boot LAND ROVER FRELANDER 2 2006 Repair Manual

Rear seat belt s
Side Curtain Airbag Modul es
CAUTION: If the head ai rbag modules are depl oyed, t he fol lowing component s mus t be replaced on the si de of thevehi cl e on whi ch the deployment occurred:
Side curt ain ai rbag modulesHeadl iner and all pil lar t ri msLink l ead bet ween airbag gas generat or and RCM harnes sAirbag ret aining cli psFront s eat bel t buckle pre-t ens i onersAny s ide i mpact s ens ors t hat have been phys i cal ly damaged or if a fault i s being regi st eredRCM
Additionally, the following items must be inspected for damage and replaced as necessary:
Component mount ing bracketsFront s eat bel ts , ret ractors and webbing, tongue lat chi ng functi on, 'D' l oop and body anchorage point sRear seat belt buckl es, webbing, buckle covers , t ongue l atching funct ion, and body anchorage point sAdjacent t rim componentsSeat bel t hei ght adjust ers
Rear impacts
CAUTION: If the s eat belt pre-tens ioners are deployed during a rear i mpact , the following component s mus t berepl aced:
Seat bel t pre-t ensi onersFront and rear s eat bel t ret ractors used during t he i mpactRCM
Additionally, the following items must be inspected for damage and replaced as necessary:
Seat bel t hei ght adjust ersFront s eat bel ts , ret ractors and webbing, tongue lat chi ng functi on, 'D' l oop and body anchorage point sRear seat belt buckl es, webbing, buckle covers , t ongue l atching funct ion, and body anchorage point s
Air Conditioning System Precautions
The air condi ti oni ng s yst em contai ns fl ui ds and components which coul d be pot ent ially hazardous to the s ervi ce engineeror the environment if not serviced and handl ed correctl y. The foll owing guideli nes are i ntended to alert t he s erviceengi neer t o pot ent ial s ources of danger and emphas is e t he i mport ance of ens uring t he i nt egri ty of t he Air Condit ioningoperati ng condi ti ons and component s i ns t alled to the vehicle.
W here neces s ary, addi ti onal s pecific precaut ions are det ail ed in t he relevant s ecti ons of t his Manual and als o in the Heal thand Safet y Sect ion. Thes e precauti ons mus t be referred to prior t o commenci ng repair operat ions .
The refri gerant us ed i n t he air condi ti oni ng s ys t em i s HFC-134a (Hydrofl uorocarbon) R134a.
• W ARNINGS:
Servi ci ng mus t onl y be carried out by pers onnel famil iar wit h bot h t he vehi cl e s ys tem and t he charging and t es ti ngequi pment. Al l operat ions mus t be carried out i n a wel l venti lat ed area away from open fl ame and heat sources .
R134a is a hazardous l iquid and when handl ed incorrect ly can caus e s erious injury. Sui table prot ect ive clot hi ng,cons is t ing of face protecti on, heat proof gloves, rubber boots and rubber apron or waterproof overal ls , mus t be worn whencarryi ng out operat ions on t he air condit ioning s ys tem.
Remedial act ions
W ARNING: Due to it s low evaporat ing t emperat ure, R134a must be handled wit h care. R134a spl as hed on any part oft he body will cause immedi ate freezing of t hat area. Als o, refrigerant cylinders and replenis hment t roll eys whendis charging wi ll freeze s ki n t o t hem if contact is made.
If an accident involving R134a s houl d occur, conduct t he followi ng remedi al acti ons :
If liquid R134a ent ers t he eye, do not rub i t. Gentl y run large quant it ies of eye wash over affected eye t o rai s e t het emperature. If an eye was h is not avail abl e, cool, clean wat er may be us ed t o fl ush the eye. Aft er ri nsi ng, covert he eye wit h a clean pad and s eek i mmediat e medical at t ent ion.If liquid R134a is s plas hed ont o t he s kin, run large quanti ti es of water over t he affected area to rais e thet emperature. Implement t he s ame acti on if t he s kin comes i n cont act wi th dis chargi ng cyl inders . W rap t hecont aminat ed body parts in bl ankets (or s imi lar mat eri al s ) and seek i mmediat e medical att ent ion.If the debil it at ing effect s of inhalati on of R134a vapour are s us pect ed, s eek fresh air. If t he affect ed pers on isuncons ci ous , move t hem away from t he cont aminated area t o fres h air and apply arti fici al respi rat ion and/or oxygenand s eek immedi at e medi cal at tenti on.
Service precauti ons
Obs erve t he fol lowing precaut ions when handl ing component s us ed in the ai r condit ioning s ys tem:

