2006 LAND ROVER FRELANDER 2 Repair Manual

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Page 17 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual Encaps ulated ('pat ched') bolt s and s crews have a t hread l ocking agent appl ied t o t he t hreads during manufact ure. Mos tt hread locking agent s are col ored, the band of color exte

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LAND ROVER FRELANDER 2 2006 Repair Manual 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 a

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.

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LAND ROVER FRELANDER 2 2006 Repair Manual 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 p

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

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LAND ROVER FRELANDER 2 2006 Repair Manual All fuel hos es are made up of two lami nat ions , an armoured rubber out er sl eeve and an inner vi ton core. W henever a hos eis removed, make sure t hat t he i nner bore is i ns pected t o che

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LAND ROVER FRELANDER 2 2006 Repair Manual Marki ngs are us ual ly provi ded on t he hos e t o i ndi cat e t he correct cli p posi ti on. If no markings are provi ded, pos it ion t heclip direct ly behind t he ret aini ng li p at the end of

Marki ngs are us ual ly provi ded on t he hos e t o i ndi cat e t he correct cli p posi ti on. If no markings are provi ded, pos it ion t heclip direct ly behind t he ret aini ng li p at the end of t he s tub pi pe. W orm dri ve clips s hould be orient at ed wi th the crimpeds ide of t he dri ve hous ing facing t owards t he end of the hos e or t he hos e may become pi nched bet ween the cli p and t hes tub pi pe ret aining l ip. Unles s ot herwis e s t ated, worm dri ve cl ips s hould be ti ght ened to 3 Nm (2 lb-ft). Make s ure t hathose cl ips do not foul adjacent components .
Oeti ker cl ips may be removed by bendi ng the tag (arrowed) and releas ing t he free end of t he cl ip. Cli ps mus t not bereus ed. W hen ins t al li ng new cli ps , make s ure cl ip is pos it ioned on hose before ti ghtening and make s ure that when cli p ist ightened, the t ag is locat ed i n t he longit udi nal s lot i n t he free end of the cl ip (arrowed in il lus trat ion).
Heat protect ion
Always make s ure that heats hields and protecti ve s heat hing are in good condit ion; replace i f damage i s evident. Part icularcare mus t be t aken when rout ing hos es cl ose to hot engine component s s uch as the exhaust mani fol ds and exhaust gasrecircul ati on (EGR) pipes . Hoses will relax and defl ect s l ightl y when hot, make s ure thi s movement is t aken into accountwhen rout ing and s ecuring hos es .
Electrical Precautions
General
The fol lowing gui del ines are int ended t o make s ure the safet y of t he operator whil s t prevent ing damage t o t he electricaland electroni c component s of this vehi cl e.
Equipment
Pri or to commencing any t est procedure on the vehicl e, make sure t hat t he rel evant test equipment i s working correctl yand t hat any harnes s or connectors are i n good condi ti on. It is parti cul arly import ant to check t he condit ion of al l pl ugs andleads of mains operat ed equipment.
Polarity
Never revers e connect the vehicle bat tery and always make s ure the correct pol arit y when connect ing t est equipment .
High voltage circuits
W henever di sconnect ing l ive ht circuit s , always us e ins ulat ed pliers and never all ow t he open end of the ht l ead to cont actother component s, part icularly ECU's .
Vehicles installed with Bi-Xenon headlamp bulbs
W ARNING: The foll owing precauti ons mus t be obs erved as fail ure t o comply may res ult i n expos ure to ul tra-vi ol etrays , s evere electric s hock, burns or ris k of an expl osi on.
Safet y goggl es and gl oves must be worn.Make s ure t hat headlamps are s wi tched off before removi ng bul bs.

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LAND ROVER FRELANDER 2 2006 Repair Manual Do not t ouch t he glas s port ion of t he bulb.On no account s hould headlamps be s wi tched on wi th t he bulb removed from the headlamp.Bulb t es ti ng may only be carri ed out wit h the bul b

