2006 LAND ROVER FRELANDER 2 engine

12-Dual mas s flywheel (manual t rans mi ss i on vehi cl es )
13-Bol t (8 off)
14-Torque convert er flex-pl ate (automat ic trans mi ss i on vehi cl es)15-Mai n beari ng lower half s hel l (4 off)
16-Lower t hrus t washer (2 off)
17-Mai n beari ng hal f cap (5 off)18-Oil pump
19-Oil level gage tube (lower)
20-Bol t21-Locati ng dowel
22-Oil pan hous i ng
23-Oil pan hous i ng bol t (20 off)24-Oil pan capt ive bolt (21 off)
25-Oil drai n plug s eal
26-Oil drai n plug27-Oil pan
28-Oil t emperature s ens or
29-Screw (2 off)30-Oil level gage tube (upper)
31-Oil level gage
32-Oil pump drive chai n33-Cranks haft pull ey bolt
34-Pl ain was her
35-Cranks haft pull ey and t ors ional vi brati on damper36-CKP sens or target ring
37-W oodruff key (2 off)
Crankshaft and Main Bearings
ItemPart NumberDescription
1-Cranks haft2-Mai n bearing upper half s hel l (4 off)
3-Upper thrust was her (2 off)
4-No. 1 main beari ng cap locati ng dowel (2 off)5-Mai n bearing cap bol t (10 off)
6-Mai n bearing hal f cap (5 off)
7-Lower thrust was her (2 off)8-Mai n bearing lower hal f s hel l (4 off)
9-Counter-balance s haft dri ve gear
10-Mai n bearing cl ass ificati on marki ngsThe crankshaft is manufact ured from st eel and formed wit h 5 main beari ng and 4 connect ing rod big-end journals . Themain bearing journals l ocat e in the cyli nder bl ock mai n beari ng hous ings , and are clamped by the 5 main bearing half caps.Each main beari ng half cap is st amped wi th t he corresponding cylinder number for identi fi cat ion. The main bearing half capidenti fi ed wit h '1F' mus t be pos it ioned at the trans mi ss i on end of the engine (No. 1 end).

ItemPart NumberDescription
1-Upper compres si on ri ng2-Lower compres si on ri ng
3-O il cont rol 's craper' ring
4-Gudgeon pin5-Gudgeon pin ci rcli p (2 off)
6-Pi st on and connecti ng rod ass embly
7-Connect ing rod big-end8-Connect ing rod s haft
9-Connect ing rod s mall -end
10-Smal l-end bus h11-Pi st on crown cooli ng channel
12-Pi st on bus h (2 off per pis ton)
The connecti ng rods are manufactured from forged s teel wi th an 'I' beam shaft cons truct ion t o provi de high s t rength anddurabil it y. The connect ing rod s mall -end i s narrowed on each s i de to form a tapered head. The taper improves t hedis t ribut ion of force between t he pis t on and connect ing rod duri ng t he combus t ion s troke. A bronze bush is i nst all ed in t hes mall -end, and formed wit h an internal groove t o al low t he flow of l ubricati ng oil around t he bush.
The connecti ng rod bi g-end i s cut and machined at t he joi nt to form a bearing housi ng and bearing cap t hat is s ecured by 2bolt s. The cyli nder pos it ion i s s tamped on adjoi ning s ides of t he joi nt to i dent ify mat chi ng connecti ng rods and beari ngcaps . A hal f shell beari ng is ins tall ed in each half of t he connecti ng rod bi g-end. The connect ing rod beari ng hous ings ands hel l bearings are manufact ured wit h a l ug that correct ly al igns t he bearing i n t he hous i ng, and prevents radial movementof the bearing s hells . Duri ng ins t al lat ion t he lugs mus t face toward the LH s ide (oil fi lt er si de) of t he engine.
To mai nt ain the correct cranks haft big-end bearing clearance, the hal f shell beari ngs are avail abl e in varying t hicknes s . Thelower beari ng hal f s hel l is only avail abl e i n 1 s ize; t he upper beari ng hal f s hel l is avail abl e in 3 s izes .

