LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
Engine Cooling - TD4 2.2L Diesel - Cooling Fan Module
Removal and Inst all ati on
Removal
• NOTE: Petrol ill ust rat ion s hown, dies el s i mil ar.
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 cool ing fan module. T orque:
6 Nm 2.
Installation To i nst all , revers e t he removal procedure.
1.

Publi s hed: 11-May-2011
Engine Cooling - TD4 2.2L Diesel - Coolant Expansion Tank
Removal and Inst all ati on
Removal W ARNING: W hen rel eas i ng the cooli ng s ys t em pres s ure, cover t he cool ant expansi on tan
k cap wi th a t hi ck cl oth.T orque:
10 Nm 1.
Clamp the relevant hos e, t o mi ni mis e coolant los s .
2. 3. CAUTION: Be prepared to col lect escaping
cool ant.
3.

4.
NOTE: Do not di s as s emble furt her if t he component
is removed for acces s only.
4.
Installation To i nst all , revers e t he removal procedure.
1.
Top-up t he cool ant.
2.

Publi s hed: 11-May-2011
Engine Cooling - TD4 2.2L Diesel - Engine Coolant Level Switch
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. T orque:
10 Nm 1.
2.
Installation To i nst all , revers e t he removal procedure.
1.

Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol -
General SpecificationItemSpecification
Recommended fuel:
UK, Europe91 - 98 RONUSAMinimum 91 CLC or AKI
Fuel injectors:
MakeDens o
Fuel Pressures
ComponentbarpsiFuel rail - normal operat ing condit ions - not usi ng IDS3.754
Fuel rail - normal operat ing condit ions - us ing IDS4.868
Fuel rail - engine off - usi ng IDS2.8 to 3.240 t o 46Fuel rail - cold s t art - us ing IDS6.594
Torque Specifications
DescriptionNmlb-ft
Fuel i njector clamp pl ate bol ts65Fuel press ure regulat or bol ts65
Fuel pump drive modul e ret aining bol ts107
Fuel rail bolt s107Fuel rail pres s ure s ens or65
Schreader valve bolt s65
Throt tl e body s crews86

Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Charging and Controls
Des cript ion and Operat ion
Authori ng Templat e
COMPONENT LOCATION
ItemPart NumberDescription1-Fuel rai l
2-Fuel inject or
3-Fuel li ne4-Fuel rai l press ure and fuel temperature s ens or
OVERVIEW
The fuel pump module, l ocat ed in the fuel t ank, i s electronical ly regulated by the Engine Management Sys t em (EMS) toprovide controll ed pres sure in the fuel railFor addit ional informat ion, refer t o: Fuel Tank and Lines (310-01A Fuel Tank and Lines - I6 3.2L Pet rol, Des cri pt ion andOperat ion)..
Suppl yi ng t he correct amount of fuel as required by the engine at any gi ven moment, eli minat es the requirement foraddi ti onal pi pes returning exces s fuel t o t he fuel t ank. The benefit s of t hi s t ype of s ys tem are:
Reduced l oad on the el ect ri cal s yst em

Improved fuel economyEli minat es the effects of fuel press uri zat ion and depres s uri zat ionEli minat es the effects of engine-heat caus i ng ext ra fuel vapor being generat ed in the fuel t ank by ret urning fuel
Clos ed-l oop Pul se W i dt h Modulat ion (PW M) control, of the fuel pump module, via t he Engine Control Modul e (ECM)regulat es the amount of fuel s uppl ied by the fuel pump to the fuel rail . The ECM receives s ignals from the combi ned fuelrai l pres sure and fuel t emperature s ens or, l ocat ed on t he fuel rai l to indicate t he pres s ure of fuel i n t he fuel rai l. Inres ponse to thes e s ignals , plus other engine and driver demand s i gnal s, t he ECM calculat es the amount of fuel requiredand reques ts t he fuel pump modul e t o vary t he fuel pump deli very t o s uit t he engi ne’s requirements .For addit ional informat ion, refer t o: Electroni c Engi ne Controls (303-14A Electroni c Engine Controls - I6 3.2L Pet rol ,Des cript ion and Operat ion).
The fuel pump mai ntains a fuel rai l pres sure 3.8 bar above manifold depres s ion under normal operati ng condit ions , thought hi s is programmed to ri se to 4.2 bar in res pons e t o eit her:
col d s t art condi ti ons , t o improve fuel vaporizati oncol d fuel condi ti ons, as t he colder the fuel the hi gher it s vis cosi ty
The fuel rai l has an int egrated puls at ion damper and a connecti on for drai ning t he fuel s yst em.
The inject ors s upplied by the fuel rail ; each have 4 micro-nozzles capabl e of injecting up to 18 mg of fuel under hi gh-loadcondi ti ons , t he inject ors als o provi de precis ion fueli ng across al l engi ne s peed and l oad condit ions .

Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Charging and Controls
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel chargi ng and cont rol s, refer t o the relevant Descri pti on and Operat ion s ect ion in t heworks hop manual .REFER to: Fuel Chargi ng and Controls (303-04A Fuel Chargi ng and Cont rol s - I6 3.2L Pet rol, Des cri pt ion and Operati on).
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: For di agnos t ic purpos es the cyli nders are divided i nt o t wo banks: Bank 1 - Cyl inder numbers 1, 2 and 3. Bank 2 -Cylinders 4, 5 and 6
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual Inspection
MechanicalElectricalFuel l evelFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel contami nati on/grade/quali tyThrot tl e bodyDamaged fuel t ank fi ller pipe capDamaged fuel t ank fi ller pipe
FusesLoos e or corroded elect rical connect orsHarnes s esSensor(s )Engine Control Modul e (ECM)
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 , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseAction
Engine cranks , but does not fi reEngine breat her s ys temdis connected/res trictedIgni ti on s ys t emFuel s ys temElectronic engine control
Ens ure the engine breat her sys tem isfree from rest ri ct ion and is correct lyi nst all edFor igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
Engine cranks and fires , but wil lnot s tartEvaporati ve emis s ions purgevalveFuel pumpSpark pl ugsHT s hort t o ground (t racki ng)check rubber boots forcracks/damageIgni ti on s ys t em
For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Di fficul t col d s t artEngine coolant level/ant i-freeze cont entBatt eryElectronic engine controlsFuel pumpPurge valve
Check t he engi ne cool ant l evel andcondit ion.REFER t o: Specificati ons (303-03AEngine Cool ing - I6 3.2L Pet rol ,Specificat ions ).Ens ure the bat tery is i n a full y chargedand s ervi ceable condit ionRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.

SymptomPossible CauseAction
REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).
Di fficul t hot st artInjector leakElectronic engine controlPurge valveFuel pumpIgni ti on s ys t em
Check for i njector leak, ins tal l newi njector as neces s ary.REFER t o: Fuel Inject or (303-04A FuelChargi ng and Control s - I6 3.2L Pet rol ,Removal and Ins t al lat ion).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Di fficul t t o s tart aft er hot s oak(vehi cl e s tanding, engi ne off, aft erengine has reached operati ngt emperature)
Injector leakElectronic engine controlPurge valveFuel pumpIgni ti on s ys t em
Check for i njector leak, ins tal l newi njector as neces s ary.REFER t o: Fuel Inject or (303-04A FuelChargi ng and Control s - I6 3.2L Pet rol ,Removal and Ins t al lat ion).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For purge valve t es ts .REFER t o: Evaporat ive Emi ss i ons (303-13Evaporati ve Emis s ions , Diagnosi s andTes ti ng).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Engine s t al ls s oon after s tartBreat her s ys temdis connected/res trictedECM relayElectronic engine controlIgni ti on s ys t emAir i ntake s yst em res trictedAir l eakageFuel l ines
Ens ure the engine breat her sys tem isfree from rest ri ct ion and is correct lyi nst all edRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).Check for bl ockage in ai r fi lt er el ementand ai r int ake s ys temCheck for ai r leakage i n air i ntakes ys temFor fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).
Engine hes it at es /poor accelerat ionFuel press ure, fuel pump, fuell inesInjector leakAir l eakageElectronic engine controlThrot tl e mot orRes tricted accelerat or pedalt ravel (carpet, et c)
For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Check for i njector leak, ins tal l newi njector as neces s ary.REFER t o: Fuel Inject or (303-04A FuelChargi ng and Control s - I6 3.2L Pet rol ,

SymptomPossible CauseAction
Igni ti on s ys t emTrans mi ss ion malfunct ionRemoval and Ins t al lat ion).Check for ai r leakage i n air i ntakes ys temRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).Read DTCs and refer t o t he DTC Index i nt his secti on for t hrot tl e mot or t es tsEns ure accelerat or pedal is free fromres tricti onFor igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).For t rans mis s ion t est s .REFER t o: Diagnos t ics (307-01 Automat icTrans mi s si on/Trans axl e, Diagnos i s andTes ti ng).
Engine backfiresFuel pump/li nesAir l eakageElectronic engine controlsIgni ti on s ys t emSt icki ng variabl e camshaftt imi ng (VCT) hub
For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Check for ai r leakage i n i nt ake airs ys temRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).Read DTCs and refer t o DTC Index forVCT tes ts .REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
Engine s urgesFuel pump/li nesElectronic engine controlsThrot tl e mot orIgni ti on s ys t em
For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).Read DTCs and refer t o DTC Index in t hiss ecti on for t hrot tl e mot or t es ts .For igni ti on sys t em t est s .REFER t o: Engi ne Ignit ion (303-07AEngine Ignit ion, Diagnosi s and Test ing).
Engine detonat es /knocksElectronic engine controlsFuel pump/li nesAir l eakageSt icki ng VCT hub
Read DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).For fuel s yst em tes ts .REFER t o: Fuel Tank and Lines (310-01AFuel Tank and Li nes - I6 3.2L Petrol,Di agnos is and Tes t ing).Check for ai r leakage i n i nt ake airs ys temRead DTCs and refer t o DTC Index forVCT tes ts .REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).
No t hrot tl e res ponseElectronic engine controlsThrot tl e mot orRead DTCs and refer t o DTC Index forel ect ronic engine cont rol tes t s.REFER t o: Elect roni c Engi ne Cont rol s(303-14A Elect ronic Engine Cont rols - I63.2L Petrol , Diagnosi s and Test ing).Read DTCs and refer t o DTC Index in t hiss ecti on for t hrot tl e mot or t es ts .