fuel cap LAND ROVER FRELANDER 2 2006 Repair Manual

Publi s hed: 11-May-2011
General Information - Standard Workshop Practices
Des cript ion and Operat ion
Vehicle in Workshop
W hen working on a vehicl e in the workshop al ways make sure t hat :
W here practi cable, t he parking brake is appli ed and t he wheel s are securely chocked to prevent t he vehi cl e movingforwards or backwards .W henever pos si ble, t he ignit ion key i s removed before any work is carried out on t he vehi cle.If the engine i s t o be run, t here i s adequat e vent il ati on, or an extract ion hos e i s us ed to remove exhaus t fumes.There i s adequat e room to rais e the vehicle and remove t he wheel s , if neces s ary.Fender covers are al ways ins tal led i f any work i s to be carri ed out in t he engine compart ment.W here practi cable, t he batt ery i s dis connected if worki ng on the engi ne, underneath t he vehicle, or if t he vehi cl e i srai sed.
• CAUTIO NS:
Prior to dis connect ing the bat tery, refer to the El ect ri cal Secti on of this manual - Bat tery dis connect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
W hen el ect ri c arc wel ding on a vehi cl e, al ways dis connect t he generator wi ri ng to prevent t he pos si bili ty of a s urgeof current caus i ng damage to the i nternal component s of the generat or.
If us i ng welding equipment on t he vehicle, a s uit abl e fire exti nguis her is readily avail able.
Battery - General
• CAUTIO NS:
Prior to carrying out any procedures which i nvol ve dis connect ing/ or connecti ng the bat tery, refer t o t he ElectricalSect ion of t his manual - Batt ery di sconnect ion/connect ion.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
A di s charged bat tery condit ion may have been caus ed by an electrical short ci rcuit . If t his condit ion exis t s there wil lbe an apparentl y li ve circuit on the vehicle even when al l normal circuit s are s wit ched off. This can cause arcing when t hejumper cables are connect ed.
W hi le it i s not recommended that the vehicl e is jump s t art ed, i t is recognized t hat thi s may occas ionall y be t he onl ypracti cal way t o mobi lize a vehi cl e. Prior t o at tempt ing a jump s t art , reference must be made to the El ect ri cal Secti on oft hi s manual - Jump St art ing.
Followi ng jump s tart ing of a dis abl ed vehi cle, the di s charged bat tery mus t be checked for s erviceabili ty and recharged offt he vehi cl e as s oon as poss ibl e t o avoi d permanent damage.
Do not rel y on t he generator t o res t ore a di s charged bat tery. For a generat or t o recharge a batt ery, it woul d take i n exces sof eight hours cont inuous dri vi ng wi th no addi ti onal loads placed on t he batt ery.
Always make s ure that t he jumper cabl es are adequate for the tas k.Always make s ure that t he s lave batt ery i s of the same vol tage as t he vehicle bat tery. The bat teries mus t beconnected i n paral lel.Always make s ure that s wit chabl e electric circui ts are s wi tched off before connecti ng jumper cabl es. This reducest he ri sk of arci ng occurring when the final connecti on is made.
Towing the Vehicle
W ARNING: W hen t owing i s neces sary, reference mus t be made to the Jacki ng, Lift ing and Towing Secti on of thi sManual .
W hen t he vehicle i s being t owed dock the remote cont rol and s wit ch on the ignit ion. (s t eering l ock releas ed and warni ngli ght s i ll uminated). Onl y t hen wil l the s t eering, turn s ignal lamps , horn and s t op lamps be operat ional. Fail ure t o followt hes e i nst ructi ons may res ult in pers onal injury. It mus t be noted that wit h t he engine not running, t he power s t eering andbrake boost er wil l be inoperat ive t herefore, great er effort wil l be needed t o s t eer t he vehicle and apply the brakes .
General Installation Instructions
Component removal
W henever pos si ble, clean component s and the surroundi ng area before removal .
Blank off openings expos ed by component removal .Followi ng dis connecti on, s eal fuel, oil or hydrauli c li nes i mmediat ely us ing sui table bl anki ng plugs or caps .Seal open ends of expos ed oil ways us i ng sui table tapered hardwood pl ugs or cons pi cuous pl as t ic pl ugs .Immediat el y a component i s removed, place it i n a sui table contai ner; us e a s eparate cont ai ner for each componentand it s as s ociat ed part s .

CAUTION: Service t ools have been devel oped for ins tal ling the majori ty of beari ngs ; t hese must al ways be usedwhere specified.
In the cas e of greas e l ubricated beari ngs , fil l t he s pace bet ween t he bearing and out er s eal wit h t he recommendedgrade of greas e before ins t al li ng the seal.
CAUTION: W hen a waxed oil s eal (ins tal led dry) t ype of oil s eal i s to be ins t al led, take great care that greas e doesnot cont aminate the runni ng s urface of t he s eal .
Always make s uit able reference marks bet ween t he components of s eparable bearings e.g. t aper roller beari ngswhen dis as sembl ing t o make s ure correct locati on of components when as s embli ng. Never ins tall new roll ers i n anouter ring, al ways ins tal l a new beari ng ass embly.
