AUX LAND ROVER FRELANDER 2 2006 Owner's Manual

5-Engine coolant pump
6-Exhaus t Gas Recircul at ion (EGR) valve cool er
7-Heat er connect ion hos es8-Cl imat e cont rol s yst em heat er matrix
9-Thermal control modul e
10-Auxil iary coolant pump (col d cli mate vehi cl es )11-Fuel Fi red Boos ter Heater (FFBH) - (cold cli mate vehi cl e)
OVERVIEW
The main requirement of t he TD4 di es el engi ne cool ing s ys tem is t o regul ate t he engines operati ng t emperature, wit hi n anopti mum range for all ambi ent and operat ing condit ions. Addit ional functi ons of t he cool ing s ys tem are to provi de heat ingt o the cl imat e cont rol s ys tem, and cooling for the EGR s ys t em, engi ne lubri cat ion sys tem, and t rans mi ss i on lubri cat ions ys t em (automat ic t rans mis s ion model s only).
The cool ing s ys tem pipes and hoses feature qui ck rel eas e coupl ings t o all ow eas y acces s to the sys tem.
On cold cl imat e market vehicles , the cooli ng s ys t em i s modified t o i ncorporate a FFBH and auxi liary cool ing pump. TheFFBH provides auxili ary heati ng t o t he vehi cl e cabi n.For addit ional informat ion, refer t o: Fuel Fired Boost er Heat er (412-02B Auxi liary Cli mate Cont rol , Des cri pti on andOperat ion).
COOLANT PUMP
ItemPart NumberDescription
1-Bolt (7 off)

ItemPart NumberDescription
A-Cool ing s yst em (t emperate cl imat e vehicles )B-Addi ti onal cool ing s ys tem components (cold cli mate vehi cl es)
1-FFBH
2-Auxil iary cool ant pump
Engine Cold
Duri ng engi ne s tarti ng the coolant pump i s dri ven by the cams haft drive belt and circul ates coolant through t he enginecyl inder block, engine oi l cooler and cyl inder head. Coolant als o flows t hrough t he cl imat e control heat er circui t and t heEGR cooler. The t hermos tat i s in the cl os ed pos it ion and prevent s the return of coolant from t he engi ne to the radiat or.
W i th the t hermos t at cl os ed, the by-pas s valve is open and direct s t he ret urn coolant t hrough the t hermal control modul eand cool ant rail t o t he cool ant pump hous ing. The cool ant conti nues t o circul ate and is progress i vel y heat ed by t he engi ne.

Publi s hed: 11-May-2011
Accessory Drive - I6 3.2L Petrol - Accessory Drive Shaft Rear Seal
Removal and Inst all ati on
Special T ool(s) 303-1227
Inst all er, Auxili ary Drive Seal
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.
Remove t he acces sory dri ve pul ley.
Refer t o: Acces sory Dri ve Pulley (303-05A Acces s ory Drive - I6 3.2L
Petrol, Removal and Ins tall ati on).
2. 3. CAUTION: Di scard the s eal.
3.
Installation Inst all t he s eal t o t he s pecial t ool
Speci al Tool (s ): 303-1227 Remove t he s eal guide.1.

Publi s hed: 11-May-2011
Accessory Drive - TD4 2.2L Diesel - Accessory Drive Belt Tensioner
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
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.
Remove t he auxi liary dri ve belt .
Refer t o: Acces sory Dri ve Belt (303-05B Acces sory Drive - TD4 2.2L
Di es el, Removal and Ins tal lat ion).
2. 3.
NOTE: Make s ure t hat the component i s ins t al led t o
t he posi ti on noted on removal .
T orque: 45 Nm 3.
Installation To i nst all , revers e t he removal procedure.
1.

