ABS LAND ROVER FRELANDER 2 2006 Workshop Manual

5
-Dus t s hi eld retai ni ng s crew (4 off)
6 -Brake di sc – s olid (TD4 di esel vehi cle)
7 -Brake di sc ret ai ning s crew
8 -Brake di sc – vent il ated (i6 gas oli ne vehi cl e)
9 -Fixed carrier
10 -Bus hed bol t rubber boot (2 off)
11 -Bus hed bol t
12 -Cali per pi st on s eal
13 -Brake pad retai ni ng s pri ng (2 off)
14 -Out er ant i-squeal shi m
15 -Cali per pi st on
16 -Out er brake pad
17 -Inner brake pad
18 -Sli ding cali per
19 -Inner anti -s queal s him
20 -Cali per bl eed screw
21 -Bleed s crew cap
22 -Bus hed bol t ret aining s crew (2 off)
23 -Rear Left-Hand (LH) wheel knuckle
24 -Fixed carrier ret aining bol t (2 off)
25 -Anti -l ock Brake Syst em (ABS) s ens or ret aining s crew
OVERVIEW
The rear brake as s embly feat ures ei ther a convent ional venti lat ed or a s olid type br ake di s c, and cast -iron sl idi ng cal iper
wit h s i ngl e act ing pi s ton.
BRAKE DISC Item
Part Number Description
A -Rear brake dis c - i 6 gas ol ine vehicle
B -Rear brake dis c - TD4 di esel vehicle
The vent il ated t ype brake dis c i s 302 x 20 mm (11.89 x 0.79 in) i n diamet er and ins t al led t o t he 3.2 l it er i6 gas oli ne
vehi cl e. The sol id t ype brake dis c i s 302 x 12 mm (11.89 x 0.47 i n) i n diamet er and ins tal led t o t he 2.2 lit er TD4 dies el
vehi cl e. The brake dis c i s s ecured to t he wheel knuckle hub wi th a s ingle screw and is al s o ret ained by t he 5 wheel
s ecuring nuts .
Both si zes of rear brake dis c are suffi ci ent ly cooled to achieve high level s of t her mal st abil it y, even duri ng s evere braking.
The s olid type brake di sc is cooled as t he vehi cles forward moti on direct s air over the di sc surfaces . The convent ional
vent il ated di sc is cooled by t he forward moti on of the vehicle drawing ai r through r adial s lots formed on t he dis c outer rim.
The air cools t he dis c from the i nsi de edge to the di s c cent er, before vent ing out t hrough s lots formed around t he dis c
cent ral bell .

3-St opl amp s wit ch
4-Hydrauli c pipes
5-Integrat ed Hydrauli c Cont rol Unit (HCU) and Anti -l ock Brake Sys t em (ABS) modul e6-Brake mast er cyl inder and flui d res ervoir
OVERVIEW
The hydraulic brake s ys t em i s a diagonally spl it dual ci rcuit s yst em and cons is ts of the brake pedal, brake mast er cyl inder,HCU and t he hydrauli c pipes and hoses . The s ys t em al so features a non-acti ve brake boost er.For addit ional informat ion, refer t o: Brake Boos ter (206-07 Power Brake Act uati on, Des cript ion and Operat ion).
The preformed rigi d brake pipes di st ri but e press ure from t he mas ter cyli nder t o t he 4 brake cali pers , vi a t he int egratedHCU and ABS modul e. Fl exi ble hos es connect the rigid brake pipes t o t he front and rear cal ipers .
BRAKE PEDAL
ItemPart NumberDescription
1-St oplamp swi tchThe brake pedal i s mounted in a bracket t hat is at tached to the rear si de of the engine bul khead. The pedal as sembl y isdifferent for LHD and RHD vehicles , and is connect ed to the brake boos t er pus h rod wit h a cl evi s pin.
The s toplamp s wit ch is mount ed on t he brake pedal bracket and wil l ill uminat e the vehicl e s toplamps when the brakepedal i s pres s ed. The s t opl amp s wit ch is al s o used as an input to the speed cont rol s ys tem, and wi ll cancel the currents peed set ti ng when t he brake pedal i s pres s ed. For addi ti onal i nformat ion, refer to:
Speed Cont rol - 3.2L (310-03 Speed Cont rol - 3.2L, Des cript ion and Operat ion),Speed Cont rol - 2.2L Di esel (310-03 Speed Cont rol - 2.2L Di esel , Descri pti on and Operat ion).
BRAKE MASTER CYLINDER AND FLUID RESERVOIR

