2006 LAND ROVER FRELANDER 2 service

Publi s hed: 11-May-2011
General Information - General Service Information
Des cript ion and Operat ion
Introduction
This manual has been wri tt en in a format t hat i s desi gned to meet the needs of Land Rover technicians worl dwide and t oas si st them in t he efficient repai r and maintenance of Land Rover vehi cl es .
This manual provides descripti ons and methods for accomplis hing adjust ment, s ervi ce and repair work usi ng t es t ed andeffect ive procedures . Fol lowi ng thes e procedures wil l hel p ens ure product rel iabil ity.
Special Tools
The Speci al Tool(s ) Tabl e provided at t he begi nni ng of each procedure li st s t he s pecial t ool (s ) requi red t o carry out repairoperati ons wit hin t hat specific procedure. W herever poss i bl e, ill ust rat ions are provided whi ch wil l as s is t t echnicians i nidenti fyi ng the s pecial tool(s ) required and als o s howing s uch tool (s ) in use.
Speci al t ools may be obt ained from the manufact urer, SPX Tool s, t he addres ses of t heir branches will be found in theSpeci al Tools Gl oss ary.For addit ional informat ion, refer t o: Special Tool Glos sary (100-00 General Informati on, Des cri pti on and Operati on).
Important Safety Instructions
Appropri at e s ervi ce methods and correct repai r procedures are es sent ial for t he s afe and reli abl e operati on of all mot orvehi cl es as well as ens uri ng the personal s afety of t he i ndi vi dual carryi ng out the work.
This manual cannot poss ibl y anti ci pat e al l s uch vari at ions and provi de advi ce or cauti ons as to each. Any pers on whodeparts from t he ins t ructi ons provi ded in this manual mus t firs t es tabl is h t hat t hey compromis e nei ther thei r personals afety nor t he vehicle i ntegri ty by their choice of met hods , tool s or parts .
Indi vi dual s who undert ake their own repai rs should have s ome skil l or training and limi t repairs t o component s which coul dnot affect t he s afety of t he vehicle or i ts pas s engers. Any repai rs requi red to s afet y cri ti cal i tems such as s t eering, brakes,s uspens ion or s uppl ement al res traint s yst em s hould be carri ed out by a Land Rover Dealer. Repairs t o s uch i tems s houldNEVER be at tempt ed by untrai ned indivi duals .
Warnings, Cautions and Notes which appear in this manual
As you read through t his manual, you wi ll come acros s W arnings, Caut ions and Notes . A W arning, Cauti on or Not e i splaced at the beginni ng of a s eries of s t eps . If the warning, caut ion or note onl y appl ies t o one s t ep, i t is pl aced at t hebegi nning of t he specific s t ep aft er the s t ep number.
Warnings, Cautions and Not es have the foll owing meanings :
Warning: Procedures which mus t be foll owed to avoid the pos s ibil it y of pers onal i njury.
Caution: Cal ls at tent ion t o procedures which mus t be foll owed to avoid damage to components .
Note: Gi ves hel pful informati on.
References
References t o the Left Hand (LH) or Right Hand (RH) si de given i n t hi s manual are made when vi ewing t he vehi cl e or unitfrom the rear.
Fault Diagnostic Equipment
The vehi cl e i s equi pped wit h a number of electroni c cont rol s yst ems t o provide opt imum performance of the vehicl e'ss ys t ems .
Land Rover approved diagnos t ic equipment is avai lable and mus t be us ed where s pecified. The use of this equi pment willas si st wit h t he fault di agnos ti c abili ti es of the Deal er workshop. In parti cul ar, t he equi pment can be us ed t o i nterrogat et he elect roni c s ys t ems for di agnos is of faul ts whi ch may become evident during t he li fe of the vehicle.
This manual is produced as a reference s ource t o s uppl ement Land Rover approved di agnos ti c equipment.
Feat ures of t he equi pment include:
a. Ful ly upgradeable s upport for t he t echnician
b. Struct ured di agnos ti cs to accommodate al l ski ll levels
c. Direct print-out of screen i nformati on and tes t res ult s
Testing the vehicle
Operat ions covered in t his manual do not include reference t o t es t ing t he vehicle after repai r. It is es s ent ial t hat work i sins pect ed and t es t ed aft er compl eti on and if neces s ary, a road tes t of the vehicle is carried out , part icul arl y where s afet yrel ated i tems are concerned.
Repairs and Replacement Parts