For furt her det ail s on connecti ng rod bi g-end beari ng ins tal lati on, refer t o t he relevant Service Repair Procedures (SRP).
The pis t ons are manufactured from al uminum alloy and are i ns t alled wit h 2 compres s ion rings , and an oil cont rol ring wi tha s piral spring. A s teel ins ert i s i ns t alled in t he pis t on upper ring groove t o provi de reinforcement. The pis t on crown i s at oroidal des i gn that forms a pronounced bowl in t he center of the pi s ton head. Recesses are als o formed in t he pis t oncrown t o provi de cl earance for t he 4 valve heads. This des ign of combus ti on chamber promot es high l evel s of swirl andt urbulence required for complete combus t ion of t he air/fuel mi xture, and al so improves t he engine emi ss i ons .
The 3 pi st on rings mus t be ins t al led wi th the ring gaps s paced at 120° (wit h permis sible tolerance of 15° t o 20°) to eachother, around the pi st on. The 2 upper compres s ion rings are s tamped wi th 't op' t o aid ins tall ati on. The gap of t he doubl ebevel ed oil cont rol ring mus t als o be oppos it e t he s pi ral s pri ng joint .
The ful l ski rt pis t on is coated wit h a graphi te bas ed s ubst ance to reduce fri cti on wit h t he cyl inder bore. The graphi te bas edcoat ing i s es pecial ly i mport ant during t he engine runni ng in period and s t art-up. The pis ton al so incorporat es 2 oil coolingchannels t hat are formed on the unders i de of the pi st on head.
Two bus hed hol es are formed at oppos it e s ides of t he pis ton s kirt for i nst all at ion of a full y floati ng gudgeon pin. Thegudgeon pi n pass es t hrough the pi s ton bus hed hol es and connecti ng rod s mal l-end, and i s ret ained at each end wit h acircl ip. The pis ton, gudgeon pi n and connecti ng rod smal l-end are s uppli ed wit h oil from an oil s pray jet, l ocat ed bel oweach cyli nder bore.
Duri ng ins tal lat ion of t he pis tons , the s t amped direct ion arrow and 'DIST' on each pis ton crown mus t face t oward t he frontof the engine (acces s ory drive end).
For furt her det ail s on pis t on and pis ton ring ins tall ati on, refer t o the relevant Service Repai r Procedures (SRP) manual.
Oil Pan Housing and Oil Separator

ItemPart NumberDescription
1-Oil fill er tube
2-Oil s eparator3-Oil t emperature s ens or
4-Oil s eparator ret urn pi pe
5-Oil pan housi ng bolt s (20 off)6-Oil pan housi ng
7-Oil level gage
The alumi num oil pan hous ing i s s ecured wit h 20 bolt s t o t he bot t om of t he cyl inder bl ock, and forms an ext ens ionbetween t he cyl inder block and oil pan. The oi l pan hous ing i s requi red i n order t o increas e t he dis tance between t he oilpump and oil pan, due to the ins tall ati on of the counter-balance s haft ass embly.
The rear of t he oil pan hous i ng provides t he lower mounti ng poi nts for the trans mi s si on cas i ng. Dril lings formed in t he LHs ide of t he hous i ng provide t he locati on for t he oil l evel gage tube, oil t emperature s ens or, and t he ret urn hos e from t hecrankcas e venti lati on oil s eparator.
The crankcas e venti lati on oil s eparator i s als o connected to t he oil fil ler t ube, located at t he rear LH si de of the engine. Oi lfor repl enis hing t he s ys t em pas ses through t he oil s eparator and return hos e, and int o t he oil pan. An oil baffle pl ate i sins t al led i n t he oil pan housi ng to reduce oil aerat ion and s plas h.
Oil Pump
The rot or type oil pump is l ocat ed bet ween t he oil pan and oil pan housi ng, and at t ached wi th 5 bol ts to the front of t hecount er-bal ance s haft as s embly. The oil pump i s dri ven by the cranks haft via a s ingle row chain. For furt her informati on,refer to 'Lubricati on Sys t em' wit hin t his s ecti on.
Oil Temperature Sensor
ItemPart NumberDescription1-Oil t emperature s ens or
The oil t emperature s ens or is locat ed at t he rear LH s ide of oi l pan hous ing. The s ens or body is s crewed i nto the oi l panhous i ng wit h t he t ip prot rudi ng int o t he oil pan. The s ens or provi des oi l temperat ure informati on t o t he ECM.For addit ional informat ion, refer t o: Electroni c Engi ne Controls (303-14 Electronic Engine Controls - 2.2L Durat orq - Td4,Des cript ion and Operat ion).
Oil Pan