Any s praying s houl d preferably be carri ed out in venti lat ed boot hs which i ncorporat e faci li ti es for removi ng vapors ands pray dropl et s from the breathing zone.
W ear appropri at e gl oves , eye and res pirat ory protecti on.
Antifreeze
May be flammabl e when undilut ed.
Vapors may be gi ven off from coolant anti freeze when heat ed. Avoid breathi ng thes e vapors .
Anti freeze may be absorbed through t he s kin i n t oxi c or harmful quanti ti es. Ant ifreeze, i f s wal lowed, can be fat al; SEEKIMMEDIAT E MEDICAL AT T ENT ION.
Battery Acids
See als o Al kal is and Acids .
Gas es releas ed duri ng bat t ery charging are expl osi ve. Al ways remove t he batt ery from t he vehi cl e pri or to chargi ng. Neverus e naked flames or al low s parks near charging or recentl y charged bat t eries . NEVER add aci d t o a bat tery, t he chemicalreacti on produced wil l be vi olent and expl os i ve. In cases of eye contact, was h affected area wit h copious amount s of wat erand SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Make s ure t here i s adequat e vent il ati on during bat tery charging, obs erve NO SMOKING POLICY .
Brake Pads and Linings
Always fit t he correct grade and s peci fi cat ion of brake pads and l inings . W hen renewi ng pads and lini ngs , always repl aceas complete axl e s ets .
Brake and Clutch Fluid
Splas hes to t he s kin and eyes are irri tat ing and i n t he long t erm can be damagi ng, avoid prolonged s ki n cont act. In casesof eye cont act , wash affect ed area wi th copious amount s of water and SEEK IMMEDIATE MEDICAL ATTENTION.
Chemical Materials
All chemical materials should al ways be used wit h caut ion and st ored and handled wi th care. They may be toxic, harmful,corros ive, irri tant or highly fl ammable and gi ve ri se to hazardous fumes and dus t s.
The effect s of exces s ive expos ure to chemi cal s may be i mmediat e or delayed; briefl y experienced or permanent ;cumulati ve; s uperficial; life t hreatening; or may reduce l ife expect ancy.
Chemical Materials - Do's
Do careful ly read and observe hazard and precaut ion warnings given on material cont ai ners (labels ) and in anyaccompanyi ng leaflets , pos ters or ot her ins truct ions . Material heal th and safet y data s heet s can be obtained frommanufacturers .Do remove chemi cal mat eri al s from the s kin and cl othing as soon as pract icable after s oil ing. Change heavily soi ledclothi ng and have it cleaned.Do organi se work pract ices and prot ect ive clot hing t o avoi d s oil ing of t he s ki n and eyes .Do avoid breat hing vapors , aeros ols , dus t s or fumes ; inadequat e container labell ing; fi re and expl os i on hazards .Do was h before job breaks, before eati ng, s moking, dri nki ng or usi ng t oi let faci lit ies when handli ng chemicalmat erial s.Do keep work areas clean, unclut tered and free of s pi ll s.Do s t ore chemical materials according to nat ional and local regul at ions .Do keep chemical materi als out of t he reach of chi ldren.
Chemical Materials - Do Not
Do Not mi x chemical materials except under the manufact urers ins truct ions ; s ome chemicals can form ot her toxic orharmful chemi cal s, gi ve off t oxi c or harmful fumes or become explos ive when mixed t oget her.Do Not s pray chemical materials , part icularly t hose bas ed on s olvents , i n confined spaces , for example when peopleare ins ide a vehicle.Do Not apply heat or fl ame t o chemical materi als except under the manufact urers ins truct ions . Some are hi ghlyfl ammable and some may rel ease toxic or harmful fumes .Do Not l eave contai ners open. Fumes given off can bui ld up to t oxic, harmful or explos ive concentrati ons . Somefumes are heavier than ai r and wil l accumulate in confi ned areas s uch as pi ts .Do Not t rans fer chemical materi als t o unlabell ed cont ainers .Do Not clean hands or cl othing wit h chemicals . Chemical s , parti cul arly sol vent s and fuel s, wi ll dry ski n and maycaus e i rrit ati on leading t o dermat it is or be abs orbed t hrough t he s ki n i n t oxi c or harmful quanti ti es .Do Not us e empt ied containers for ot her mat eri al s except when t hey have been cleaned under s upervis edcondi ti ons .Do Not s niff or smel l chemi cal mat eri al s , even brief expos ure to hi gh concentrat ions of fumes can be toxic orharmful.
Corrosion Protection Materials
Some corrosi on prot ect ion mat eri als are highly flammabl e – obs erve NO SMOKING POLICY.
Thes e materials are vari ed and the manufact urers ins truct ions mus t always be foll owed. The mat eri als may contai ns olvent s , res ins or petroleum product s. Skin and eye cont act s houl d be avoided. They s hould only be s prayed in condit ionsof adequate vent il at ion and not i n confined s paces .

