2006 LAND ROVER FRELANDER 2 Repair Manual

engine fog light bulb four wheel drive brake rotor child restraint differential

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LAND ROVER FRELANDER 2 2006 Repair Manual Publi s hed: 11-May-2011
General Information - Important Safety Instructions
Des cript ion and Operat ion
Safet y Noti ce
Appropri at e s ervi ce methods and correct repai r procedures are es sent

Page 10 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual Publi s hed: 11-May-2011
General Information - How To Use This Manual
Des cript ion and Operat ion
Copyright Statement
Copyright.© Land Rover Ltd., 2006
All rights res erved. No part of thi s publ

Publi s hed: 11-May-2011
General Information - How To Use This Manual
Des cript ion and Operat ion
Copyright Statement
Copyright.© Land Rover Ltd., 2006
All rights res erved. No part of thi s publ icati on may be reproduced, s tored in a ret ri eval s yst em or t rans mit t ed in any form,electroni c, mechanical, photocopyi ng, recordi ng or other means, wi thout pri or wri tt en permi s si on of Land Rover Ltd.,Banbury Road, Li ght horne, W arwi ck, CV35 0RG
How To Use This Manual
This manual covers al l aspects necess ary in order to s ervi ce the vehicle effect ively.
The manual i s s truct ured into fi ve main secti ons , General Informat ion, Chass is , Powert rai n, El ect ri cal and Body and Paintwit h each s ect ion deali ng wit h a specific part of a vehi cl e s ys t em.
Each of t he five mai n s ect ions contain sub-sect ions deal ing wi th it ems which form a part of t hat s pecific s ys tem.
Pages at t he s t art of the manual li s t all s ect ions avai lable. Each s ect ion has a content s li s t det ail ing, where appli cable,Speci ficat ions, Des cri pt ion and Operati on, Di agnos is and Tes ti ng, General Procedures and Repair Procedures.
W here components need t o be removed or dis ass embled in s equence, each operat ion i n the s equence wil l be identi fi ednumeri cal ly and als o graphi cal ly i n an accompanying i ll us t rat ion.
All l eft -hand and ri ght-hand references t o t he vehi cl e are taken from a posi ti on s itti ng in the driver seat l ooking forward.
All l eft -hand and ri ght-hand references t o t he engi ne are taken from a pos i ti on at the flywheel looki ng t owards t he frontcamshaft pul ley.
Ins pect ion and Verificati on
Vis ual Ins pect ion Chart s , Sympt om Charts and ot her informati on charts (s uch as diagnos t ic rout ines ) or s upplement t estprocedures wit h t echnical s pecificati ons wil l navigat e t he user t o a s peci fi c t es t procedure.
Symptom Chart
The s ymptom chart indicates s ymptoms, s ources and act ions t o addres s a condit ion.
Pinpoint Test s
For el ect ri cal s yst ems , pinpoint t es t s t eps are us ed to identi fy t he s ource of a concern in a logi cal, s t ep-by-s t ep manner.Pinpoint t es t s have two col umns: CONDITIO NS and DETAILS/RESULTS/ACTIONS.
The CONDITIONS column is us ed excl usi vel y for graphi cs and icons (wi th or wi thout capt ions ) and the DETAILS/RESULTS/ACTIONS column provi des direct ion t o another tes t s tep or s pecifi c correct ive acti ons .
The boxed numbers indicate the order in whi ch the des cribed acti on is to be carri ed out.
Component Tes ts
A component t es t is us ed when a component i s t est ed in mult ipl e pinpoint t es t s, or if a procedure i s too compl icated t o beformatt ed wi thi n a s ingle page of t he pinpoint t est .
Graphics
Test graphi cs show the meas urement or t es t t o be carried out i n a t est st ep.
A repres ent ati ve tes t er graphi c is us ed for vol tmet ers and ohmmet ers .
If mult iple measurement s are made i n a s ingle graphic, the t es t leads are drawn wi th a s ol id line unt il t he t es t l ead spl it st o indicate the mult iple measurement s , at which point dashed l ines are used.
Breakout box t ype t es t ers are repres ented by a doubl e circl e t est pi n. Tes t pins are labell ed wit h t he pin number.
• NOTE: Dimens i ons quot ed are t o des ign engineeri ng s pecificati ons wit h s ervice l imits quot ed, where appl icable.
Workshop Manual Organization
The fi ve main s ect ions, t ogether wit h t he areas whi ch they cover are given below:
Section 1 - General Informat ion.Section 2 - Chas si s.Section 3 - Powert rai n.Section 4 - Elect rical.Section 5 - Body and Paint .
Sub-s ect ion numbers appear aft er the i nit ial s ect ion number, for exampl e, Section 412-01 covers Cli mate Cont rol, whi ch ispart of t he electrical s ecti on.
In the number given above, t he first di git of the number ' 4' indicates t he s ect ion i.e. Electrical.
The s econd and t hird digit s ' 12' of t he number indicate the vehicle sys tem i.e. Climate Control.