ItemPart NumberDescription
1-Brake pipe t o LH front cali per2-ABS modul e
3-Brake pipe t o RH front cali per
4-Mas t er cyli nder primary circuit connect ion5-Brake pipe t o LH rear cal iper
6-HCU
7-Brake pipe t o RH rear cal iper8-Mas t er cyli nder s econdary ci rcuit connect ion
The HCU i s located on the rear LH s ide of t he engi ne compartment and i s an i nt egral component wit h t he ABS module. TheHCU i s a 4 channel uni t that modulat es the s upply of hydrauli c pres sure t o t he brakes under t he cont rol of the ABSmodule.
The pri mary and secondary outl et ports of t he mas ter cyli nder are connect ed via 8 mm (0.315 in) diamet er brake pipes t ot he primary and s econdary ci rcuit s of the HCU. The primary circui t in t he HCU provi des 2 s eparate out let port s t o t he RHfront and LH rear brakes . The secondary circuit in t he HCU provi des 2 s eparate out let port s t o t he LH front and RH rearbrakes.
The HCU i ncorporates 3 brake operati ng modes as fol lows :
Normal braki ng/ El ect ronic Brake Force Dis t ri but ion (EBD)ABS brakingActi ve braking.
As t he HCU and ABS modul e is a ful ly i ntegrat ed unit , the des cript ion and operat ion det ai ls for the HCU and ABSfuncti onal it y, i ncl udi ng t he 3 braking modes , are det ail ed in the Ant i-Lock Control - Stabil it y As si st secti on of the manual .For addit ional informat ion, refer t o: Anti -Lock Cont rol - St abi li ty As s is t (206-09 Anti -Lock Cont rol - St abi li ty As s is t ,Des cript ion and Operat ion).
Servicing Information
The ABS module and HCU form a s ingle component and must not be s eparat ed. The ABS modul e and HCU as s embly i ss uppl ied i n a pre-fill ed s tat e. Aft er i nst all at ion, t he hydraul ic brake sys t em only requi res a conventi onal bleed of t hes ys t em; t here is no requirement to press ure bleed t he s ys t em.
• NOTE: The ABS module and HCU i s a fragil e component and mus t be dis carded if dropped or damaged.
PRINCIPLES OF OPERATION
As t he brake pedal i s pres s ed, t he front push rod i n t he brake boost er pus hes t he mas ter cyl inder pri mary pi st on along t hebore of t he housi ng. This produces pres s ure in t he pri mary pres sure chamber and i n conjunct ion wi th the primary s pri ng,overcomes the s econdary s pring and s i mult aneous ly moves t he s econdary pi st on along the bore.
The ini ti al movement of the pi s tons away from the pi st on s t ops cl os es t he pri mary and secondary cent er val ves l ocat edins ide the mas t er cyli nder. Further movement of the pi st ons then press uri zes the flui d in the primary and s econdarychambers and t he brake circuit s . The fl uid i n t he chambers behi nd the pi s tons i s unaffected by the movement of the

pis t ons and will flow unrest ri cted t hrough t he inlet ports , between t he chambers and t he res ervoir.
Pres s urized fluid ent ers the HCU that i s mounted on t he front of the ABS modul e. The HCU t hen modul ates t he s uppl y ofpres s urized fluid to the brakes under cont rol of the ABS modul e.For addit ional informat ion, refer t o: Anti -Lock Cont rol - St abi li ty As s is t (206-09 Anti -Lock Cont rol - St abi li ty As s is t ,Des cript ion and Operat ion).