Publi s hed: 11-May-2011
Starting System - TD4 2.2L Diesel, Vehicles Built From: 01-03-2009 -
Starting System
Des cript ion and Operat ion
STOP/START SYSTEM
COMPONENT LOCATION
Stop/St art s ys tem component locati on
ItemPart NumberDescription
1-Volt age quali ty modul e2-Batt ery moni toring s yst em modul e
3-Absorpt ion gl ass mat batt ery
4-Gear neut ral s ens or5-Starter mot or
6-Auxi li ary cool ant pump
7-Linear cl ut ch s ens or8-Brake vacuum s ens or
9-Stop/St art s wi tch
OVERVIEW

ItemPart NumberDescription
1-Brake vacuum s ens or2-Engine cont rol module
3-Gear neut ral s ens or
4-Batt ery junct ion box5-Auxili ary coolant pump*
6-Starter mot or
7-Hil l decent cont rol s wit ch8-Driver’s safety-bel t buckle-swi tch
9-Driver’s door ajar-s wi tch
10-Linear cl utch s wit ch11-Clut ch pedal t op-of-travel s wit ch
12-Clut ch pedal bott om-of-t ravel s wit ch
13-Volt age qual it y module14-Stop/Start swi tch and s t atus LED
15-Central junct ion box
16-Res trai nts control modul e17-Terrain respons e cont rol module
18-ABS (ant i-lock brake s ys tem) modul e
19-W heel s peed s ens or20-Hood lat ch ajar s wit ch
21-Batt ery moni toring s ys tem module
22-Automat ic t emperat ure control modul e23-Ins t rument clus ter
24-Trai ler module

25-Fuel fired heat er (i f fi tt ed)
26-Auxili ary coolant pump **
* Vehicles wit hout fuel fired heat er.
** Vehicles wi th fuel fi red heater.
INTELLIGENT TECHNOLOGY
New and revi s ed components as di s cus s ed in this secti on have been developed t o ensure t hat al l vehicl e s ys t ems operatevirtuall y uninterrupt ed in a Stop/St art cycl e.
Voltage Quality Module
Duri ng an engine St op/Start cycle t he VQM (volt age qual it y module) mai ntains t he vehicle’s el ect ri cal s yst ems by s upplyinga s upport volt age around the vehicle's electroni c components during an engine res tart. This al lows crucial vehicle s ys temst o cont inue unint errupt ed when t here i s a s udden draw of amps from the bat tery.
The vehi cl e’s s t art er mot or cons umes 2kW of el ect ri cal power and can draw s everal hundred amps of current from thebatt ery during cranking. Thi s s udden draw of current causes a momentary volt age drop around al l t he vehicle ci rcuit s. Manyof the vehicle's electroni c s ys t ems are des i gned t o operat e at a nomi nal 12 volt s , so thi s s udden drop in bat tery volt agewit hout the VQM ins t al led woul d temporaril y i nt errupt servi ces such as :
audi o s yst emcel lul ar phonenavi gat ion sys temmes s age Cent er.
Once the engi ne is runni ng a s ignal from t he ECM triggers a relay wit hi n t he VQM t o bypass the converter s t age andvolt age control is gi ven back t o t he vehi cl e's normal charging sys tem. The VQM is specified t o boost vol tage for ones econd, alt hough i n many s it uati ons i t can s upply a volt age boos t for up t o 5 seconds .
The VQM is effecti vel y a DC (direct current) converter, which convert s a variable DC input vol tage from as l ow as 6V up t oa s t abl e 12V DC out put ± 0.5V.
Rated at a nominal 180W , it can s uppl y up t o 15 amps of load at 12 vol ts . The VQM can t olerat e i ns t ant aneous s pikes upt o 300 W at ts , enough to maintai n uninterrupt ed power t o vehicle s ys tems during engine cranking.
VQM fault s are trans mi tt ed via a diagnost ic l ink t o t he CJB where they are hel d; the fault codes can be di agnos ed us ingLand Rover approved diagnos t ic equipment .
Battery Monitoring System
Mounted on t he batt ery negat ive t ermi nal t he BMS (batt ery moni toring s yst em) module is i ntegral wi th t he batt erynegat ive cable.
Batt ery healt h s t at us i s a fundamental fact or in t he correct operat ion of t he Stop/St art s ys tem. Computat ion of t he batt erys tat us is performed by t he BMS module and will i nit iate a ‘St op Inhi bit or’ or ‘Start Ini ti at or’ i n a St op/Start cycle if t hebatt ery cannot meet t he requi red demand. For addit ional informati on refer to the ‘Stop Inhi bit ors , Start Init iat ors and St art