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LAND ROVER FRELANDER 2 2006 Repair Manual The las t t wo digi ts of t he number '01' indicate the part of the s ys tem covered by the s ub-s ecti on i.e. Air Conditioning(A/C) Compressor.

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LAND ROVER FRELANDER 2 2006 Repair Manual 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 need

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

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LAND ROVER FRELANDER 2 2006 Repair Manual Land Rover part s are manufact ured to t he s ame exact ing st andards as t he origi nal fact ory fit t ed components . For thisreas on, it is ess enti al t hat onl y genui ne Land Rover part s a

Land Rover part s are manufact ured to t he s ame exact ing st andards as t he origi nal fact ory fit t ed components . For thisreas on, it is ess enti al t hat onl y genui ne Land Rover part s are used during mai ntenance or repai r.
Att enti on is parti cul arly drawn t o t he fol lowing poi nt s concerni ng repairs and t he fi tt ing of replacement parts andacces sories .
Safet y feat ures and corros ion prevent ion t reat ments embodied in t he vehicle may be impai red i f other than Land Roverrecommended part s are fi tt ed. In cert ain t errit ori es , l egi sl ati on prohibi ts t he fit ti ng of parts not t o manufact urer'ss pecificati on. Torque wrench s ett ing figures , where gi ven, mus t be adhered t o and l ocking devices , where s peci fi ed mus tbe us ed. If t he efficiency of a locki ng devi ce is impaired duri ng removal it mus t be repl aced.
Owners purchas ing acces s ori es whils t t ravell ing abroad mus t ens ure t hat the acces s ory and it s fi tt ed locati on on t hevehi cl e conform t o legal requirements .
The t erms of t he vehi cl e warranty may be i nvali dat ed by t he fit ti ng of parts ot her than t hos e recommended by Land Rover.
• NOTE: The fit ti ng of non-approved Land Rover parts and acces s ori es or the carrying out of non-approved al terati ons orconvers i ons may be dangerous . Any of the foregoing could affect t he s afety of t he vehicle and occupants ; al so, t he termsand condi ti ons of t he vehi cle warranty may als o be inval idated .
All Land Rover recommended part s have t he ful l backing of t he vehi cl e warranty.
Land Rover Dealers are obli ged to s upply onl y Land Rover recommended part s .
Specifications
Land Rover are cons tant ly s eeki ng t o improve the specificati on, des ign and producti on of their vehicles and al terat ionst ake pl ace accordingly. W hi ls t every effort i s made t o ens ure t he accuracy of t his Manual, i t should not be regarded as aninfalli ble guide to current s pecificati ons of any parti cular vehicle.
This Manual does not cons t it ute an offer for sal e of any part icul ar vehi cl e. Land Rover dealers are not agents of Land Roverand have no authori ty to bi nd the manufact urer by any expres sed or i mpli ed undertaking or repres ent ati on.

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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 her

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 .

