LAND ROVER FRELANDER 2 2006 Repair Manual

5. NOTE: A flas hing green l ight indi cat es low bat tery volt age.In t hi s case, place t he batt ery on charge and make s ure t hatt he batt ery i s ful ly charged before us ing t he s moke tes tequipment.
Obs erve the power indicat or l amp on t he s moke t es tequipment . Make s ure t hat a cont inuous green l ight isdi s pl ayed.
6. NOTE: In some cas es i t may be neces s ary t o remove the ai rcleaner(s) t o al low acces s t o t he air cleaner out let pi pes .
• NOTE: In s ome cas es it wi ll be neces s ary t o cap one of t heair cleaner out let pi pes . Us e t he blanking caps suppli ed in thekit t o cap t he open orifice.
Dis connect t he air cl eaner outl et pi pe(s ).

7. NOTE: Make s ure t he s moke tes t equipment adapt er is agood fi t t o the ai r cleaner out let pipe. Thi s mus t be an ai rt ight s eal .
Connect the s moke t est equipment s uppl y hos e to the ai rcl eaner outl et pi pe.
1. Ins tall t he appropri at e adapter t o t he air cleanerout let pi pe.
2. Connect t he s moke t es t equipment s uppl y hose tothe adapter l ink hos e.
8. NOTE: The fl ow cont rol valve mus t be i n t he ful ly openpos it ion.
• NOTE: Smoke i s produced for 5 mi nutes . The smoke tes tequipment wil l aut omati cal ly s wi tch off aft er t his period oft ime.
Swi tch t he s moke t est equipment on.
9. Remove the oi l fil ler cap, and obs erve unti l a cons t ant flow ofs moke is vi s ible leavi ng t he oil fi ll er orifice. Ins tal l the oi l fil lercap.
10. NOTE: The l onger s moke is allowed t o exit from a l eak, t hemore fl uorescent dye wil l be depos it ed at a l eak locat ion.
Us ing the t orch s uppl ied i n t he kit s et to whit e li ght, l ook fores capi ng smoke. Alt ernat ively, use the ul travi olet li ght to l ookfor fluores cent dye depos it s at the source of a leak.

Publi s hed: 23-Aug-2011
Engine - I6 3.2L Petrol -
Lubricants, Fluids, Sealers and AdhesivesDescriptionLand Rover Part No.
Cam cover to cyli nder head jointLR006801 (Loct it e 510)
Bedplate to oi l s umpSTC50550Block t o bedpl ateSTC50550
Engine oil - NAS, Mi ddl e Eas t and Nort h Africa Models5W /30 - ACEA A1 + ILSAC GF-3 or ILSAC GF-3*
Engine oil - ROW Models0W /30 - ACEA A5/B5The recommended oil change i nterval for ILSAC GF-3 is 5000 mi les .
C apacities
ItemCapacity (liters/pints/USquarts)
Dry fi ll i ncludi ng fi lt er9.3/16.4/9.8
Service fil l - includes fi lt er7.7/13.6/8.1Amount of oil required t o bri ng the level from the lower to the upper mark on thedips t ick0.8/1.4/0.9
General Specification
ItemSpecificationType3.2 li ter, inli ne 6 nat urall y aspi rat ed pet rol engine, twi n overheadcams haft s, 4 val ves per cylinderCyli nder arrangementInli ne 6
Cyli nder numberi ng1-6 from front of engine
Bore - nominal84.0 mm (3.307 in)St roke96.0 mm (3.779 in)
Capaci ty3192 cm³ (195.8 i n³)
Firing order1 - 5 - 3 - 6 - 2 - 4Compres s ion rati o10.8:1
Di recti on of rotat ionCl ockwis e from front of engi ne
Maximum power171 kW (230 hp) @ 6300rpmMaximum t orque317 Nm (234 lb-ft ) @ 3200rpm
Engine oil pressure*:
At 800 rev/min1.03 bar/103 kPa/15 lb/in²At 4000 rev/min3.45 bar/345 kPa/50 lb/in²
Oil pump
Oi l pump to cranks haft clearance0.087mm ±0.022 mm (0.00343 i n ± 0.000866 i n)Maximum permissible cylinder head w arp:
Over head length0.05 mm (0.00196 i n)
Over head widt h0.03 mm (0.00118 i n)Cyli nder head height149.4 mm ± 0.15 mm (5.882 in ± 0.0059 i n)
Maximum permi s si ble amount t o be removedduri ng s ki mmi ng0.3 mm (0.0118 in)
Main bearing journals:
Number7
Di amet er s tandard65 mm + 0.004 - 0.015 mm (2.55 in + 0.000157 - 0.000590 in)Maximum diamet er variat ion0.006 mm (0.000236 in)
Big end journals:
Di amet er s tandard50 mm + 0.004 - 0.015 mm (1.96 in + 0.000157 - 0.000590 in)Maximum diamet er variat ion0.01 mm (0.000393 i n)
Camshaft:
Number of bearings7 per cams haftT appets+:
InletHydrauli c
Exhaus t +GradedValves:
Valve clearance - Exhaus t0.45mm ±0.05 mm (0.0177 in ± 0.00196 in)
Lengt h - i nlet valve106.19 mm ± 0.07 mm (4.18 in ± 0.0275 i n)Lengt h - exhaus t valve129.96 mm ± 0.07 mm (5.12 in ± 0.0275 i n)
Seat angl e45° ± 0.01°
Head diamet er - inlet valve33 mm ± 0.15 mm (1.29 in ± 0.0590 i n)Head diamet er - exhaus t val ve28 mm ± 0.15 mm (1.10 in ± 0.0590 i n)
St em diamet er - inlet valve5.97 mm + 0 -.015 mm (0.235 in + 0 -000590 i n)
St em diamet er - exhaus t val ve5.962 mm +0 -0.007 mm (0.234 in +0 -0.000275 i n)St em t o guide clearance - i nlet val ve50-70 µm
St em t o guide clearance - exhaus t valve50-70 µm
Valve springs:TypeConical
Lengt h (free)45 mm (1.77 in)
* Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometres) must be carried out. Do notattempt to attain normal engine operating temperature by allowing the engine to idle.
+ T here are 50 different thicknesses of graded tappet available ranging from 2.950mm to 3.685 mm (0.116 in to0.145 in) rising in increments of 0.015 mm (0.0005 in).
Torque Specifications

