lock LAND ROVER FRELANDER 2 2006 Service Manual

Engage wheel-free and l ower ramp unt il weight of vehi cl e res t s on s upport blocks and road wheels are jus t clear of ramp.
Ensure t hat vehicle is correct ly support ed on all four s upport blocks, t hat bl ocks are s ti ll correct ly pos it ioned and are in fullcont act wit h the body mount ing point s .
W ARNING: Make sure t hat t he vehicle i s s table before commencing work

For addit ional informat ion, refer t o: Parking Brake Cabl e Adjus tment (206-05 Parki ng Brake and Actuat ion, GeneralProcedures).
Door Locks and Hinges
1. Check operat ion of all door locks, bonnet lock and fuel fi ll er flap.
2. Lubricate al l door check s t raps , bonnet cat ch and fuel fill er fl ap cat ch.
Cooling System
CAUTION: Anti-freeze concentration must be maintained at 50%.
1. Check s peci fi c gravit y of cool ant us ing a hydrometer.
• NOTE: A s uit able hydromet er is avail abl e from the Equipment Programme under Part Number 511 3302 001 00.
2. Top-up cool ing s ys tem if neces s ary.For addit ional informat ion, refer t o: Specificati ons (303-03A Engine Cool ing - I6 3.2L Pet rol , Specificati ons ).
Cooling system - Check/Top-up
W ARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the fillercap from the coolant expansion tank whilst the system is hot.
• CAUTIO NS:
Engine coolant w ill damage the paint finished surfaces. If coolant is spilled, immediately remove the coolantand wash the area with water.
Always top-up with a 50% mixture of anti-freeze and water.
Check t he l evel of cool ant i n t he expans ion t ank. W it h t he engi ne col d, the coolant level must be to the UPPERLEVEL indicat or mark above the COLD FILL RANGE t ext on the s i de of the expans i on tank. Ignore any coolantwhich may be vis ible in t he t op s ect ion of t he t ank.If topping-up i s requi red, remove expans ion tank fill er cap and top-up coolant level to the UPPER LEVEL indicat ormark.For addit ional informat ion, refer t o: Specificati ons (303-03A Engine Cool ing - I6 3.2L Pet rol , Specificati ons ).Ins t all expans ion t ank fi ll er cap, ti ght en cap unti l ratchet is heard to 'cli ck'.
Coolant - Replace
Every 10 years: Repl ace the coolant.For addit ional informat ion, refer t o: Cool ing Sys tem Drai ning, Fi ll ing and Bl eeding (303-03A Engine Cooli ng - I6 3.2L Pet rol,General Procedures ).
Ignition System
Every 75,000 miles (120,000 km). Replace s park plugs .For addit ional informat ion, refer t o: Specificati ons (303-07B Glow Pl ug Sys t em, Specificati ons ).
Accessory Drive Belt
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
Check t he condi ti on of the access ory drive bel t.Remove all t races of mud and dirt from t he dri ve belt and pull eys .Check t he drive belt for si gns of s pli tt ing and wear.Every 105,000 miles (168,000 km) - Petrol models: Replace the accessory drive belt. For addi ti onalinformat ion, refer t o: Acces s ory Drive Belt (303-05A Acces s ory Drive - I6 3.2L Pet rol , Removal and Ins t allat ion).