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LAND ROVER FRELANDER 2 2006 Repair Manual Clean bench and provide marking mat eri al s , labels and containers before di s as s embli ng components .
Disassembling
Obs erve s crupul ous cl eanl ines s when dis as sembl ing component s, parti

Clean bench and provide marking mat eri al s , labels and containers before di s as s embli ng components .
Disassembling
Obs erve s crupul ous cl eanl ines s when dis as sembl ing component s, parti cul arly when brake, fuel, air s us pens ion or hydrauli cs ys t em parts are dis as sembl ed. A part icle of dirt or cloth fragment could caus e a s eri ous malfunct ion i f trapped i n t hes es ys t ems .
Blow out al l tapped holes , crevi ces , oil ways and flui d pass ages wit h dry, compres s ed air.
W ARNING: Sui table eye protecti on mus t be worn.
Us e s uit abl e marker i nk to identi fy mat ing parts , do not us e a s cri ber or cent re punch as t hey coul d ini ti at e cracksor dis torti on.W i re or t ape mat ing part s t oget her where neces s ary t o prevent acci dent al i nterchange.Suit abl y identi fy parts which are to be renewed and t o thos e part s requi ri ng further ins pect ion. Keep thes e part ss eparate.To make s ure that t he correct replacement part has been obt ained, do not dis card a part due for renewal unt il aftercomparing i t wit h t he new part.
Cleaning Components
Always us e cleaning agents whi ch are s uit able for the work being undert aken and the component s being cleaned. NEVERus e gasol ine (pet rol ) as a cleaning agent (degreas er). Always make s ure that the component bei ng cleaned is compati blewit h t he cleaning agent.
Always follow the manufact urer's i ns t ructi ons regarding the us e of cleaning agents and make sure t hat t he envi ronment inwhich t he work is being undert aken is s uit able. See Healt h and Safet y Precaut ions for furt her informati on regardi ngcleaning.
General Inspection of Components
All component s s houl d be i ns pect ed for wear or damage before reas s embl ing.
Always make s ure that component t o be i ns pected i s clean and free from oil or greas e.W hen a component is t o be checked di mensi onal ly agains t desi gn s pecified values , use the appropriat e meas uringequi pment i.e. micromet ers , verniers, s urface plates , dial t es t i ndi cat ors (DTI).Always make s ure that all meas uri ng equi pment is correct ly cali brat ed before us e.Reject a component which i s not wit hin specified values /l imi ts or i f it appears t o be damaged.A component may be rei ns t alled if dimens ions obt ai ned during checki ng are at t he maximum t olerance l imi t and itis in an undamaged condi ti on.Bearing journal clearances should be checked where neces s ary us ing Pl ast igauge.
Joints and Joint Faces
All gas ket s s houl d be i ns t alled dry unles s s tat ed otherwis e. Always appl y t he s pecified l ubricant to O-rings and i nst allO-ri ngs us ing the fingers onl y.
Us e gasket removal s pray and/or plas t ic s crapers t o remove traces of old gas ket.
CAUTION: DO NOT us e met al s crapers or emery clot h as t hes e may damage the s eali ng s urfaces.
Many joi nts us e s ealants ins tead of gasket s as t he seal ing medium. W here t his is t he cas e, t he s eal ant t oget her wit h i tspart number wil l be found l is ted i n t he rel evant repair operat ion and al so in the s ealants table.
CAUTION: Always remove all t races of the ol d s eal ant prior t o reas s embly. Use plas tic s crapers, s pecifi ed s olvent swhere avail abl e or dry, l int free clot h. DO NOT us e met al scrapers or emery clot h as t hese may damage the seali ngs urfaces . Make sure t hat s eali ng s urfaces are free from oi l or greas e as sealant s wil l not adhere properly to contaminateds urfaces .
Do not all ow s ealant to ent er tapped holes or oil ways .
Locking Devices
Always repl ace locki ng devi ces wit h one of the s ame des ign and of t he correct s ize.
Tab washers
Always release locki ng t abs before l oos ening fixings , do not reus e t ab washers.
Locknuts
Always us e a backing s panner when l oos ening and t ighteni ng locknut s, brake and fuel pipe unions .
Roll pins
Always i ns t all new roll pins of t he correct s ize.
Circlips
Always i ns t all new circl ips ens uri ng that t hey are of t he correct s ize for t he groove.