DescriptionNmlb-ft
Cams haft beari ng hous ing to cyli nder head bolt sAA
Camshaft drive sprocket boltsExhaus t75 + 90°55 + 90°
Inlet11081
Cyli nder head bolt sAACyli nder head wiring harnes s mount ing bolt s65
Di ps t ick t ube bol t107
Engine i ns ulat or lower bolt s11081Engine i ns ulat or lower heat s hield Torx s crew107
Engine i ns ulat or upper bolt s11081
Engine mount bracket LH:M8*2518
M12*8059
Engine mount LH bolts175129Engine mount RH bolts8059
Engine mount bracket RH bolt:
M10*4533M12*8059
Flywheel flexplat e bolt s45 + 50°33 + 50°
Exhaus t manifold bol tsAAIntake manifold bol ts1612
Lifti ng bracket bol ts4835
Lower inlet mani fold bol ts107Lubricant drain plug3828
Oi l cooler as sembl y t o block ret aining bol ts107
Oi l cooler hos e bolt s107Oi l fil ter2518
Oi l level s ensor bolt86
Oil pan bolts:M71713
M104533
Oi l pump adjus ter bolt1713Oi l pump lock adjus ter s leeve bolt86
Oi l st rai ner pi ck-up ass embly bol t1713
Oi l squirt jet65Throt tl e body to block support bolt107
Throt tl e body s crews*86
Timing chain t ensi oner bolt107Timing cover bolt sAA
VVT s olenoid107
VVT unit retai ni ng boltAA* New nuts/bolts must be fitted
A = refer to procedure for correct torque sequence

Published: 11-May-2011
Engine - I6 3.2L Petrol - Engine
Descript ion and O peration
EXTERNAL VIEW OVERVIEW
The Si6 pet rol engine is a 3.2 litre, inline 6-cylinder, nat urally as pirat ed unit, w it h 4 valves per cylinder, operated by 2 overhead
cams haft s. The engine emis sions comply with EURO 4 (European Union emiss ion regulati ons ) and Ultra Low Emiss ions Vehicle
(ULEV) II legis lat ive requirement s and employs catalyt ic convert ers , elect ronic engi ne management control and pres sure cont rolled
crankcas e vent ilat ion to limit t he emiss ion of pollut ant s . The cooling s yst em is a l ow volume, high velocit y s yst em. The Engine