Publi s hed: 11-May-2011
Anti-Lock Control -
General SpecificationItemSpecification
Syst em make / typeConti nent al Teves - MK23E1
Wheel speed sensors:MakeConti nent al Teves
Yaw rate sensor:
Make / t ypeConti nent al Teves - RSC03Locat ionCenter cons ole in front of gear shi ft
Torque SpecificationsDescriptionNmlb-ft
ABS module to mount ing bracket nuts107
Accel erometer bolt s65Brake flui d t ube uni ons1511
Front road wheel s peed sens or to wheel knuckle bol t54
Rear road wheel speed s ensor t o wheel knuckle bolt54

1
2
Publi s hed: 11-May-2011
Anti-Lock Control - Anti-Lock Control
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the Ant i-lock Braking Sys t em (ABS), refer to the relevant Des cri pt ion and Operati on s ect ion i nt he works hop manual . REFER t o: Anti -Lock Cont rol - St abi li ty As s is t (206-09C Anti -Lock Cont rol - St abi lit y As s is t,Des cript ion 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.
• NOTE: Pri or to any t es ti ng or ins pect ion, the vehicle should be check for any relevant warning l amps bei ng il lumi nat ed. Ifa warning l amp is ill uminat ed, check for DTCs and refer to t he relevant DTC Index, if no warni ng lamp is i ll uminated,cont inue wi th diagnos t ic procedures below.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of damage and s ys t em i ntegri ty.
Visual InspectionMechanicalElectrical
Brake flui d levelVacuum s ys t emW heel s peed sens or ins tall ati onW heel s peed sens or ai r gapSt eering wheel rot ati on sens orAccel erometer/s ens or clus t er i nst all ati onIncorrect wheel or t ire s ize
W arning light operat ionFus esW heel s peed s ens orsConnect ors /Pi nsHarnes s esSt eering wheel rot ati on s ens orAccel eromet er/sens or cl ust erHydraul ic Control Uni t (HCU)
2.
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 , check t he ant i-lock braking sys tem and s teering rot ati on s ens or modules forDi agnos ti c Trouble Codes (DTCs) and refer t o t he rel evant DTC Index.4.
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 addi ti onalinformat 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 an up-t o-date cal ibrat ion cert ificate. W hen tes ti ng res is t ance al ways take t he res is t ance of t he DMMleads i nt 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: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• 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 .
For a compl ete lis t of all Di agnos ti c Trouble Codes (DTCs) t hat could be logged on this vehicle, pleas e refer to Sect ion100-00.REFER t o: Di agnos t ic Trouble Code (DTC) Index - DTC: Ant i-Lock Braki ng Sys t em (ABS) (100-00 GeneralInformat ion, Des cript ion and Operat ion).
Pinpoint Tests
PINPOINT TEST A : BRAKE VACUU M ASSIST FU NCTION
T ESTCONDIT IONSDET AILS/RESULT S/ACT IO NS
A1: CHECK T HE BRAKE PEDAL T R AVEL WIT H T HE ENGINE OFF
Set i gnit ion s wit ch t o OFF.
Pump t he brake pedal s ix ti mes and hold firm press ure on t he pedal .
Did t he pedal t ravel decreas e and t he pedal go hard as i t was pumped?YesGO t o A2.NoCHECK the vacuum circui t to the brake boos t er. Start the engine and idle for three mi nut es, s wi tchignit ion OFF t hen repeat t he tes t. If t he pedal t ravel does not decreas e, s uspect the brake boos t er.
A2: CHECK T HE BRAKE PEDAL T R AVEL WIT H T HE ENGINE RUNNING

Publi s hed: 11-May-2011
Anti-Lock Control - Anti-Lock Brake System (ABS) Module
Removal and Inst all ati on
Removal
• CAUTIO NS:
Extreme cleanli nes s mus t be exercis ed when handli ng thes e component s.
If brake fluid is s pil t on the pai ntwork, t he affect ed area must be immedi ately washed down wi th col d wat er.
All vehicles
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.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
2.
Remove 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).
3.
Right-hand drive vehicles
Remove t he plenum chamber panel.4.
Left-hand drive vehicles
Remove t he winds hield wiper motor and l inkage.
Refer t o: W i nds hield W i per Mot or (501-16 W ipers and W as hers ,Removal and Ins tall ati on).
5.
6. CAUTION: Make s ure that all openi ngs ares ealed.6.
All vehicles

