correct s pecificati on fl uid as necess ary.REFER to: Speci fi cat ions (303-03A Engi ne Cool ing - I6 3.2L Petrol , Specificati ons) /Cool ing Sys tem Drai ning, Fi ll ing and Bl eeding (303-03A Engine Cooli ng - I6 3.2L Pet rol, GeneralProcedures).TEST the s ys tem for correct operat ion.NoVeri fy t he cust omer compl aint.