Cont rol Module (ECM) cont rols t he fuel injection s ys t em and t he ignit ion s yst em.
The cylinder block is of aluminum alloy cons truct ion wit h cast iron liners and a pres s ed aluminum bedplat e s ect ion bolt ed to t hebot tom of t he block t o improve lower st ruct ure rigidit y. The s ingle-piece oil s ump is als o of a press ed aluminum const ruct ion. Thecylinder head and the cams haft bearing housing are manufact ured from cas t aluminum. The exhaus t manifolds are of a fabricat edst ainles s s t eel twin s kin design incorporat ing cat alyt ic convert ers and a moulded plast ic acous tic cover is fit t ed over t he upperengine t o reduce engine-generat ed nois e.
Engine Structure
ItemPart NumberDescription1-Cams haft bearing housing2-Cylinder head3-Cylinder block4-Bedplat e section5-Oil pan6-Gear housing
Technical features
The engines t echnical feat ures include:
A 6-cylinder, inline configurat ion, liquid cooled, aluminium cylinder block wit h cast iron linersPist ons are cast from a light alloy met al, wit h 2 compress ion rings and a 3-piece oil cont rol ringAluminum cylinder head, incorporat ing 2 cams haftsFour valves per cylinderVariable lift height hydraulic valve t appet s (intake only)Variable Cams haft Timing (VCT) (int ake only)Cranks haft vibrat ion damper t o give the crankshaft a s moother operat ionA single gear driven cams haft timing chain drives both cams haft sAn aluminum bedplat e s ect ion between t he oil pan and cylinder blockA forged s t eel cranks haft wit h induct ion hardened bearing surfacesForged s teel connect ing rods

A Rear End Ancillary Drive (READ) s yst emTwo fabricated s t ainles s s t eel t win s kin exhaust manifoldsA 3-pos ition Variable Intake Sys t em (VIS)An advanced Engine Management Syst em (EMS) incorporat ing elect ronic t hrot tle controlFour cat alyt ic converters
Technical data
DESCR IPT IO NT YPEConfigurationInline 6-cylinderO utput171 kW at 6200 rpmT orque320 Nm at 3200 rpmDisplacement3192 cm³Stroke/bore96.0 mm/84.0 mmCompression ratio10.8:1Firing order1-5-3-6-2-4Approximate weight180 kg (including int ake pipe, exhaus t manifold, alt ernator and oil)
ItemPart NumberDescriptionA-Torque (Nm)B-Power (kW )
CYLINDER BLOCK COMPONENTS
The main cylinder block components are:
Cylinder blockConnect ing rods and pis tonsPist on cooling jet sGenerat orGear hous ingThermos tat hous ingCranks haft Pos it ion (CKP) s ensorKnock s ens orsCoolant pumpCoolant inlet pipe
Cylinder Numbering
The cylinders are numbered as shown below, wit h cylinder 1 at t he front of the engine.

Cylinder Block
ItemPart NumberDescription1-Identificat ion markingsThe cylinders and crankcas e are cont ained in t he cylinder block, which is of a cas t aluminum cons truct ion. The cylinder sleeves aremade of cas t iron and cast in bores. The cylinder block is of a pen coolant mant le design, which allows coolant t o flow freelyaround t he upper s ect ion of the cylinders .
Connecting rods and Pistons

ItemPart NumberDescription1-Pis t on2-Connect ing rod bearings3-Connect ing rod and cap ass emblyThe connect ing rods are 'L' profile forged with a t rapezium shaped (a s hape with 4 sides with 2 of it s s ides parallel) s mall end. Thebig end has a fract ure s plit bearing cap, which gives a s t able joint becaus e t he bearing cap and connecting rod are secured in t heact ual fract ure surface. Aluminium bearings are us ed for both t he lower and upper bearing half.
The pist ons are cast from a light -alloy met al cons ist ing of aluminium and s ilicon. The pist on s kirt is graphite coated at t he frontand rear to ens ure low frict ion bet ween t he pis ton and cylinder, part icularly during cold st art ing and during s hort periods ofext reme load. The pis ton is 'weight opt imis ed', which means, for example, that t he pis t on pin is comparat ively s hort and t hat t hepis ton is miss ing mat erial from t he s ides .
Each pis t on has 3 pis t on rings :
An upper compres sion ring of nit rat ed s teelA second ring of alloyed cast iron, which funct ions as bot h a compress ion ring and an oil s craper ringA 3-part oil ring made of nitrated s t eel
Piston Cooling Jets

ItemPart NumberDescription1-Pis t on cooling jet (6 off)Jet s locat ed in the cylinder block s pray oil on t o t he ins ide of t he pis ton t o provide pis t on and pis ton pin lubricat ion and cooling.The oil is dist ribut ed through t he cylinder block, via t he main oil gallery and channels bored in t he block.
Generator
ItemPart NumberDescription1-Rubber s leeve2-GeneratorThe generat or is locat ed at the rear of t he int ake side of t he cylinder block. The generator is driven by the crankshaft gearwheelvia t he auxiliary unit shaft gearwheel and t he auxiliary unit inner shaft gear wheel (s ee gear housing s ect ion for moreinformat ion).
Gear Housing Components