11.
CAUTIONS: Be prepared t o collect es caping flui ds .
Make s ure that all openings are sealed.
11.
All vehicles 12.
CAUTIONS: Be prepared t o collect es caping flui ds .
Make s ure that all openings are sealed.
12.
Installation All vehicles
Inst all t he ABS module.
T orque: 10 Nm 1.
Inst all t he brake fluid tubes.
T orque: 15 Nm 2.
Inst all t he bat t ery t ray s upport .
T orque: M6 10 Nm M8
25 Nm 3.
Left-hand drive vehicles Connect t he brake boost er vacuum l ine.
4.
All vehicles Inst all t he ECM.
5.
Secure t he vacuum line and harnes s .
6.
Left-hand drive vehicles

3-Right -Hand (RH) rear wheel s peed s ens or
4-Steering wheel modul e (including s t eering angle sens or)
5-Left -Hand (LH) rear wheel s peed s ens or6-Sensor clus ter
7-LH front wheel speed s ensor
8-Int egrat ed Anti -l ock Brake Sys t em (ABS) modul e and Hydrauli c Cont rol Unit (HCU)9-RH front wheel speed s ensor
10-Central Junct ion Box (CJB)
OVERVIEW
The vehi cl e ABS and s t abi li ty control sys tem feat ures a Cont inental Teves Mk25E1 module, wi th an int egral 4-channel HCU.The int egrated ABS modul e and HCU is l ocat ed on t he rear LH s ide of t he engine compart ment, and i s ins tal led i n t hebrake hydrauli c ci rcuit bet ween the brake mas ter cyl inder and the 4 brake calipers.
The ABS module is connect ed to the hi gh s peed Cont roll er Area Net work (CAN) bus , and acti vel y int eracts wi th othervehi cl e s yst em cont rol modules and as sociat ed s ens ors to recei ve and transmit current vehicle operat ing informati on.
W hen requi red, t he ABS module wi ll acti vel y int ervene and operate the HCU during braki ng or vehi cl e maneuvers t o correctt he vehi cl e att it ude, s t abi li ty, t racti on or speed. During severe incident s of vehicle correct ion, t he ABS module will al soreques t the Engine Cont rol Modul e (ECM) to reduce engi ne power i n order t o further stabil ize and correct t he vehicle.
To provide full s ys tem functi onali ty, t he ABS and DSC s ys tems compris e t he fol lowing component s :
DSC s wit chHDC s wi tch4 wheel s peed s ens orsSens or clus terSteering angle s ens orIns t rument clus ter i ndi cat or lampsInt egrat ed ABS module and HCU.
The ABS s yst em al s o provides brake funct ions t hat are des igned to ass is t t he vehi cle or aid the driver. The followi ngfuncti ons are det ai led i n t he s ect ion 'Principl es of Operati on':
Anti -l ock Brake Sys t em (ABS)Corner Brake Control (CBC)Dynamic St abi li ty Cont rol (DSC)Electroni c Brake Force Di s tributi on (EBD)Electroni c Tracti on Control (ETC)Emergency Brake As s is t (EBA)Engi ne Drag-Torque Control (EDC)HDC (wit h gradi ent releas e cont rol )Roll Stabi lit y Control (RSC)Terrai n Res pons e™ sys tem int egrati on.
All t he brake funct ions li s ted, apart from HDC, are automat icall y act ive when t he i gni ti on is in power mode 6 (igni ti on) andt he engi ne is runni ng.
DYNAMIC STABILITY CONTROL SWITCH
The DSC s wit ch all ows the DSC functi on to be s elect ed off. The DSC s wi tch i s non-latchi ng and is i nst all ed in the floorcons ole, forward of the gear s el ect or lever. Pres s ing t he DSC s wi tch connects an ignit ion power feed to t he ABS modul e.W i th the firs t pres s of the DSC swit ch, t he ABS module di sabl es the DSC funct ions . When t he DSC s wi tch i s pres sed agai n,t he ABS module re-enables t he DSC funct ions. The DSC swi tch must be press ed for a minimum of 0.3 s econd for the ABSmodule t o react . The DSC functi on is re-enabled at t he beginning of each ignit ion cycle.
To confirm that t he DSC functi on is sel ect ed off, the amber colored DSC warni ng indicator l amp located i n t he ins t rumentclus ter, is conti nuous ly i ll uminated. On vehicles i nst all ed wit h a hi gh-li ne ins t rument clus ter, a mes sage i s als o di spl ayedin the mess age cent er to confirm t hat DSC is s elect ed off.
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).
W hen t he DSC funct ion i s s elected on, t he DSC warni ng indicator l amp is ext inguis hed.
Alt hough Land Rover recommend t hat DSC is s elected on for all normal driving condit ions, i t may be benefi ci al t o de-sel ectDSC i n order t o maximi ze tract ion under t he foll owing condit ions:
To rock t he vehicle out of a holl ow or a s oft surface.W hen driving on loose s urfaces or wit h s now chains ins t al led.W hen driving i n deep s and, s now or mud.W hen driving on tracks wi th deep l ongi tudinal rut s .
Even when DSC is des elected, dri ving maneuvers wi th ext reme yaw or lateral acceleration may trigger RSC act ivit y t oas si st the vehicle st abili ty.
To prevent mis -use of, or in the event of a broken DSC s wit ch, a Diagnost ic Troubl e Code (DTC) i s s tored in the ABSmodule memory i f the input from t he DSC s wit ch is hel d high for more than 1 minut e.
HILL DESCENT CONTROL SWITCH
The HDC s wi tch control s t he s el ect ion of t he HDC funct ion.