ItemPart NumberDescription
1-Oil pan2-Oil pan capti ve bol t (21 off)
3-Oil drai n plug
The pres s ed s teel oil pan is sealed wit h a l iquid sealant , and secured wi th 21 capt ive bolt s t o t he oil pan housi ng. Anengi ne oil drai n plug is l ocat ed at the rear RH s ide of t he oil pan.
• NOTE: The vehi cle undert ray mus t be removed to gai n acces s t o t he oil pan drain plug.
The oil l evel gage is l ocat ed on t he LH s ide of t he engi ne. Two not ches in t he end of t he gage indicate t he mi nimum andmaximum oil l evels . For further informat ion, refer t o 'Lubricat ion Sys t em' wit hi n t his s ect ion.
Crankshaft Pulley and Torsional Vibration Damper
ItemPart NumberDescription
1-Cranks haft pull ey and torsi onal vibrat ion damper
2-Plai n was her3-Cranks haft pull ey bol t
The combined crankshaft pul ley and t ors ional vi brat ion damper provides dri ve from t he crankshaft to the acces s orycomponents , via a 6 ribbed polyvee type drive belt .
The as sembl y is mount ed t o t he front of t he crankshaft in front of t he CKP s ens or ring, and i s s ecured wit h a pl ain was herand bolt . The damper compri ses a s teel out er cas i ng formed wit h drive belt grooves around t he outer circumference,bonded t o an inner rubber coupl ing and metal hub.
The t ors ional vi brati on damper act s to reduce vibrat ions produced by the engines reci procal component s .
Dual Mass Flywheel (Manual Transmission Vehicles Only)

ItemPart NumberDescription
1-Dual mas s flywheel2-Clut ch fricti on plate face
3-Clut ch cover locat ing dowel (3 off)
4-Engi ne ti mi ng special t ool l ocati on5-Bolt (8 off)
The dual mas s flywheel is i nst all ed on vehi cl es wit h manual transmis si on. On automatic t rans mis s ion vehicles , a t orqueconvert er fl ex-plat e is ins tall ed.
The dual mas s flywheel compris es a primary mas s and a s econdary mass that t rans mit s dri ve, vi a the cl utch dri ven plate,t o the gearbox. The s econdary mas s i s s upported on a rol ler bearing wit hi n t he pri mary mass . The pri mary mas s is s ecuredt o the fl anged rear end of t he crankshaft wit h 8 bolt s . The drive bet ween the primary and s econdary mass es i s transmit tedt hrough a t ors ional spring damper. The flywheel provi des a cons t ant drive s peed to the gearbox, wit hout trans mi tt ingt ors ional and t rans ient vibrat ions produced by t he engi ne.
The outer face of t he fl ywheel i s machi ned to provide a smoot h s urface for the cl utch fri ct ion pl at e t o engage on. Threedowels are equal ly s paced around the out er edge of t he s econdary mas s , and provide the l ocati on for t he clut ch coveras sembl y. The flywheel is dynamically bal anced t o eli mi nat e vibrat ions from t he rot at ing as s embly.
A ring gear formed on t he outer circumference of the primary mas s al lows t he engagement of the s t art er motor.
Two holes are formed on t he engine s ide of t he dual mass fl ywheel. The l arger diameter hole is provi ded to accept theins ert ion of an engine ti ming s peci al tool.
CAMSHAFT TIMING COMPONENTS

The cyl inder head and st ructural cams haft cover are manufactured to form mat ing parts . The part s are mil led i n a si ngl eoperati on and accurat ely pos it ioned wi th 2 alignment s leeves. The 2 components mus t al ways be ins tall ed t oget her, andnot renewed as s eparate component s . The cyl inder head and cams haft cover are s eal ed to each ot her during manufact urewit h a gas ket and s ili cone bas ed s eal ant, and are s ecured wit h 27 bolt s . An oil s eal i nst all ed at the front of t he cyl inderhead provides s eal ing of t he exhaus t camshaft hous ing. The open port s at the rear of the cyli nder head are sealed wit ht he vacuum pump and hi gh-pres s ure fuel pump s eal ing rings .
Two ali gnment sl eeves correct ly l ocat e t he cyl inder head and gas ket to t he cylinder block. The cyli nder head is secured t ot he cyl inder bl ock wit h 10 deep-s eat ed bolt s .
• NOTE: The cyl inder head bol ts are not acces si ble wit h the st ruct ural cams haft cover i nst all ed.
• NOTE: The cyl inder head is not t o be reworked.
The cyl inder head is manufact ured from al uminum alloy, havi ng valve s eats and guides made of s i nt ered st eel. Thecyl inder head is precis ely machi ned and mil led t o i ncorporate t he 4 combus ti on chambers, cams haft l ower beari nghous i ngs , oil drill ings and cool ant gal leri es, and t he air i ntake, val ve ti ming and fuel sys t em component bores andhous i ngs .
The desi gn of the cyli nder head maximizes air flow and s wi rl i n the combus ti on chambers. The 2 int ake val ve seat s aremachined wit h rais ed profil es that act to promote swi rl of t he int ake ai r fl ow. Combined wit h t he acti on of the i ntakemanifold heli cal port , t he s wirl effect of the 2 int ake port profi les al lows t he air and i nject ed fuel t o complet el y mi x, andreach t he outer edge of the combus ti on chamber.
The s truct ural camshaft cover is manufact ured from alumi num all oy, and i s machined on t he upper s urface wit h t hecamshaft upper bearing hous ings . The cover is al so formed wi th 4 int ake ai r fi ll ing t racts , fuel i nject or bores and ori fi cesfor t he cyl inder head cover PCV components . The i nt ake air t racts join the i ntake air mani fold to the cyli nder head int akefi ll ing port s .
The cyl inder head al s o provides t he mounti ng locati ons for the foll owing:
Front engi ne mounti ngFront and rear engine l ifti ng eyesInt ake and exhaus t manifol dsEGR valve and coolerFuel fil ter s upport bracketThermal cont rol moduleVacuum pump and high-press ure fuel pump.
Cylinder Head G asket
ItemPart NumberDescription
1-Engi ne type i dent ificati on
2-Gas ket thi cknes s identi fi cat ion3-Gas ket thi cknes s identi fi cat ion
The cyl inder head gas ket is made from l aminated metal and is avail abl e i n 4 di fferent thickness es . Lugs formed on thes ide of t he gasket are 'dot' marked to i dent ify t he engi ne t ype, and t he thi ckness of t he gas ket i nst all ed. A new gasket iss elect ed bas ed on t he pis ton protrusi on meas urement from t he cyl inder block.
For furt her det ail s on cyl inder head gas ket sel ect ion, refer t o t he rel evant Servi ce Repair Procedures (SRP) manual .
Camshafts