Brake Pads and Linings
Always i ns t all t he correct grade and s peci fi cat ion of brake pads and li nings . W hen repl acing thes e it ems , always repl ace ascomplete axl e s ets .
Brake Hydraulics
Always obs erve t he fol lowing recommendat ions when worki ng on t he braking s ys tem:
W ARNING: Do not int ermi x brake fluid of di fferent specificati ons .
Always us e t wo s panners when loos eni ng or ti ght ening brake pi pes or hos e connect ions.Make s ure t hat hos es run in a natural curve and are not kinked or twi st ed.Ins t all brake pipes and hos es s ecurel y in their retaini ng clips and make sure t hat they cannot cont act a pot enti alchafing point .Containers used for brake fluid must be kept abs ol utel y cl ean.Do not s tore brake fluid in uns ealed containers, t he fluid will abs orb wat er which wi ll lower t he boili ng point of thefl uid.Do not all ow brake flui d to be cont aminat ed wit h ot her fluids such as mi neral oil and do not put brake fl uid i n acont ainer which has previous ly been us ed for s t oring ot her fl ui ds.Do not reus e brake flui d which has been bled from t he s ys t em.Always us e brake flui d or a s uit abl e brake cleaning flui d t o clean hydraulic component s .Unles s s tat ed otherwis e, us e onl y clean brake fluid to lubri cat e hydraulic seals and components .Always i ns t all blanking plugs t o hos es, pi pes or component s immediatel y aft er dis connect ion.Check t hread compati bili ty of origi nal equipment wit h repl acement component s.Obs erve absol ute cl eanli ness when working wi th hydraul ic component s .
Pipes and Hoses
W hen removing or ins t al li ng fl exi ble hydrauli c pipes and hoses , make s ure that t he foll owing procedures are observed tomake s ure component servi ceabil it y:
Pri or to removal , clean area around hos e or pipe end which is to be dis connect ed.Obtai n appropri at e bl anking pl ugs or caps before dis connecti ng hose or pi pe end fi ttings i n order t hat connect ionscan be plugged immedi atel y fol lowing di sconnect ion.Always i ns t all blanking plugs or caps to pipes and unions immedi atel y fol lowing di sconnect ion.Clean hos e or pipe and bl ow t hrough wit h an ai r line.
W ARNING: Sui table eye protecti on mus t be worn.
Check hos es external ly for cracks , separat ion of pl ies , securi ty of end fit ti ngs and ext ernal damage; repl ace fault yhoses .Check pi pes for s igns of corros ion and chafi ng, replace as neces s ary.
CAUTION: If pipes are found to be chafed, rect ify cli ps, mount ing point s etc., to prevent furt her probl ems in service.
W hen i nst all ing hos es , make s ure that no unneces s ary bends are i ntroduced and t hat hos es are not ki nked, twi s tedor pos i ti oned cl os e t o pot ent ial chafing poi nt s .W hen i nst all ing pipes , make s ure t hat pipes are pos it ioned and cli pped cl ear of potent ial chafing point s .Always repl ace seali ng was hers i ns t alled to banjo bol ts , s ealing pl ugs etc.Always us e a backing s panner when t ightening uni ons and do not overt ight en union nuts or banjo bol ts .Aft er any work on hydraul ic s yst ems , always check for flui d leaks whil s t a s econd operat or appli es worki ng pres suret o the brake pedal or operates t he s yst em that has been worked on.
Fuel s ys tem hos es

Flammabl e - OBSERVE NO SMOKING POLICY .
Irrit at ion of t he mout h and t hroat may res ult from s wallowi ng. The main hazard from s wallowi ng ari ses if li qui d as pirat ionint o t he lungs occurs.
Liquid contact dri es the ski n and can caus e i rrit at ion or dermati ti s. Splas hes in the eye may be s light ly i rrit ati ng.
In normal circums t ances t he low vol ati lit y does not give ris e t o harmful vapors . Expos ure to mis t s and vapors fromkeros ene at el evat ed t emperature s houl d be avoi ded (mis ts may ari s e in dewaxing). Avoi d s ki n and eye cont act and makes ure t here i s adequat e vent il ati on.
If sw allow ed, DO NOT induce vomiting - SEEK IMMEDIAT E MEDICAL AT T ENT ION.
Gas Cylinders
Gas es such as oxygen, acet ylene, argon and propane are normall y s tored in cyli nders at pres s ures of up t o 138 bar (13800kPa) (2000 lbf/i n²) and great care should be taken i n handl ing t hese cyli nders t o avoi d mechani cal damage t o t hem or t ot he val ve gear at tached. The contents of each cylinder s houl d be clearl y ident ifi ed by appropri ate markings .
Cylinders should be s tored in wel l vent il at ed encl osures, and protected from ice and s now or direct sunli ght . Fuel gas es,for example acetyl ene and propane should not be st ored i n clos e proximit y t o oxygen cylinders .
Care should be exerci sed to prevent l eaks from gas cyl inders and l ines and als o t o avoid s ources of ignit ion.
Only trai ned pers onnel s houl d undertake work involving gas cyli nders .