For addit ional informat ion, refer t o: Parking Brake Cabl e Adjus tment (206-05 Parki ng Brake and Actuat ion, General
Procedures).
Door Locks and Hinges
1. Check operat ion of all door locks, bonnet lock and fuel fi ll er flap.
2. Lubricate al l door check s t raps , bonnet cat ch and fuel fill er fl ap cat ch.
Cooling System CAUTION:
Anti-freeze concentration must be maintained at 50%.
1. Check s peci fi c gravit y of cool ant us ing a hydrometer.
• NOTE: A s uit able hydromet er is avail abl e from the Equipment Programme under Part N umber 511 3302 001 00.
2. Top-up cool ing s ys tem if neces s ary.
For addit ional informat ion, refer t o: Specificati ons (303-03B Engine Cool ing - TD4 2.2L Dies el, Speci fi cat ions ).
Cooling system - Check/Top-up W ARNING:
Since injury such as scalding could be caused by escaping steam or coolant, do not r emove the filler
cap from the coolant expansion tank whilst the system is hot.
• CAUTIO NS:
Engine coolant w ill damage the paint finished surfaces. If coolant is spilled, immed iately remove the coolant
and wash the area with water.
Always top-up with a 50% mixture of anti-freeze and water.
Check t he l evel of cool ant i n t he expans ion t ank. W it h t he engi ne col d, the coolant level must be to the UPPER
LEVEL indicat or mark above the COLD FILL RANGE t ext on the s i de of the expans i on tank. Ignore any coolant
which may be vis ible in t he t op s ect ion of t he t ank. If topping-up i s requi red, remove expans ion tank fill er cap and top-up coolant level
to the UPPER LEVEL indicat or
mark.
For addit ional informat ion, refer t o: Specificati ons (303-03B Engine Cool ing - TD4 2.2L Dies el, Speci fi cat ions ).
Ins t all expans ion t ank fi ll er cap, ti ght en cap unti l ratchet is heard to 'cli ck'.
Coolant - Replace
Every 10 years: Repl ace the coolant.
For addit ional informat ion, refer t o: Cool ing Sys tem Drai ning, Fi ll ing and Bl eeding (303-03B Engine Cooli ng - TD4 2.2L
Dies el, General Procedures).
Accessory Drive Belt CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
Check t he condi ti on of the access ory drive bel t. Remove all t races of mud and dirt from t he dri ve belt and pull eys .
Check t he drive belt for si gns of s pli tt ing and wear.
Every 150,000 miles (240,000 km): Replace the accessory drive belt.
For addit ional i nformati on, refer t o:
Acces s ory Drive Belt (303-05A Acces s ory Drive - I6 3.2L Pet rol , Removal and Ins t allat ion).
Camshaft Timing Belt, Tensioner and Pulley
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.

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

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.

LOWER CONTROL ARM
ItemPart NumberDescription
1-Subframe2-Bal l bus h
3-Bol t - front att achment
4-Bol t - rear at tachment (2 off)5-Nut - rear att achment (2 off)
6-Hydrabus h
7-Locknut8-Taper ball joi nt
The lower cont rol arm as s embly compri s es the control arm, a rubber bus h, a hydrabus h and a bal l joint .
The cont rol arm i s a pres s ed s teel fabricati on. The outer end i s fi tt ed wi th a non-serviceabl e t aper ball joint which mat eswit h t he wheel knuckl e.
The 2 i nner at tachment s l ocat e in the s ubframe. The forward at tachment is a non-s erviceabl e rubber bus h whi ch is press edint o t he cont rol arm. Thi s joi nt locat es in a s lot i n t he subframe and is s ecured wit h a bol t which i s s crewed int o at hreaded bos s on t he s ubframe.
The rearward at tachment is a hydrabus h whi ch is l ocat ed on a s pigot on t he cont rol arm. The hydrabus h has 2 wel dedbracket s whi ch provi des for i ts at tachment to the s ubframe wi th 2 bolt s and nuts . The hydrabus h contai ns hydraul ic fluidand valves which all ow control led di spl acement of the bus h t o i mprove bump and handli ng charact eris t ics and als o reduceroad noi se trans mi s si on. The bus h becomes progres si vel y s ti ffer as the forces on i t increas e, s uch as s evere braking.
WHEEL KNUCKLE AND HUB ASSEMBLY

ItemPart NumberDescription
1-Locknut (hi dden)2-Ball joi nt
3-Link
4-Ball joi nt5-Locknut
6-Clamp
7-Bus h8-Stabi lizer bar
9-Bolt (2 off)
The s tabil izer bar i s at tached to the rear of t he s ubframe wit h bus hes and mount ing bracket s. The pres s ed s teel bracket slocate over t he bus hes and are att ached t o t he cros s member wit h bolt s s crewed i nto t hreaded locati ons in t he s ubframe.The s tabil izer bar has 'ant i-s huffl e' coll ars press ed i n posi ti on on t he ins ide edges of the bus hes. The coll ars prevents ideways movement of t he s tabil izer bar.
The s tabil izer bar i s manufactured from 20.5 mm diamet er, manganes e s t eel bar. Each end of t he s tabil izer bar curvesforwards t o at tach t o a ball joint on a s t abi li zer l ink. Each s t abi li zer l ink i s s ecured to a bracket on t he damper body wit h alocknut . The li nks , which are not handed, allow the st abili zer bar t o move wi th the wheel travel provi di ng maximumeffect iveness .
The s tabil izer bar bus hes are t he compres s ion t ype which gri p t he bar under compres si on by t he mount ing bracket s. W henfi tt ing replacement bus hes, i t is import ant to ens ure the bus hes are correct ly orient ated t o t he bar. Fail ure t o correct lyali gn the bus hes wil l res ult i n exces si ve pre-load (wind-up) i n t he bus hes when t he s us pensi on is at it s nominal ri deheight.