ItemPart NumberDescription
1-Exhaus t cams haft2-Intake cams haft
3-No. 3 bearing (end-fl oat control)
4-Si ngl e row t imi ng chai n5-Exhaus t cams haft pull ey
The int ake and exhaus t cams haft s are manufactured from cast -iron. The 2 cams haft s are mount ed between the s t ructuralcamshaft cover and cyl inder head, wit h each camshaft locat ed i n 5 machined beari ng hous i ngs . Shel l bearings are not us edin the beari ng housi ngs , t he camshafts run direct ly in t he alumi num beari ng. Lateral movement of t he camshaft s i scont rol led by No. 3 cams haft beari ng, and i s not adjust able. The bearing is manufactured on both camshaft s t o provi de thecorrect end-float.
• NOTE: In product ion, t he camshaft end-fl oat i s 0.070 mm t o 0.168 mm (0.003 in t o 0.007 in). In s ervi ce, if t he end-floatis out of s peci fi cat ion t he cams haft(s ) and/or cyli nder head and s t ructural cams haft cover may requi re renewal.
Each cams haft has 8 machi ned lobes formed in pai rs al ong the length of t he cams haft. The cams haft lobes operat e t heinl et and exhaust valves t hrough hydraulic las h adjus ters and rol ler-t ype finger levers
A s pur gear wi th 19 teet h is formed on t he front end of each cams haft. The 2 gears are joined by a 40-li nk s ingle rowt imi ng chai n. The 2 cams haft gears are marked wit h a ti ming mark t hat coi ncides wi th the 2 col ored l inks on t he camshaftt imi ng chai n. A dri ve sl ot is formed in t he rear end of each camshaft to provi de t he drive to t he flange mounted vacuumpump and high-pres sure fuel pump. The vacuum pump is driven by t he inl et cams haft ; the hi gh-pres s ure fuel pump isdri ven by the exhaust cams haft .
The exhaus t camshaft is driven by t he cranks haft drive gear vi a a toothed t iming belt . The exhaus t camshaft pul leycont ains 42 t eeth and is keyed and bol ted to t he front of the exhaust cams haft . The int ake cams haft i s dri ven by theexhaus t camshaft vi a t he s ingle row chain.
The exhaus t camshaft pul ley i s manufactured wit h cut-out s and a not ch in the center hub. The cut -out s form t he t argetarea for the CMP s ens or. The not ch provides the locat ion for a cams haft t imi ng pin speci al tool. The s peci al tool is us ed i nconjunct ion wi th other s pecial t ool s t o s et the exhaus t cams haft duri ng engi ne ti ming.
For furt her det ail s on s ett ing t he engine valve t imi ng, refer t o t he rel evant Service Repair Procedures (SRP) manual.
Engi ne Valve Ti ming
The valve t imi ng val ues are s hown i n t he fol lowing t able:
ValvePositionInlet val ve opens15 degrees BTDC
Inlet val ve clos es12 degrees ABDC
Exhaus t valve opens23 degrees BBDCExhaus t valve clos es17 degrees ATDC
Key:
BTDC = Before Top Dead Cent erABDC = Aft er Bot t om Dead CenterBBDC = Before Bot t om Dead CenterATDC = Aft er Top Dead Cent er.
Camshaft Position (CMP) Sensor