A clock face sys tem is somet imes us ed as an al ternat ive method of indi cat ing t he s trengt h grade. The external chamfers ora face of t he nut is marked i n a pos it ion relati ve to the appropriat e hour mark on a cl ock face to indicate the s t rengthgrade.
A dot i s used to l ocat e t he 12 o'clock posi ti on and a das h t o indi cat e t he st rengt h grade. If t he grade i s above 12, t wodots i dent ify t he 12 o'clock posi ti on.
W hen t ight eni ng a s lot ted or cas tell ated nut , never loos en it t o i nsert a s pli t pi n except where s pecified as part of anadjus tment procedure. If di fficult y is experi enced i n correct ly pos it ioning t he s lot, alt ernati ve washers or nut s s houl d bes elect ed.
W here a nut is ti ght ened to adjust or mai ntain bearing pre-l oad, t he ti ght ening procedure must be adhered to.
Self-locking nuts
Unles s s tat ed otherwis e, sel f-locki ng nuts once removed must be di s carded and new nut s of t he s ame t ype and st rengthgrade i nst all ed.
Ball and Roller Bearings
W hen removing and i ns t alli ng bearings , make s ure t hat the foll owing pract ices are obs erved t o make s ure components erviceabi li ty:
CAUTION: Service t ools have been devel oped for removing the majori ty of beari ngs ; t hes e must al ways be usedwhere specified.
Remove all t races from beari ng under i ns pecti on by cl eani ng wit h a sui table degreas ant; maintai n absol ut ecleanlines s t hroughout operati ons.Conduct a vis ual ins pect ion for markings on roll ing element s , raceways , out er s urfaces of outer or inner surfaces ofinner ri ngs . Reject any bearings found to be marked s ince marking i n thes e areas i ndicat es ons et of wear.Hold inner race of bearing between finger and t humb of one hand and rotat e outer race to check that it revol vesabsol ut ely smoot hly. Repeat holding out er race and rot ati ng inner race. DO NOT spi n t he bearing.Rotat e outer ring gentl y us ing a reci procati ng movement whi ls t holding i nner ring; feel for any check or obs truct iont o rot ati on. Reject beari ng if movement is not abs ol utel y s moot h.Check beari ng for bl uei ng or si gns of overheat ing.Lubricate bearing wi th the s pecifi ed lubricant .Ins pect bearing s urface of s haft and beari ng hous i ng for dis colorat ion or ot her markings which i ndi cat e overheati ngof bearing or movement between beari ng and s eat ing.Before ins tal li ng bearing, make s ure t hat shaft and bearing hous ing are cl ean and free from burrs .If one bearing of a pair s hows s igns of wear, overheati ng etc., i t is advis able to replace bearings as a pai r unl ess itis sus pect ed t hat one beari ng may have been fault y when i nst all ed, was i nst all ed incorrect ly or t he faul t aros e duet o oil s eal fail ure.Never reins tal l a bearing unles s i t is i n a full y s erviceabl e condi ti on.
W hen i nst all ing a bearing t o a s haft , only apply force t o t he inner ri ng of the beari ng. W hen ins t al li ng a beari ngint o a hous ing, onl y apply force t o t he out er ri ng of the bearing.