The HDC s wi tch i s non-lat chi ng and is ins tall ed in the floor cons ole, forward of the gear s el ect or lever. Moment aril ypres s ing and releasi ng t he HDC s wit ch connects an ignit ion power feed t o t he ABS module. W it h t he fi rs t pres s and rel easeof the HDC s wit ch, t he ABS module enables operat ion of t he HDC funct ion. W hen t he HDC swi tch i s pres s ed and rel eas edagai n, the ABS modul e dis ables operat ion of t he HDC funct ion.
To prevent mis -use of, or in the event of a broken HDC s wi tch, if t he s wit ch is press ed for more t han 10 s econds nochange of s tat e occurs. A DTC i s s tored in t he ABS module memory if t he input from the HDC swi tch i s held hi gh for moret han 1 mi nut e.
HDC Activating Stoplamps
Operat ion of t he vehi cl e s toplamps during HDC is controll ed by the CJB. The ABS module monit ors t he brake s yst emhydraulic press ure and request s t he CJB, vi a t he high s peed CAN bus, t o energi ze the s t opl amps duri ng act ive braki ng.
A press ure thres hold and ti me fil ter prevents t he s topl amps from fli ckeri ng whil e HDC i s braking.
Stop/St art Vehicl es - From 2010 MY
Acti vat ion of Hi ll Descent Cont rol wi ll deact ivate the St op/St art s yst em. However, if Hi ll Des cent Control i s acti vat ed whent he engi ne is s hutdown in a St op/St art cycl e t he engi ne wil l aut omati cal ly rest art . If during t his event the St op/St arts ys t em cannot det ect t he dri ver's occupancy, for exampl e eit her t he driver’s safety belt or door is unl at ched, t he engi newil l not res tart. The St op/Start sys tem wi ll request the driver to depres s t he clut ch to res tart the engine. The dri ver wi ll beinformed of t his by ‘RESTART REQUIRED PRESS CLUTCH’ being di spl ayed i n t he mes sage center.
The dri ver mus t respond t o t hi s reques t wit hin a li mit ed t ime period, or otherwi s e a convent ional engine res tart us i ng theignit ion swi tch will be requi red.For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
WHEEL SPEED SENSORS