Page 16 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual Woodruff keys
W oodruff keys may be reus ed provided t here i s no i ndi cat ion of wear or dis torti on.
Remove any burrs from edges of keyways us ing a fine fil e.
Split pins
Never at tempt t o s

Woodruff keys
W oodruff keys may be reus ed provided t here i s no i ndi cat ion of wear or dis torti on.
Remove any burrs from edges of keyways us ing a fine fil e.
Split pins
Never at tempt t o s t raight en and reus e a s pli t pin, always make s ure that repl acement pins are of the correct si ze for t hehole i n which t hey are to be ins tal led.
Screw Threads
Damaged nuts , bolt s and s crews mus t always be dis carded. Att empti ng to recut or repai r damaged threads wi th at ap or di e i mpai rs the s t rength and fi t of t he t hreads and is not recommended.
• NOTE: Duri ng cert ai n repai r operat ions , it may be neces sary t o remove t races of t hread locking agent s us ing a tap.W here thi s is neces sary, t he i ns t ructi on to do s o wi ll appear in the relevant operation and it i s ess enti al that a t ap of thecorrect s ize and t hread i s used.
Some bolt s are coat ed wit h a thread locki ng agent and unles s s tat ed otherwis e, they mus t not be reus ed. Newbolt s havi ng the same part number as the original mus t always be i nst all ed. W hen nuts or bolt s are to bedis carded, t he repai r operat ion and relevant torque chart will i ncl ude an ins truct ion to that effect . Do not usepropri etary thread locki ng agent s as t hey may not meet the specificati on required. See al so Encapsul at ed('Patched') Bol ts and Screws.Always make s ure that repl acement nuts and bol ts are at leas t equal i n s trengt h t o thos e t hat they are repl acing.Cast ell ated nut s mus t not be loosened t o accept a s pli t pin except in recommended cas es when thi s forms part ofan adjus tment .Do not all ow oil or greas e t o enter bli nd holes , the hydrauli c acti on res ult ing from ti ght ening t he bolt or s tud cans plit t he housi ng and als o gi ve a fal s e torque reading.Always t ighten a nut, bolt or s crew to t he s peci fi ed torque fi gure, damaged or corroded threads can give a fals et orque reading.Nut and bolt loos ening and t ightening sequences , where gi ven, mus t ALW AY S be foll owed. Di st ort ion ofcomponents or fault y s eal ing of joints wil l res ul t if t he s equences are not fol lowed. W here an ins t ructi on is gi ven tot ighten i n s tages , thes e s tages mus t be adhered t o; do not at t empt to combi ne st ages part icul arl y where cert ains tages involve t ight eni ng by degrees.To check or re-t ighten a fi xing t o a s peci fi ed t orque, firs t loosen a quart er of a turn, t hen ret ighten to the s peci fi edt orque fi gure.Unles s ins t ructed ot herwis e, do not lubricat e bolt or nut t hreads pri or t o i nst all ing.
W here it i s s tat ed t hat bolt s and s crews may be reus ed, t he fol lowi ng procedures must be carri ed out:
Check t hat threads are undamaged.Remove all t races of locki ng agent from the threads .
CAUTION: DO NOT us e a wi re brus h; take care t hat threads are not damaged.
Make s ure t hat threads are clean and free from oil or greas e.Apply t he s pecified locki ng agent t o t he bolt t hreads .
Bolt and Nut Identification
An ISO met ri c bolt or s crew made of s t eel and l arger than 6 mm in di ameter can be identi fi ed by eit her of t he s ymbols ISOM or M emboss ed or i ndent ed on top of t he bolt head.
In addi ti on t o marks i dent ifying t he manufacturer, t he top of t he bolt head is als o marked wit h s ymbol s indi cat ing t hes trengt h grade e.g. 8.8, 10.9, 12.9, 14.9. Alt ernati vel y, some bol ts and screws have t he M and s trengt h grade s ymbols tamped on the flat s of the hexagon.
Encapsulated ('Patched') bolts and screws

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