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

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:

Publi s hed: 11-May-2011
General Information - Special Tool Glossary
Des cript ion and Operat ion
Service Tools
Speci al s ervi ce tools have been devel oped to faci li tat e removal, di smant li ng and as sembl y of mechanical components in acos t effecti ve and ti me effi ci ent manner. The us e of s uch s pecial t ool s als o helps prevent t he potenti al for damage tocomponents .
Some operat ions described in thi s manual cannot be carried out properly wi thout t he aid of t he rel evant s ervice t ools .
All orders and enqui ri es from t he Unit ed Kingdom and European count ries except Germany, Aus tria, Swit zerland and Spainand count ri es not i n t he fol lowing lis t s hould be s ent direct t o:
SPX UK Ltd.,
Genoa Hous e,
Everdon Park,
Davent ry,
Nort hant s ,
NN11 5Y J
Engl and
T el: 0044 (0) 1327 303467/303455
Fax: 0044 (0) 1327 706632
e-mail: s pxs al esuk@s ervi ces oluti ons.s px.com
Overs eas orders for the foll owing count ries s houl d be placed wi th the l ocal dis t ribut or.
Germany, Aust ria and Swi tzerl and
SPX Europe GMBH,
Pors ches t ras se 4,
63512 Hai nburg,
Germany
T el: 0049 61829590
Fax: 0049 6182959299
Spai n
SPX Iberica SA,
C/Francis co Arit io,
158 nave 72 (Nudo O es t e),
19004 Guadalajara,
Spai n
T el: 0034 949208381
Fax: 0034 949208327
Nort h America
SPX Corporation
665, Ei senhower Dri ve,
Owat onna,
MN 55060,
USA
T el: 0018 772979110
Fax: 0018 005787375
Aust ral ia
SPX Australia,

Publi s hed: 11-May-2011
Maintenance Schedules - Maintenance Schedules - Gasoline Engines
Des cript ion and Operat ion
Under Bonnet View
ItemPart NumberDescription1-Coolant expans ion t ank
2-Brake flui d res ervoir (LH drive i llus t rated - RH dri ve on oppos i te si de)
3-Engine oi l fil ler cap4-Power s teeri ng res ervoir
5-Engine oi l l evel i ndi cat or
6-W indscreen washer fl uid res ervoi r
Maintenance Operations
CAUTION: Not e that t he 'A' and 'B' Service Interval s li s ted on the 'Maintenance Check Sheet' for vehicles operat ingunder arduous condi ti ons , vary from t hos e s pecifi ed for vehicles operat ing under normal condit ions . Reference mus tt herefore, always be made to the 'Arduous Condi ti ons secti on for vehicles operat ing under thes e condi ti ons .
Unles s s tat ed otherwis e, the foll owi ng operati ons mus t be carri ed out at every s ervice int erval.
Battery

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.

Air Filtering
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 12 months or 15,000 miles (24,000 km).
Replace the ai r fi lt er el ement.For addit ional informat ion, refer t o: Air Cl eaner (303-12A Int ake Ai r Dis t ri but ion and Fi lt ering - I6 3.2L Petrol ,Removal and Inst all ati on).
Accessory Drive Belt
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 5 years or 75,000 miles (120,000 km).
Replace the access ory drive bel t.For addit ional informat ion, refer t o: Acces sory Drive Belt (303-05A Acces s ory Drive - I6 3.2L Pet rol , Removal andIns t allat ion).
Radiator and Cooling Fan
CAUTION: When vehicles are operating under arduous conditions, the following item must be carried out.
Vis uall y check radi at or for external obs truct ions , check cool ing fan blades for damage.
Continuous Use In Severe Off-Road Conditions
CAUTION: After 50 miles (80 km) continuous use in severe off-road conditions i.e. w ading, deep mud andabrasive grit/slurry, the following items must be cleaned and inspected.
The parking brake.The acces sory dri ve belt .
Vehicles used in dusty or field conditions or d eep wading:
More frequent att enti on to the ai r cl eaner wi ll be requi red.
Additional Items That May Require Attention
1. Every 6 years: It i s recommended t hat al l brake fl uid hydrauli c s eal s are replaced.
• NOTE: This i s in addi ti on to the maintenance requirement that fl exi ble brake hos es MUST be replaced at thi s s erviceint erval.