To ens ure t he vehi cl e’s braki ng s ys t em i s never compromi sed, a brake vacuum s ens or is int roduced on Stop/St art vehiclest o monit or vacuum reserves in t he brake s ervo. The vacuum sens or is mount ed in the vacuum pipe and hardwi red to t heECM. In the event of brake vacuum decreas ing below a s et threshold during a Stop/St art cycl e t he ECM wi ll s end a s ignalt o eit her:
Rest art t he engine and consequentl y replenis h vacuum reserves .Inhi bi t t he engi ne s hut ti ng down if vacuum res erves are not s uffi ci ent.
An example of vacuum res erves deplet ing, is by t he dri ver repeat edly pres s ing t he brake pedal when the engine iss hut down duri ng a St art/Stop cycle. This acti on wil l init iat e an engine res tart when vacuum reserves decreas e below thes et thres hold.
If a fault develops wi th the brake vacuum s ensor a DTC wil l be logged in the CJB.
Auxiliary Coolant Pump
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 auxil iary el ect ri c cool ant -pump has been integrat ed i nt o t he cool ing s ys tem to maint ain t he cool antfl ow t hrough t he cabi n’s heat er core. Thi s s upporti ng ci rculat ion t herefore prol ongs t he s et temperat ure set ti ng in the cabinand accordi ngl y prevents an early engine res tart.
Dependi ng on vehi cl e clas s ifi cat ion the auxil iary coolant pump i s eit her:
Hardwi red di rectl y to the ECM.Or if t he vehicle i s fit ted wi th a FFBH (fuel fi red boos ter heat er), t he FFBH coolant pump i s uti li zed and act ivatedvia t he FFBH.
The functi onal it y of bot h t ypes of auxil iary coolant pump i s t he s ame wi th regards the Stop/St art s ys tem.
To dis guis e t he acti vat ion s ound of the auxil iary pump, t he pump i s acti vat ed at the same ti me as t he engine s huts down.
Remote Handset
To all ow t he dri ver eas e of use, a revis ed remot e handset releas e has been introduced. Thi s all ows t he driver t o ins t ant lyrel eas e t he remote hands et from t he s tart cont rol module when t he engine i s s hut down in a Stop/Start cycle.
The vehi cl e reverts t o t he conventi onal remote hands et releas e when not in a Stop/Start cycle, that i s by pres s ing t heignit ion St art /St op butt on before rel eas i ng the remote hands et.
Stall Recovery
In the event of an engi ne s tal l, t he Stop/St art s ys tem ent ers a unique ‘s t al l recovery’ mode. This feature aut omat ical lyatt empts to res tart the engine as soon as t he driver full y depres ses t he clut ch pedal; t he natural react ion of t he dri verwhen experiencing a s t alled engi ne si tuat ion.
Once the cl utch s ensor detects the ‘bot t om of t ravel’ threshold, refer to ‘Linear Clut ch Sens or’, t he s t arter mot or isact ivat ed to res tart the engine. The warni ng indicat ors normal ly as s oci ated wi th an engi ne s tal l, for example the i gni ti onand low oil pres s ure i ndi cat ors i n t he ins t rument clus ter wil l be s uppress ed s o wi ll not il lumi nat e. The Eco indicator does

ItemPart NumberDescription
A-Doubl e web pl anet ary gear train - RearB-Single web planetary gear t rai n - Front
1-Clut ch C2
2-Brake B23-Free wheel cl utch F2
4-Count er drive gear
5-Brake B16-Clut ch C1
7-Clut ch C3
8-Fluid pump9-Input s haft
10-Different ial gear as s embly
11-Count er gear as s embl y12-Pinion gears
13-Sun gears
14-Ring gear15-Pinion gear
16-Sun gears
17-Ring gearThe planetary gear t rai ns used on the AW F21 t rans mis s ion compris e a s i ngl e web planet ary gear train and a double webplanetary gear t rai n. Thes e gear trains are known as Ravi gnaux t ype gear t rains and together produce the s i x forwardgears and t he one revers e gear.
Engi ne t orque is trans ferred, via operat ion of s i ngl e or combi nati ons of clut ches t o t he t wo planetary gear t rai ns. Bot h geart rains are cont rol led by react ionary i nput s from brake clut ches t o produce the si x forward gears and one revers e gear. The