1. Check for free play i n all s uspens ion and body mounti ng rubbers .
2. Check condit ion of s uspens ion rubber boot s and gait ers .
Fuel System
Check fuel sys tem pipes , hos es and unions for chafi ng, l eaks and corros ion.
Electrical Harnesses
Check al l el ect ri cal harnes s es for chafing.
Oil/Fluid Leaks
Check for oil/fluid leaks .
Power Steering
Check power s teering rod bal l joi nt fixi ngs , gait ers and condi ti on of bal l joi nt s and dus t covers .Check power s teering pipes , hos es and unions for chafi ng, leaks and corros ion.
Exhaust System
Check exhaust s ys tem for l eaks , securi ty and damage.
Fault Lamp(s)
If fault l amp(s ) are ill uminat ed, t est the as s oci at ed s yst em us i ng T4 and report findings .
Road Test
Carry out road t est of vehicle.For addit ional informat ion, refer t o: Road/Roller Tes ti ng (100-00 General Informati on, Des cri pt ion and Operati on).
General
Endors e Service Record.Report any unus ual features of vehi cl e condi ti on and any addi ti onal work required.
Vehicles Operating Under Arduous Conditions
Service i ntervals for vehi cles operati ng under arduous condi ti ons are det ailed bel ow.
Braking system
CAUTION: When vehicles are operating under arduous conditions, the following service items must be carriedout every 3 months or 3,750 miles (6,000 km).
Ins pect front brake pads for wear.Ins pect rear pads for wear.Check brake cal ipers for s igns of fl ui d l eaks .Check brake dis cs for condi ti on.Check al l brake boos t er and brake s ys t em pipes and hos es for condi ti on, chafi ng and leaks.Clean road wheel hub s pigot s and appl y greas e, Land Rover Part Number RY L 105020 t o t he wheel mat ing surfaceof each s pigot .
Brake Fluid Replacement
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 2 Years or 30,000 miles (48,000 km).
Replace brake fluid.
Road Wheel Speed Sensors
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 3 months or 3,750 miles (6,000 km).
Ins pect the road wheel s peed s ens or harness es for damage.
Engine Oil and Filter
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 3 months or 3,750 miles (6,000 km).
Renew engi ne oil and fil ter.

For addit ional informat ion, refer t o: Specificati ons (307-01 Aut omati c Trans mis s ion/Transaxle, Speci fi cat ions ).
Manual Transmission
Every 10 years or 150,000 miles (240,000 km): Renew manual t rans mi ss ion fl ui d.
For addit ional informat ion, refer t o: Specificati ons (308-00 Manual Trans mis s ion/Transaxle and Clutch - General
Informat ion, Speci ficat ions).
Power Transfer Unit
Every 10 years or 150,000 miles (240,000 km): Renew power t rans fer unit oi l. For addi ti onal informat ion, refer to:
(308-07B Transfer Case)
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D (Removal and
Ins tal lat ion),
Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Trans mis s io n AW D (Removal and
Ins tal lat ion).
Differential Assembly - Rear
Every 10 years or 150,000 miles (240,000 km): Renew rear different ial oil .
For addit ional informat ion, refer t o: Specificati ons (205-02 Rear Drive Axle/Different ial, Specifi cat ions ).
Suspension and Body Mountings Check for free play i n all s us pens ion and body mounti ng rubbers . Check condit ion of s uspens ion rubber boots and gait ers .
Fuel System
Check fuel sys tem pipes , hos es and unions for chafi ng, l eaks and corros ion. Electrical Harnesses
Check al l el ect ri cal harnes s es for chafing. Oil/Fluid Leaks
Check for oil/fluid leaks . Power Steering
Check power s teering rod bal l joi nt fixi ngs , gait ers and condi ti on of bal l joi nt s an d dus t covers .Check power s teering pipes , hos es and unions for chafi ng, leaks and corros ion.
Exhaust System
Check exhaust s ys tem for l eaks , securi ty and damage. Clutch
1. Check clut ch pipes and unions for chafi ng, l eaks and corrosi on.
Fault Lamp(s) If fault l amp(s ) are ill uminat ed, t est the as s oci at ed s yst em us i ng Land Rover approv ed di agnos ti c equipment and
report findi ngs . Road Test
Carry out road t est of vehicle.
For addit ional informat ion, refer t o: Road/Roller Tes ti ng (100-00 General Informati on, Des cri pt ion and Operati on).
General
Endors e Service Record. Report any unus ual features of vehi cl e condi ti on and any addi ti onal work required.
Vehicles Operating Under Arduous Conditions
Recommended s ervi ce interval s for vehicles operat ing under arduous condit ions are de t ail ed below.
Braking System CAUTION:
When vehicles are operating under arduous conditions, the following service items mu st be carried
out every 3 months or 3,750 miles (6,000 km).
Ins pect front brake pads for wear.