General Workshop Tools and Equipment
It is es s ent ial t hat al l tools and equipment are maint ained in good condit ion and t he correct s afet y equi pment is us edwhere required.
Never us e t ools or equipment for any purpos e other t han that for whi ch they were desi gned. Never overl oad equi pments uch as hoi st s , jacks, axle and chas si s s tands or li ft ing sl ings . Damage caus ed by overloading i s not always immediatel yapparent and may res ult i n a fatal fai lure the next t ime that t he equi pment is us ed.
Do not us e damaged or defect ive t ools or equipment, part icularly hi gh s peed equipment s uch as gri ndi ng wheel s . Adamaged grindi ng wheel can dis int egrate wit hout warning and cause serious i njury.
W ear s uit abl e eye prot ect ion when us ing grinding, chis elli ng or s and bl ast ing equi pment .
W ear a s uit able breat hing mas k when us i ng abrasi ve blas ti ng equi pment or us i ng sprayi ng equi pment.
Make s ure t here i s adequat e vent il ati on to cont rol dust s , mis t s and fumes .
High Pressure Air, Lubrication and Oil Test Equipment
Always keep high press ure equi pment i n good condi ti on, and regul arly maint ai ned, parti cularly at joint s and uni ons.
Never di rect a high press ure nozzle, for example dies el i njector, at t he s kin as the fluid may penet rat e t o t he underlyingt is sue and caus e s eri ous i njury.
Jacking
Always refer to the Jacki ng and Lifti ng s ect ion of t hi s manual prior t o rai s ing t he vehi cl e off the ground.
W hen vehicle is t o be rais ed by means of a jack, ensure t hat i t is st andi ng on l evel ground, that parking brake is appli edand wheels are chocked. ALW AY S us e t he recommended jacking poi nt s and ens ure t hat vehi cl e jack has s ufficient loadcapacit y for t he weight of t he vehi cl e.
W ARNING: Do not work on or under a vehi cle s upported onl y by a jack. Always s upport t he vehi cl e on s afet y s tands .
Ensure t hat hois t s have s uffi ci ent load capacit y for t he wei ght of t he vehi cl e.
Legal Aspects
There are many l aws and regulat ions rel at ing to healt h and s afet y i n the us e and di spos al of materials and equipment i n aworks hop.
For a s afe worki ng envi ronment and t o avoi d environment al poll uti on, workshops s hould be famil iar, i n detai l, wi th t hemany healt h and s afety laws and regul ati ons wit hi n t hei r count ry, publ is hed by both nat ional and local aut horit ies .
Lubricants and Greases
Avoi d all prolonged and repeat ed contact wit h mi neral oils . All l ubricants and greases may be irri tat ing t o t he eyes ands ki n.
Used Engine Oil
Prol onged and repeat ed cont act wi th engi ne oil wil l res ult i n t he removal of nat ural fat s from the s kin, leading to drynes s ,irri tat ion and dermati ti s. In addit ion, used engi ne oil cont ains potent iall y harmful cont aminants whi ch may caus e s kincancer. Adequat e means of s kin protecti on and washi ng facil it ies mus t be provi ded.
Do not employ us ed engine oi ls as l ubricants or for any appli cat ion where appreciable s kin cont act i s li kel y t o occur.

s tored on open ground coul d eit her leak or have contami nati ng subs tances was hed off them that would cont aminate theland. Always s tore t hes e materi als i n s uit abl e s kips or s imi larly robus t cont ainers .
Legal compliance
Some s it es may have a di scharge cons ent for effl uent di scharge t o t he foul drai n for a car was h et c. It is ess enti al t o knowt he types of effluent which are al lowed t o be di scharged i nto t he drai n and t o check t he res ult s of any monit ori ng carri edout by the W ater Company.
W here paint s praying operat ions are carried out i t may be necess ary to apply to the Local Aut horit y for an ai r emis s ionsli cence t o operate the pl ant . If such a licence is necess ary, addit ional precaut ions wil l be neces s ary t o comply wi th therequirements and t he resul ts of any air quali ty moni toring mus t be checked regul arl y.
Checkli s t
Alw ays adhere to the following:
Know what legal cons ents and l icences apply t o t he operat ions.
Check t hat the emis s ions and dis charges compl y wit h l egal requi rements .
Waste Management
Pollut ion can be reduced by careful handli ng, s t orage and dis posal of all was te materials that occur on s it es. Legis lat ionmakes it i ll egal t o dis pose of was t e mat eri al s other t han to licens ed wast e carriers and dis pos al s it es.
This means t hat it i s neces sary t o not onl y know what the wast e mat eri al s are but als o to have the neces s arydocument at ion and licences .
Handl ing and s t orage of was te
Ensure t hat was t e mat erial s are not poured down the drai n or on t o s oil and are st ored in s uch a way t hat they do notes cape on t o l and or soi l.
All was te mus t be s egregat ed int o i ndi vi dual t ypes e.g. oils , met als , bat t eries , s crap component s etc. This wi ll prevent anyreacti on between di fferent materials and as s is t i n dis posal .
Dis pos al of was te
Dis pos e of wast e i n accordance wi th t he followi ng guidelines :
Fuel, hydraulic fluid, anti-freeze and oil: Keep s eparate and dis pos e of t o s peci alis t contract ors .