Publi s hed: 11-May-2011
Rear Suspension -
C oil Spring SuspensionItemSpecification
RearConvent 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 C olor C oding - Rear
Part NumberSpring ColorIsolator
RKB 500210GreyLR 003092 (9mm)RKB 500210Grey/W hit eLR 005304 (15mm)
RKB 500220BrownLRL 003092 (9mm)
RKB 500220Brown/W hi teLR 005304 (15mm)• NOTE: The grey or brown s prings have a 9 mm thi ck i s ol ator
• NOTE: The grey/whi te or brown/whi te springs have a 15 mm t hick is olat or
To mai nt ain correct trim height make s ure t he s pri ng col our and appropriate is olat or i s mat ched
Torque SpecificationsDescriptionNmlb-ft
Damper locknut8059
Front l ower arm t rans vers e li nks nut s & bol ts175129Rear ri de hei ght sens or107
Rear lower arm nuts & bolt s175129
Spri ng and damper as s embly t op mounti ng nuts3224St abi lizer bar bus hing cl amp bolt s*6044
St abi lizer li nk nuts *6044
Trai li ng arm nut s and bolt s270199Trai li ng arm bracket t o body bolt s*11081
W heel knuckle to damper clamp bol t11081
* New nuts/bolts must be fitted

SPRING AND DAMPER
ItemPart NumberDescription
1-Boot
2-Spri ng aid3-Locknut
4-Cap
5-Locknut (3 off)6-Gas ket
7-Top mount as sembl y
8-Spacer9-Spri ng is olat or
10-Spri ng
11-Spri ng is olat or12-Damper body
13-Spri ng s eat
14-Damper pis t on rodThe 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. A mas s damper is at tached t o the damper s pri ng s eatt o absorb vibrat ion and prevent nois e i ntrus i on int o t he vehi cl e int eri or.
The t op mount is fit ted wit h a gas ket t o prevent the ingres s of mois t ure bet ween the t op mount and t he turret mounti ng.

The t op mount at t aches t o a s t rengthened turret on t he chas s is wit h 3 i ntegral s tuds and s elf-l ocking 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.
TRANSVERSE LINKS
ItemPart NumberDescription1-Locknut
2-Eccentric bol t
3-Bush - inner4-Eccentric cam washer
5-Locknut
6-Rear trans vers e l ink7-W as her
8-Bolt
9-Bush - outer10-Locknut
11-Locknut
12-Bush - outer13-W as her
14-Bolt
15-Front t ransverse link16-Bush - inner
17-Bolt
Lateral wheel locat ion is provi ded by 2 t rans verse li nks whi ch are l ocat ed between the s ubframe and the wheel knuckle.The li nks are l ong to gi ve excell ent camber cont rol . Each l ink i s fi tt ed wi th dynamic bus hes t o cont rol t he rear camber i n aprogres s ive manner as corneri ng loads increas e which gi ves a li mit ed amount of pas s ive rear wheel s teeri ng. The 2t ransverse links are different i n t hei r des i gn. The front li nk is a s teel pres si ng. The rear li nk is fabricated from s queezedand cropped tube. The li nks are des igned to wit hst and vehi cle jacking loads.
The front trans vers e l ink i s fi tt ed wi th bus hes which compres s under cornering forces to provide a cont roll ed amount of rearwheel t oe-i n, in addit ion t o t he camber control. The front li nk has a deform point in a central pos it ion al ong it s lengt h.This al lows t he li nk to be deformed in the event of a s evere lat eral rear wheel i mpact , for example st ri king a kerb. In t heevent of a s evere l ateral i mpact , t he li nk wil l permanent ly deform, abs orbing t he i mpact and prot ect ing the s ubframe fromdamage. The amount of deformat ion creat es exces s ive t oe-in which i s immedi ately not iceable t o t he dri ver.
The rear t rans verse li nk is mount ed to the subframe us ing an eccentric bolt and was her which all ows for adjus t ment of t hewheel t oe angle.
Both trans vers e l inks are at t ached t o t he s ubframe wit h bolt s and locknut s . The out er ends of each li nk locate in mount ingholes i nt egral wit h t he wheel knuckl e and are s ecured wit h bolt s and locknut s .
LONGITUDINAL LINK