engine LAND ROVER FRELANDER 2 2006 Manual PDF

9. CAUTION: Before dis connecti ng or removing t he
component s, make sure t he area around t he joi nt faces
and connecti ons are clean. Plug open connecti ons to
prevent cont aminati on.
• NOTE: Some flui d s pill age is i nevi table during t his
operat ion.
• NOTE: Care mus t be taken t o avoid contami nat ion of
t he acces sory dri ve bel t.
Di sconnect t he power s t eering hi gh-pres s ure pi pe
union.
9.
Inst all t he O-ring seal. Inst all t he s pecial t ool s.
Speci al Tool (s ): 211-011-12 ,
211-011-02 ,
211-011-02 ,
211-011-01 ,
211-287 Tie the press ure gauge as ide under t he hood.10.
11. CAUTION: Only us e new fl uid from a s ealed container.
Refi ll and bleed t he power st eeri ng.
Refer t o: Power St eering Sys tem Bleeding (211-00 St eering Sys tem -
General Informat ion, General Procedures ).
11.
Connect t he batt ery ground cable.
12.
13. NOTE: Make sure t he s teeri ng components and tes t equi pment
are free from leaks .
• NOTE: Mai nt ain the maxi mum flui d level during t he t est .
• NOTE: Make s ure the s t eering i s i n the st rai ght ahead pos it ion. W it h the tes t val ve open s tart the engine. Turn the s t eering full y lock t o lock, st op t he engi ne.
Top-up t he power st eeri ng fl uid reservoi r.13.
For power s t eering press ures , refer to the s t eering s peci fi cat ion
s ect ion.
Refer t o: Specificati ons (211-02 Power Steering, Specificati ons ).
14.
15. CAUTION: Do not hold st eering at full l ock for longer t han
15.

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).
3. CAUTION: Di scard fl ui d s iphoned from t he power st eeri ng
s yst em.
Siphon t he fl uid from t he power s t eering res ervoi r.
3.
Pos it ion an abs orbent cl oth t o coll ect fluid s pi ll age.
4. 5. CAUTION: Before di s connect ing or removi ng
the component s , make s ure t he area around the joint
faces and connect ions are clean. Pl ug open
connect ions t o prevent cont aminat ion.
• NOTE: Some fluid spi llage i s inevit able duri ng t hi s
operati on.
• NOTE: Care mus t be t aken to avoi d cont aminat ion of
the acces s ory drive belt .
Dis connect the power s teeri ng high-press ure pipe
uni on.
5.
Inst all t he O-ring seal. Inst all t he s pecial t ool s.
Speci al Tool (s ): 211-313 ,
211-011-02 ,
211-011-11 ,
211-011-01 ,
211-287 ,
211-325 Tie the press ure gauge as ide under t he hood.6.
7. CAUTION: Only use new fl uid from a s ealed container.
Refi ll and bleed t he power st eeri ng.
Refer t o: Power St eering Sys tem Bleeding (211-00 St eering Sys tem -
General Informat ion, General Procedures ).
7.
Connect t he batt ery ground cable.
8.
9. NOTE: Make s ure t he s teeri ng component s and tes t equipment
are free from leaks .
• NOTE: Mai nt ain the maxi mum flui d level during t he t est .
• NOTE: Make s ure the s t eering i s i n the st rai ght ahead pos it ion. W it h the tes t val ve open s tart the engine. 9.

Turn the s t eering full y lock-t o-l ock, s top t he engine.
Top-up t he power st eeri ng fl uid reservoi r.
For power s t eering press ures , refer to the s t eering s peci fi cat ion
s ect ion.
Refer t o: Specificati ons (211-02 Power Steering, Specificati ons ).
10.
11. CAUTION: Do not hold st eering at full l ock for longer t han
10 s econds .
W it h the engi ne at idle, s lowl y turn t he s teeri ng wheel and
hold on full l ock. Record t he pres s ure readi ng.11.
Repeat t he above procedure for t he other s ide. Record t he pres s ure readi ng.12.
W it h the engi ne at idle, rel ease the s t eering wheel. The press ure
s houl d be, at or bel ow, the pres s ure specified.
13.
Pres s ure out si de t hi s t olerance, i ndicat es a fault .
14.
15. CAUTION: Pump damage wi ll occur if t he t est valve is
clos ed for l onger peri ods .
To det ermi ne if t he fault is i n t he st eeri ng pump or the st eeri ng
rack, clos e the tes t val ve for a maxi mum of 5 s econds.
15.
If the press ures recorded fal l out s ide t he given values, replace the
power st eeri ng pump.
16.
If the maxi mum pump pres sure i s correct, t hen s uspect the power
s teering rack.
17.
18. CAUTION: Dis card flui d s iphoned from t he power st eeri ng
s yst em.
On compl et ion of t he t est s t op the engi ne, dis connect t he bat t ery
ground cable and s i phon t he fluid from t he power st eering res ervoir.
18.
Di sas s emble t he t es t equipment .
19.
Clean t he component mat ing faces . Inst all a new O-ring s eal.
Connect t he high-press ure pipe union t o t he power st eeri ng
pump. T orque:
25 Nm 20.
Inst all t he air cleaner hous ing.
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).
21.
Connect t he batt ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
22.