Refrigerant: Col lect in s peci ali st equipment and reus e.
Detergents: Safe to pour down t he foul drai n if di luted.
Paint, thinners: Keep separat e and dis pose of to speciali st contract or.
Components: Return t o s uppl ier for refurbi shment or dis as sembl e and reus e any s uit able part s . Dis pose ofremai nder i n ordi nary was te.
Small parts: Reuse any sui table parts , dis pos e of the remainder in ordinary was t e.
Metals: Can be s old i f separat e from general was t e.
T yres: Keep s eparate and di s pos e of t o s peci al is t cont ract or. DO NO T att empt to dis pos e of t yres by burni ng.
Components/materials containing asbestos: Keep separat e and dis pose of to speciali st contract or.
Oil and fuel wastes (e.g. rags, used spill kit material): Keep s eparate and dis pos e of t o s peci alis t contract ors .
Air filters: Keep s eparat e and dis pose of to s peciali st contract ors .
Rubber/plastics: Dis pos e of i n ordi nary was te.
Hoses: Di s pos e of i n ordinary was te.
Batteries: Keep separat e and dis pose of to speciali st contract ors .
Air bags - DANGER EXPLOSIVES: Keep s eparate and dis pos e of t o s peci alis t contract ors .
Electrical components: Return to suppli er for refurbis hment or dis ass emble and reus e any s uit abl e components .Dis pos e of remai nder in ordinary wast e.
Catalytic converters: May be s ol d i f kept s eparate from general wast e.
Packaging: Compact/recycl e as much as pos s ible and di s pos e of i n ordinary was te.
Office/paper waste: Recycl e paper and t oner and i nk cart ridges , dis pos e of remainder in ordinary was t e.
Noise
Car alarm t es t ing, panel beati ng, runni ng engi nes , us ing ai r tools et c. are operat ions which i nvariably produce a largeamount of noi se. The l ocati on of s uch act ivit ies and als o the t ime of day must be carefull y cons idered havi ng regard to theproximit y of hous es s chools et c.

Publ is hed: 24-Jun-2011
Jacking and Lifting - Jacking
Des cript ion and Operat ion
General
W ARNING: The foll owing i nst ructi ons mus t be adhered to before rais i ng the vehicle off t he ground:
Posi ti on vehi cl e on a sol id, level surface.Apply t he parking brake.Select 'P' - PARK on automat ic t rans mis s ion sel ect or.Select 'N' - Neutral on manual t rans mis s ion.
W ARNING: If t he dri ve s haft(s ) are t o be di sconnect ed, i t wil l be neces s ary t o rai s e all four wheels off the ground inorder t hat t he s haft (s ) can be rot ated. DO NOT us e the cus tomer jack and ens ure that t he vehi cl e is adequatel y s upport edon axle s t ands . W i th the vehicle rai sed, it will be necess ary to releas e t he park brake and sel ect Neutral - 'N' in the mai nt ransmis s ion t o enabl e t he dri ve s haft(s ) to be rot ated.
• CAUTIO NS:
To avoid damage t o t he underbody components of t he vehi cle, the foll owing i ns t ructions mus t be adhered to:
Do not pos it ion jacks or axle s t ands under the foll owing component s :
Body s truct ure ot her t han any approved jacki ng or li ft ing point sRear subframeBumpersFuel l inesFuel t ankBrake l inesFront or rear s uspens ion armsSteering l inkageRear di fferenti al uni tTrans mis s ionEngi ne oil pan - See not e below
• NOTE: For certain repair operat ions, i t may be necess ary to support t he engine under t he oil pan. In thi s cas e, a bl ock ofhardwood or a rubber pad mus t be pos it ioned on t he jack li ft ing pad t o protect the oi l pan.
Hydraulic jack
• W ARNINGS:
Before commenci ng work on undersi de of vehi cl e, ens ure that axle s t ands are correctly pos it ioned and vehi cle i ss ecurel y s upported.
Al ways chock the rear wheel s when jacking t he front of the vehicle.
A hydrauli c jack wi th a mi ni mum li ft ing capacit y of 1500 kg, (3,300 l bs) must be us ed.
Raising and Supporting the Vehicle
To as si s t in rais ing the vehicle, us e t he cus t omer jacki ng poi nts on the s i ll or on t he trolley jack pos i ti on at the rear of t hefront subframe as indicated i n t he fol lowing ill ust rat ions .
Raising the front of the vehicle
W ARNING: Always chock t he rear wheels when jacki ng the front of t he vehi cl e.
Apply t he parking brake.
Select 'P' - Park on aut omat ic trans mi s si on s el ect or.
Select 'N' - Neutral on manual t rans mis s ion.

For addit ional informat ion, refer t o: Parking Brake Cabl e Adjus tment (206-05 Parki ng Brake and Actuat ion, GeneralProcedures).
Door Locks and Hinges
1. Check operat ion of all door locks, bonnet lock and fuel fi ll er flap.
2. Lubricate al l door check s t raps , bonnet cat ch and fuel fill er fl ap cat ch.
Cooling System
CAUTION: Anti-freeze concentration must be maintained at 50%.