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.

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.

Publi s hed: 11-May-2011
Front Drive Halfshafts -
General SpecificationItemSpecification
TypeFully fl oat ing, s ol id shafts wi th inner and out er cons tant velocit y joi nts
Recommended Lubricant
ItemSpecification
Front dri ve halfshaft (auto onl y)W ei con ant i-s ei ze greas eOut board joi ntUs e greas e s upplied wit h repl acement boot ki t
Inboard joi ntUs e greas e s upplied wit h repl acement boot ki t
Torque Specifications
DescriptionNmlb-ftExtens ion s haft beari ng anchorage t o bl ock bolt s - 3.2L Pet rol4835
Extens ion s haft beari ng anchorage t o t rans mis s ion bol ts - 3.2L Petrol2518
Extens ion s haft beari ng anchorage t o bl ock bolt s - 2.2L Di es el6548Extens ion s haft beari ng anchorage t o t rans mis s ion bol ts - 2.2L Dies el2518
Front halfshaft to hub bol t*45 + 80°33 + 80°
Heat s hi eld t o beari ng anchorage107* New nuts/bolts must be fitted

Publi s hed: 11-May-2011
Front Drive Halfshafts - Inner Constant Velocity (CV) Joint Boot
Removal and Inst all ati on
Special T ool(s)
303-D121Pull er, General Purpose
Removal
• NOTE: RH i nner const ant vel oci ty joint boot s hown, LH i s s imi lar.
Remove t he hal fs haft .
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removaland Inst all at ion).Refer t o: Front Halfs haft LH (205-04 Front Drive Hal fs haft s , Removaland Inst all at ion).
1.
2. NOTE: Dis card t he ret aining cl ips .2.

Speci al Tool (s ):
303-D121 5.
Installation 1. CAUTION: Extreme cleanli nes s mus t be exercis ed when
handl ing t hese components .
Clean and i nspect the components for det eri orati on.
1.
Inst all t he inner CV boot ont o t he halfshaft .
2.
3. NOTE: Ins t al l a new retaini ng clip.
Inst all t he inner CV joi nt inner ont o t he halfshaft .
3.
4. CAUTION: Make s ure that thes e component s are ins tall ed t o
t he noted removal pos it ion.
Inst all t he inner CV joi nt out er ont o t he halfshaft.
4.
Pack the i nner CV joint wi th the grease suppli ed.
5.
6. NOTE: Ins t al l new ret aining cl ips .
Secure t he inner CV joi nt boot t o t he inner CV joint.
6.
Inst all t he hal fs haft .
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removal
and Inst all at ion).
Refer t o: Front Halfs haft LH (205-04 Front Drive Hal fs haft s , Removal
and Inst all at ion).
7.

Publi s hed: 11-May-2011
Front Drive Halfshafts - Outer Constant Velocity (CV) Joint Boot
Removal and Inst all ati on
Special T ool(s)
303-D121Pull er, General Purpose
Removal
• NOTE: The outer cons t ant vel ocit y joint mus t not be removed from the s haft . The inner joi nt and boot have to beremoved t o all ow t he outer joi nt boot t o be replaced. The i nner and outer boots are s uppl ied t ogether as a kit .
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.
Remove t he hal fs haft .
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removaland Inst all at ion).Refer t o: Front Halfs haft LH (205-04 Front Drive Hal fs haft s , Removaland Inst all at ion).
2.
3. NOTE: Dis card t he ret aining cl ips .3.
4. NOTE: Dis card t he ret aining cli ps.4.