Publi s hed: 11-May-2011
Power Steering - Power Steering PumpTD4 2.2L Diesel
Removal and Inst all ati on
Removal
CAUTION: Always pl ug any open connect ions t o prevent cont aminati on.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m andOrnament ati on, Removal and Ins tal lat ion).
1.
Remove t he acces sory dri ve bel t.
Refer t o: Acces sory Dri ve Belt (303-05B Acces sory Drive - TD4 2.2LDi es el, Removal and Ins tal lat ion).
2.
3. W ARNING: Power s t eering fluid is ext remely fl ammable.Make s ure that power s t eering flui d is not s pil t over t he engine andt hat t he power s teeri ng fl uid reservoi r cap is s ealed.
Siphon t he fl uid from t he power s t eering res ervoi r.
3.
4. CAUTIONS:
Be prepared t o collect es caping oi l.
Make s ure that t he area around the component i sclean and free of foreign materi al.
Al ways pl ug any open connect ions t o preventcont ami nat ion.
Pos it ion a contai ner t o coll ect t he oil s pill age.
4.
5. CAUTIONS:
Be prepared t o collect es caping oi l.
Make s ure that t he area around the component i sclean and free of foreign materi al.
Al ways pl ug any open connect ions t o preventcont ami nat ion.
5.

Publi s hed: 11-May-2011
Engine System - General Information - Engine
Diagnosi s and Tes ti ng
For addit ional informat ion. REFER t o:
Engi ne (303-01A Engine - I6 3.2L Petrol, Diagnos is and Tes ti ng),Engi ne (303-01B Engine - TD4 2.2L Di esel , Diagnos is and Tes t ing).

Publi s hed: 11-May-2011
Engine System - General Information - Cylinder Head Gasket SelectionTD4
2.2L Diesel
General Procedures
Special T ool(s) 303-979
Meas uri ng Bri dge, Pis t on Prot us i on 1. CAUTION: Make s ure that the surface is cl ean
and free of foreign mat eri al.
Zero the gauge on t he cyl inder block machi ned face.
Speci al Tool (s ): 303-979 1.
2. CAUTION: Make s ure that the surface is cl ean
and free of foreign mat eri al.
• NOTE: Not e t he dial gauge readi ngs .
Take 2 meas urement s on each pi s ton crown.
2.

3. CAUTION: The gas ket t hicknes s i s identi fi ed byt he number of holes (1 t o 4) at eit her of t he l ocat ionss hown.
Us e t he highest pi s ton prot rus i on measurment, t os elect the correct thicknes s cyli nder head gasket .
Refer t o: Specificati ons (303-01B Engine - TD4 2.2LDi es el, Specifi cat ions ).
3.

Publ is hed: 02-Jun-2011
Engine System - General Information - Leakage Test Using Smoke Test
Equipment
General Procedures
CAUTION: The compres s ed air li ne s uppl y pres s ure mus t be bet ween 3.5 and 12 bar (50 and 175 psi ) for t he s moket es t equipment t o functi on correctl y. Do not exceed t hi s pres s ure. Fai lure t o fol low t his ins truct ion may res ult in damage tot he smoke tes t equi pment.
• NOTE: The vehi cle bat tery mus t be in good condit ion and ful ly charged before carryi ng out thi s procedure.
• NOTE: On vehicles wit h 3.0L TDV6, it wi ll be necess ary to ins ert s moke at bot h ai r cl eaner outl et pi pes independentl y ift he ri ght hand t urbocharger and as s oci at ed hos es are t o be t es ted.
• NOTE: In s ome cases i t may be necess ary to remove undert rays, t ri m or engine covers t o obt ai n acces s t o all potent ialleak l ocat ions.
• NOTE: Some vari ati on in the i ll us t rat ions may occur, but the es s ent ial informat ion i s always correct .
• NOTE: For furt her informati on regardi ng operati on of the tes t equi pment refer t o the manufacturers operat ors manuals uppl ied wi th the ki t.
1. W ARNING: Use an addi ti onal s upport to prevent t hehood from fall ing i f the s moke t es t equi pment i s s ecured tot he hood. Fail ure t o follow thi s ins truct ion may res ult i npers onal i njury.
Ins tal l t he s moke t est equipment t o a s uit able l ocat ionunder the hood.
2. Connect a s uit abl e compres sed ai r li ne to the s moke t es tequipment.
3. Connect the s moke t est equipment pos it ive power cabl e to thebatt ery pos it ive t erminal.
4. W ARNING: Do not connect t he s moke tes t equipmentnegat ive cable t o t he batt ery negati ve terminal.
Connect t he s moke tes t equipment negat ive cable t o a sui tablebody ground point .

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