1. Check s peci fi c gravit y of cool ant us ing a hydrometer.
• NOTE: A s uit able hydromet er is avail abl e from the Equipment Programme under Part Number 511 3302 001 00.
2. Top-up cool ing s ys tem if neces s ary.For addit ional informat ion, refer t o: Specificati ons (303-03A Engine Cool ing - I6 3.2L Pet rol , Specificati ons ).
Cooling system - Check/Top-up
W ARNING: Since injury such as scalding could be caused by escaping steam or coolant, do not remove the fillercap from the coolant expansion tank whilst the system is hot.
• CAUTIO NS:
Engine coolant w ill damage the paint finished surfaces. If coolant is spilled, immediately remove the coolantand wash the area with water.
Always top-up with a 50% mixture of anti-freeze and water.
Check t he l evel of cool ant i n t he expans ion t ank. W it h t he engi ne col d, the coolant level must be to the UPPERLEVEL indicat or mark above the COLD FILL RANGE t ext on the s i de of the expans i on tank. Ignore any coolantwhich may be vis ible in t he t op s ect ion of t he t ank.If topping-up i s requi red, remove expans ion tank fill er cap and top-up coolant level to the UPPER LEVEL indicat ormark.For addit ional informat ion, refer t o: Specificati ons (303-03A Engine Cool ing - I6 3.2L Pet rol , Specificati ons ).Ins t all expans ion t ank fi ll er cap, ti ght en cap unti l ratchet is heard to 'cli ck'.
Coolant - Replace
Every 10 years: Repl ace the coolant.For addit ional informat ion, refer t o: Cool ing Sys tem Drai ning, Fi ll ing and Bl eeding (303-03A Engine Cooli ng - I6 3.2L Pet rol,General Procedures ).
Ignition System
Every 75,000 miles (120,000 km). Replace s park plugs .For addit ional informat ion, refer t o: Specificati ons (303-07B Glow Pl ug Sys t em, Specificati ons ).
Accessory Drive Belt
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
Check t he condi ti on of the access ory drive bel t.Remove all t races of mud and dirt from t he dri ve belt and pull eys .Check t he drive belt for si gns of s pli tt ing and wear.Every 105,000 miles (168,000 km) - Petrol models: Replace the accessory drive belt. For addi ti onalinformat ion, refer t o: Acces s ory Drive Belt (303-05A Acces s ory Drive - I6 3.2L Pet rol , Removal and Ins t allat ion).

For addit ional informat ion, refer t o: Parking Brake Cabl e Adjus tment (206-05 Parki ng Brake and Actuat ion, General
Procedures).
Door Locks and Hinges
1. Check operat ion of all door locks, bonnet lock and fuel fi ll er flap.
2. Lubricate al l door check s t raps , bonnet cat ch and fuel fill er fl ap cat ch.
Cooling System CAUTION:
Anti-freeze concentration must be maintained at 50%.
1. Check s peci fi c gravit y of cool ant us ing a hydrometer.
• NOTE: A s uit able hydromet er is avail abl e from the Equipment Programme under Part N umber 511 3302 001 00.
2. Top-up cool ing s ys tem if neces s ary.
For addit ional informat ion, refer t o: Specificati ons (303-03B Engine Cool ing - TD4 2.2L Dies el, Speci fi cat ions ).
Cooling system - Check/Top-up W ARNING:
Since injury such as scalding could be caused by escaping steam or coolant, do not r emove the filler
cap from the coolant expansion tank whilst the system is hot.
• CAUTIO NS:
Engine coolant w ill damage the paint finished surfaces. If coolant is spilled, immed iately remove the coolant
and wash the area with water.
Always top-up with a 50% mixture of anti-freeze and water.
Check t he l evel of cool ant i n t he expans ion t ank. W it h t he engi ne col d, the coolant level must be to the UPPER
LEVEL indicat or mark above the COLD FILL RANGE t ext on the s i de of the expans i on tank. Ignore any coolant
which may be vis ible in t he t op s ect ion of t he t ank. If topping-up i s requi red, remove expans ion tank fill er cap and top-up coolant level
to the UPPER LEVEL indicat or
mark.
For addit ional informat ion, refer t o: Specificati ons (303-03B Engine Cool ing - TD4 2.2L Dies el, Speci fi cat ions ).
Ins t all expans ion t ank fi ll er cap, ti ght en cap unti l ratchet is heard to 'cli ck'.
Coolant - Replace
Every 10 years: Repl ace the coolant.
For addit ional informat ion, refer t o: Cool ing Sys tem Drai ning, Fi ll ing and Bl eeding (303-03B Engine Cooli ng - TD4 2.2L
Dies el, General Procedures).
Accessory Drive Belt CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
Check t he condi ti on of the access ory drive bel t. Remove all t races of mud and dirt from t he dri ve belt and pull eys .
Check t he drive belt for si gns of s pli tt ing and wear.
Every 150,000 miles (240,000 km): Replace the accessory drive belt.
For addit ional i nformati on, refer t o:
Acces s ory Drive Belt (303-05A Acces s ory Drive - I6 3.2L Pet rol , Removal and Ins t allat ion).