The fuel deli very module flange i s s eal ed to the t ank wit h an O-ring and s ecured wi th a locki ng ring.
The lower part of t he fuel deli very module forms the fuel del ivery pot , and provides the locat ion for the in-t ank pump andt he 2 jet pumps . The delivery pot provi des a cons t ant res ervoir of fuel for t he engine drawn fuel supply. The engine fuels uppl y and ret urn l ines are immers ed in the del ivery pot .
The delivery pot is mai ntained full by t he 2 jet pumps . The i n-t ank pump draws fuel from wit hin the fuel deli very pot andforces the fuel t hrough t he 2 jet pumps . The flow of fuel t hrough each jet pump creat es a venturi effect t hat draws fuelfrom bot h s ides of t he fuel tank i nto the fuel deli very pot. Surpl us fuel entering the fuel deli very pot overflows into theus abl e s ide of t he fuel t ank.
A valve i s l ocated in t he l ower (usabl e tank s i de) jet pump s uppl y ori fi ce. The valve i s open when the i n-t ank pump isenergized and t he lower jet pump is s upplying fuel i nto the fuel del ivery pot . The val ve wil l cl os e when the i n-t ank pump isde-energized t o prevent fuel drai ni ng from the fuel del ivery pot .
The in-tank pump is energized by t he fuel pump relay l ocat ed in the Cent ral Juncti on Box (CJB). The Engine Cont rol Module(ECM) energi zes the fuel pump relay at al l ti mes when t he ignit ion i s in power modes 4 (Acces s ory) t o 9 (Engi ne crank).For addit ional informat ion, refer t o: Electroni c Engi ne Controls - 2.2L Dies el (303-14 El ect ronic Engine Cont rols - 2.2LDies el, Des cript ion and Operat ion).
A modi fi ed fuel delivery modul e i s ins tal led for col d climat e market vehicl es that feat ure a fuel fi red boos ter heater andauxi li ary fuel pump. The modified fuel del ivery modul e incorporat es a s eparate fuel supply line that connects t o anauxi li ary fuel pump, mounted on the ext erior RH si de of the tank. An addi ti onal fuel l ine connects the auxil iary fuel pumpt o the fuel fi red boos ter heat er.For addit ional informat ion, refer t o: Fuel Fired Boost er Heat er (412-02B Auxi liary Cli mate Cont rol , Des cri pti on andOperat ion).
Fuel Sender Units
The 2 MAPPS fuel s ender uni ts are located on eit her s ide of t he s addl e s haped tank, and connect t o t he int ernal elect ricalconnecti ons on the fuel del ivery modul e fl ange. Each s ens or provides an elect rical signal t o t he CJB t hat i s proport ionatet o the fuel level i n each s ide of t he tank.
The act ual fuel level i n t he t ank i s calculated by the CJB and t rans mit t ed via t he medium s peed Cont roll er Area Net work(CAN) bus t o t he ins t rument clus ter.
A warning l amp is incorporat ed in t he i ns t rument clus ter and wi ll il lumi nat e when t he fuel l evel is at, or below apredetermined l evel . On vehi cles wi th a high-l ine i nst rument clus ter, a mes s age is di spl ayed and a chi me i s s ounded t oinform the driver to refuel .
For addit ional informat ion, refer t o:
Ins trument Clus ter (413-01 Ins t rument Clus t er, Descripti on and Operat ion),Informat ion and Mes s age Cent er (413-08 Informati on and Mes sage Cent er, Descripti on and Operat ion).
Fuel Tank Breather Valve
The breat her valve i s located i n t he fuel t ank and is connected to the fuel deli very module fl ange vi a an i nt ernal breatherhose. The breat her valve al lows ai r to es cape and ent er the fuel tank t o compens at e for t he changing vol ume wit hin thet ank.
FUEL TANK FILLER