Camshaft Timing Belt, Tensioner and Pulley
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.

Ensure that the steering wheel is in the straight ahead position, do not turn the st eering w heel prior to checking the
fluid level.
Check t hat the flui d level is t o t he mi d-way mark between the MAX and MIN marks on t he fluid res ervoir, t op-up i f
neces s ary. Clean t he area around the res ervoi r fi ll er cap, remove cap.
CAUTION:
Do not fill reservoir above the MAX mark.
If necess ary, t op-up us ing t he recommended fluid to the mid-way mark on the reservoi r.
For addit ional informat ion, refer t o: Specificati ons (211-02 Power St eering, Specificati ons).
Ins t all the res ervoir fill er cap.
Windshield Washer Reservoir
Remove the winds hi eld was her res ervoir fill er cap.
Top-up t he res ervoir us ing a mi xt ure of an approved wi nds hiel d was her flui d and wate
r unti l the level i s t o the
bott om of t he gauze fil ter i n t he res ervoir fil ler neck. Ins t all the res ervoir fill er cap.
Engine Oil and Filter
• CAUTIO NS: For vehi cl es operati ng under arduous condi ti ons see relevant secti on.

Vehicles operating on high sulphur content fuel - above 0.7%, the oil and filter cha nge period MUST NOT
exceed 3 months or 3,750 miles (6,000 km).
Vehicles operating on moderate sulphur content fuel - 0.3 to 0.7%, the oil and filte r change period MUST NOT
exceed 6 months or 7,500 miles (12,000 km).
Renew engi ne oil and fil ter.
For addit ional informat ion, refer t o: Oil Fil ter El ement (303-01A Engine - I6 3.2L Pet rol , Removal and Ins t allat ion).
Air Filtering
CAUTION: For vehi cl es operati ng under arduous condi ti ons s ee relevant s ecti on.
1. Every 2 years or 30,000 miles (48,000 km): Replace the ai r cl eaner element .
For addit ional informat ion, refer t o: Air Cl eaner (303-12B Int ake Ai r Dis t ri but ion and Fi lt ering - TD4 2.2L Di es el, Removal
and Ins t allat ion).
Fuel Filter
1. Every year or 15,000 miles (24,000 km): Drai n water from the fuel fi lt er.
1. Every 2 years or 30,000 miles (48,000 km): Replace fuel fi lt er el ement.
For addit ional informat ion, refer t o: Fuel Fil ter (310-01B Fuel Tank and Lines - TD4 2.2L Dies el, Removal and Ins tall ati on).
Automatic Transmission
Every 10 years or 150,000 miles (240,000 km): Renew automat ic t rans mis s ion flui d.

Not s ens it ive to brake tes ti ng on a chas si s dynamomet er.
Generati on 4 Acti ve On-Demand Coupli ng - Vehicles from 2009MY
The generati on 4 coupl ing does not have the di fferenti al s peed dri ven pump used on the previ ous generat ion 3coupl ing, but i s fit ted wi th a bigger capacit y electrically operated axial pump and a hi gh pres s ure accumul ator.The proport ional throt t le valve and press ure s ens or on t he generat ion 3 coupli ng is replaced wit h a proport ionalpres s ure reducing val ve.The t orque li mit er pres sure reducing valve on the generat ion 3 coupli ng is replaced by an electroni c cont rol valveand cont rol ling software.
The generati on 4 acti ve on-demand coupli ng gives t he fol lowing improvements over t he previous generati on 3 coupl ing:
Reduced bas e t orque at high different ial s peedsTorque acti vat ion i s now i ndependent of different ial s peedAccurat e t orque l imi ter cont rolEnergy s tored in hi gh pres s ure accumul ator givi ng a low maximum current consumpt ion of t he electric pump andfas t er res pons e.
Control Module - G eneration 3 and 4 Couplings
The cont rol module, at tached to the cas ing of t he act ive on-demand coupling, forms a s ingle unit wit h t he cont rolvalve/axial s ol enoi d. By anal yzi ng informat ion from other vehi cl e modules and s ensors t he cont rol module regul ates t heaxial sol enoi d t o cont rol t he hydraul ic flui d pres s ure s uppl ied t o t he clut ch pl ates. Some of t he modul es and s ens ors thecont rol module communi cat es wit h are li s ted below:
Hardwi red:- Control valve / axi al s olenoid- Electric hydrauli c pump- Oi l press ure and temperat ure sens orHigh speed CAN (cont rol ler area net work):- Engine cont rol module- Anti -l ock brake s ys t em / t racti on cont rol module- Tracti on res ponse swit ch- Y aw rate sens or- Steering wheel rot at ion sens or
The axial sol enoi d cons t ant ly adjust s t he cont rol valve output us ing a Pul se W i dt h Modulat ion (PW M) s i gnal. The flui dpres s ure deli vered t o t he cl utch plat es determines t he amount of t orque t hat is delivered t o t he rear axl e.
The act ive on-demand coupli ng has int egrated oi l press ure and temperature s ens ors to enable the control modul e t oaccurat ely manage t he t orque t ransfer under all environment al and operat ing condit ions . Usi ng thes e s ignals the controlmodule will us e s t rategi es to protect the coupli ng from overheati ng; in extreme cas es to protect t he coupli ng from damaget he coupli ng wil l dis engage i f the t emperat ure of t he hydraul ic flui d exceeds 105°C. The coupl ing wi ll ret urn to normalfuncti onal it y when t he temperat ure fall s below 101°C.
The cont rol module has an int egrated di agnos ti cs sys tem, whi ch cons tant ly moni tors the act ive on-demand couplings ys t em as wel l as it s input and output s ignals . If t he control modul e detects a fault a Diagnost ic Troubl e Code (DTC) i ss tored. The DTC is acces s ed usi ng t he Land Rover approved di agnos t ic s yst em.
Electric Hydraulic Pump
W hen negoti ati ng very low frict ion s urfaces s uch as wet gras s , snow or i ce; i nit ial wheel -s pin can cut i nt o t he s urface andreduce gri p. W it h a re-act ive on-demand coupl ing, almos t 60 degrees of wheel rotat ion woul d occur before torque could bet ransmit ted t hrough t he coupl ing.
On Generat ion 3 coupli ngs , t o count eract thi s Land Rover devel oped a uni que high-pres s ure pre-charge faci li ty whi chenergizes t he hydraul ic circui t as s oon as the engi ne is s t art ed. Es s ent ial ly an el ect ri cal ly operat ed hydraul ic pump wasdesi gned to maintai n a pot ent ial of 500 Nm (369 l b ft ) of t orque pres s ure wi thi n the coupli ng. (This pre-charge t orquecapacit y has been increas ed to 1500Nm (1106 l b ft ) for t he Generat ion 4 coupli ng.)
Vehicles fit ted wi th Terrai n Res pons e als o add furt her benefi ts by varying t he level of pre-charge t o deli ver opti mumt racti on over a range of di fferent t errai n s urfaces . The level of pre-charge is varied dependi ng on t he part icul ar terrainres ponse mode, for exampl e:
Terrai n respons e in 'Speci al Programs Off' mode as common wit h vehi cl es wit hout terrain res pons e, the coupli ng isprogrammed t o transmit 500 Nm 369 lb ft of t orque on Generat ion 3 couplings and 1500 Nm (1106 l b ft) of t orqueon Generat ion 4 couplings t o t he rear axle when the vehicle moves from res t i n a s t raight l ine. Thi s s trategymi ni mi zes t ract ion l os s from a s t andi ng-s tart regardles s of t he terrain. W hen the vehicle accelerat es the pres surein the coupling is decreas ed to improve fuel economy.The abili ty to sens e t he s teeri ng angl e all ows t he coupli ng t o be programmed t o provide no torque trans fer t hrought he coupli ng. This prevent s t he coupli ng locking when t he vehicle i s maneuvring at low s peeds and acute s teeri ngangl es.In 'Grass / Gravel / Snow' mode t he coupl ing i s programmed to maint ai n i ts pre-charge s t at e unt il much highers peeds are obtained. The s ame applies even i f the vehicle is t raveli ng at low speeds and acut e s t eering angles , ast racti on takes precedence over coupli ng lock-up on l ow-fri ct ion s urfaces .
For addit ional informat ion, refer t o: Ride and Handli ng Opti mizat ion (204-06 Ride and Handli ng Opt imi zat ion, Descripti onand Operat ion).
Mechanical Hydraulic Pump - Generation 3 Couplings - Vehicles up to 2009MY
The dri ves haft i s att ached t o t he coupl ing's front clut ch pl ate as s embly (i nput ), with the rear cl ut ch plat e as sembl yconnected t o t he different ial pini on (out put ). A s was h-pl ate wit h 6 hydrauli c rol lers is al so att ached t o t he different ialpinion. W hen there is no s peed difference bet ween the coupling's input and out put, the rol lers do not funct ion.

However, when the front and rear axl es st art t o rotat e at different s peeds , t he s wash-pl ate rot at es rel ati ve to the roll erswhich generat es the hydrauli c pres s ure. Thi s pres s ure i s us ed to force the opposi ng clut ch pl ates t oget her, i ncreas ing thet ransmis s ion of t orque t o the rear axl e. As the di fference in axl e s peed i ncreases the hydrauli c pres sure pushes t he clut chplat es further together t o increas e t he t orque to the rear axl e.
A control val ve/axi al s olenoid cont rols the amount of pres s ure appli ed to the clut ch plat es , and hence the amount oft orque transmit ted t o t he rear wheels . Clos e manufact uring t olerances and except ional ly low component wear ens uret orque cont rol remai ns accurat e t hroughout t he vehi cl e's l ife.
Mechanical Hydraulic Pump - Generation 4 Couplings - Vehicles from 2009MY
The Generati on 4 coupl ing does not us e the swas h pl at e t o mechanical ly rais e hydrauli c pres s ure; ins tead, a new hydraul icpump i s used to generat e hydrauli c pres sure and force the cl utch plat es toget her. The removal of t he s was h plat e all ows alarger overal l cl ut ch plat e s urface area, whi ch in t urn reduces t he hydrauli c pres sure requi rement. The press ure required toachi eve 1500Nm (1106 l b ft ) has been reduced from 100 Bar for Generat ion 3 coupli ngs to 40 Bar for Generati on 4coupl ings.
The posi ti oni ng of the Generat ion 4 coupl ing's i nput and output remains t he s ame as t he Generati on 3 coupl ing, asdescribed above.
By-pass Valve
On very low fricti on s urfaces, driveli ne drag t orque can occur, for exampl e:
revers e t orque from engi ne braking, orforced movement of t he dri ves haft by t he front wheel s .
This can i nfluence rear wheel s peed, maki ng it i mpos si ble t o determine the t rue fricti on capabil it y of the rear wheel s, bydis t orti ng t he wheel s peed s ignal. To prevent thi s, t he acti ve on-demand coupli ng is des i gned t o open i mmediat el y inres ponse to a s tabil it y cont rol event . This i s achi eved by a by-pass val ve ins tant ly reducing sys tem pres s ure t o nomi nal .
To balance the 4 bar bas e press ure (s ee below for detai ls ), t he Generati on 3 coupling us es a large Bel levill e s pri ng to forcet he cl utch plat es clear of each ot her t o prevent torque transmis si on t hrough the coupli ng. Even at 0°C, t orque t rans mis s ionis reduced from 300 Nm to Zero wi thi n 10 ms . The Generat ion 4 coupling however, does not require a Bel lvil le s pri ng t os eparate t he plat es as t he coupli ng does not have a si gni fi cant bas e pres s ure pus hi ng t he plates together.
Accumulator
The further t he cl utch pl at es have to move in order to contact each other, t he longer it t akes to di spl ace the hydrauli c fl uidneces s ary t o buil d pres s ure and t rans mit torque. To count er thi s, t he Generati on 3 coupling incorporates an accumulat or.This retains a nominal 4 bar pres sure wi thin the hydraul ic circui t. Al though thi s is not enough pres sure t o caus e s i gni fi cantt orque transmis s ion t hrough the coupli ng, i t forces t he plat es very clos e t oget her so that very l it tl e fluid di s pl acement i srequired t o achi eve full engagement and maxi mum t orque t rans fer. Ful l torque t rans miss i on can be achieved i n 150 ms .
On Generat ion 4 coupli ngs , t he 150ms act ivat ion t ime is achieved through the us e of a Bel lvil le s pri ng t hat acts to pus ht he plates t ogether (wi thout caus i ng si gnifi cant t orque t rans mis s ion t hrough t he coupl ing). As t he pump i s notcont inuousl y us ed to create t his bas e pres s ure (as i t was wit h Generat ion 3 coupli ng), improvement s i n fuel economy havebeen achi eved.
Wet Clutch Pack
The clutch pack is made up of 7 pairs of plat es ; t he inner dis cs are produced from hardened st eel wit h t he out er dis csmanufactured from s t eel wi th a s int ered face. The clutch pl ates operat e in trans mi s si on fl uid.
Torque t rans mis s ion acros s t he clutch pack is li mit ed t o 1500 Nm (1106 lb ft ). This ens ures t he l ower gears ret ai n anelement of front-wheel -drive for t ract ion s t abi lit y. W i thin the hi gher gears the coupl ing i s t heoreti call y capabl e oft ransmit ti ng all t he dri ve to the rear axle; al though condit ions woul d have to be ext reme for t his t o occur.
PRINCIPLES OF OPERATION
Generation 3 Couplings - up to 2009MY
An i nt ernal electroni cal ly-controll ed pump provides hydrauli c pre-charge pres sure wit hin the coupling. The pre-chargepres s ure s upplies t he requi red operat ing pres s ure to the clut ch plates to el imi nat e i nit ial wheel -s pin as the vehicleaccelerates from s tandst il l.
In conjunct ion wi th the pre-charge pres s ure a mechanical hydraul ic pump operates wi thi n the cl utch plat es to s upply thecoupl ing's mai n hydraulic operat ing pres sure. The mechanical pump is funct ioned by the 'i nput ' and 'output' of t he coupli ng:
input - dri ves haft connect ion from the front axle,output - different ial connecti on to the rear axl e.
Any s peed di fference bet ween t he front and rear axl es wil l st art t he operat ion of t he mechanical hydraul ic pump. Theamount of hydrauli c pres s ure appli ed to the cl ut ch pack by the pump det ermines the gap bet ween t he cl utch plat es. Forexampl e, the great er the hydraul ic pres s ure, t he s maller t he gap between t he plat es and s ubs equent ly t he great er thet orque transmit ted t hrough t he coupli ng from the front axle t o t he rear axle.
This mai n hydrauli c pres sure is des i gned t o t rans mit the t orque for tract ion demands of off-road drivi ng, and t o provi delock-up as requi red.
Generation 4 Couplings - from 2009MY
The Generati on 4 coupl ing s t il l us es an el ect ri cal ly-controlled pump to provide hydrauli c pre-charge to el imi nat e wheel-s pinfrom st ands t il l; however, the s ame pump is al s o used to provi de t he coupli ng's mai n hydraul ic operat ing press ure.