Do not t ouch t he glas s port ion of t he bulb.On no account s hould headlamps be s wi tched on wi th t he bulb removed from the headlamp.Bulb t es ti ng may only be carri ed out wit h the bul b ins t al led i n t he headl amp.Bulbs mus t be di spos ed of in accordance wit h the local aut horit y bye-laws .
Connectors and harnesses
The engi ne compart ment of a vehi cl e is a part icularl y host il e environment for el ect ri cal component s and connectors. Al waysobserve the foll owing:
Make s ure el ect ri cal ly related it ems are dry and oil free before di sconnect ing/connecti ng t es t equipment .Make s ure t hat dis connect ed mul ti pl ugs and s ens ors are prot ect ed from any pos s ibl e oil , coolant or other li qui dcont aminat ion. Any such contami nat ion could impair performance or l ead to component fail ure.Never force connectors apart or pull on t he wiring harnes s .Always make s ure locki ng t abs are dis engaged before di sconnect ing mul ti plugs etc. and make s ure that correctori ent ati on is achieved before connecti on.Make s ure t hat any protecti on covers, i nsul at ion et c. are replaced if dis t urbed.
Having confirmed t hat a component is fault y, carry out t he fol lowing:
Swit ch off t he ignit ion and di s connect t he batt ery.Remove the component and support t he dis connected harnes s .W hen replaci ng electrical components , keep oily hands away from electrical connect ions and make s ure that lockingt abs on connect ors are ful ly engaged.
Battery Disconnection/Connection
Always refer to the El ect ri cal Secti on of this manual - Bat tery Connecti on/Dis connecti on pri or t o at tempt ing t o connect ordis connect the bat tery.For addit ional informat ion, refer t o: Specificati ons (414-01 Bat t ery, Mount ing and Cables , Speci ficat ions).
Fuel Handling Precautions
The fol lowing informati on li s ts bas ic precauti ons which mus t be obs erved if fuel i s t o be handl ed s afely. It als o outl inesother areas of ris k which mus t not be i gnored. As t his informati on is is sued for basi c gui dance only, consul t your local Fi reDepart ment where any doubt as to personal and envi ronmental s afet y exi s ts - See al so Heal th and Safety Precaut ions .
General precaut ions
Always have t he correct type of fire ext inguis her cont aining Foam, CO2, Gas or powder acces s ible when handl ing ordrai ni ng fuel or dis mantl ing fuel s ys tems . Fire exti ngui shers mus t als o be l ocat ed in areas where fuel i s s tored.
Make s ure t hat sui table warning si gns are exhibit ed.
Keep all s ources of ignit ion wel l away from areas where fuel is bei ng handl ed.
Make s ure t hat any leadlamps are fl ameproof and kept clear of spi ll age.
• W ARNINGS:
Do not di sas s emble or reas s emble fuel sys tem components whils t vehicle is over a pit .
No one should be permi tt ed to repair component s as sociat ed wit h fuel wi thout fi rs t having s peci alis t t rai ni ng.
Always dis connect t he vehi cl e batt ery before carryi ng out dis ass embly, reas s embly or drai ning work on a fuel sys tem.
Fuel t ank and s ys t em drai ning
Drai ning mus t be carried out in accordance wit h t he procedures given in the relevant Fuel Syst em s ecti on of thi s manual .
• W ARNINGS:
Never drain fuel or work on a fuel sys t em whil e t he vehi cl e i s over a pi t. Ext raction or draining of fuel must becarri ed out in a well venti lated area.
Al ways at tach fuel vapor warning l abel s t o fuel t anks i mmediat ely after drai ni ng.
Contai ners us ed for s toring fuel must be cl early marked wit h t he cont ents and pl aced i n a safe s torage area whichmeets the requi rement s of the local authorit y.
CAUTION: Some fuel l ines are now i ns t alled wit h 'quick release' connectors. If a connect or i s damaged, no at t emptmus t be made t o repai r the connect or, a new fuel line and connect or(s ) as s embly must be ins tall ed.
Always release pipe cli ps full y before att empti ng t o dis connect fuel pipes.
Fuel tank repairs
CAUTION: No at tempt s hould be made to repair a pl ast ic fuel tank. If t he s truct ure of t he t ank is damaged, a new

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LAND ROVER FRELANDER 2 2006 Repair Manual t ank must be ins tall ed.
Oil seals
Never us e a seal which has been improperly st ored or handled.
Take great care when removi ng old seals that t he seal ing s urfaces and s eal hous ing are no

t ank must be ins tall ed.
Oil seals
Never us e a seal which has been improperly st ored or handled.
Take great care when removi ng old seals that t he seal ing s urfaces and s eal hous ing are not damaged.Careful ly exami ne seal before ins tal li ng to make s ure t hat it is cl ean and undamaged.Make s ure t hat the s urface on which t he s eal i s t o run and als o t he s eal housi ng is cl ean and free from burrs ors cratches. Renew t he component i f the s eali ng surface cannot be rest ored.Speci al t ools and prot ect ion sl eeves are provided for ins tall ing t he majori ty of s eals and mus t be us ed whens pecified.Many s eal s are now coat ed wi th a prot ect ive wax and DO NOT need t o be l ubricated prior t o ins t al li ng. Al wayscheck t he rel evant repair procedure which wil l s tat e if a seal mus t be ins t al led dry. Never t ouch t hes e seals wit hoil y hands as the oi l will contami nat e t he prot ect ive coati ng and affect t he s eal ing properti es of the s eal; al so,make s ure that ins tal li ng tools and protecti on s leeves are free from oil and greas e. Seal s which mus t be l ubricat edpri or to i nst all ing s hould have t he recommended lubri cant appli ed to the areas specified i n t he repair procedure.Make s ure t hat a s eal i s ins t al led t he correct way round. For exampl e, the l ip of t he s eal must face towards thelubricant whi ch it i s s eal ing.W hen i nst all ing an oi l seal, make sure t hat i t is pos it ioned s quare t o s haft and housi ng. W here t he s eal i s t o beins t al led t o a hous ing prior t o ins t al li ng over a shaft , t ake care not to al low the wei ght of an uns upported s haft t ores t on t he s eal .
Always us e t he recommended s pecial t ool and prot ecti on sl eeve to ins tall an oi l seal. If no t ool i s s peci fied, us e as uit abl e mandrel approximat el y 0.4 mm (0.015 in) s mall er than t he outs ide di ameter of the seal. Us e adhes ivet ape on the s haft t o protect the s eali ng li p of the seal.
Pres s or dri ft t he s eal i n t o t he dept h of it s hous ing i f the hous ing i s s houldered or fl us h wit h the face of thehous i ng where no shoulder is provi ded. Make s ure that t he s eal i s not ti lt ed in the hous ing when i t is i nst all ed.
Supplementary Restraint System (SRS) Precautions
W ARNING: Do not ins tal l rear facing chil d s eat s i n the front pas s enger s eat .
The SRS cont ains component s which are potent iall y hazardous t o s ervi ce personnel if not handl ed correctl y. The foll owingguideli nes and precaut ions are intended t o alert pers onnel to pot enti al s ources of danger and emphasi s e the import ance ofensuring t he int egrit y of t he SRS components ins tal led t o t he vehi cl e.
W ARNING: The foll owing precauti ons MUST be adhered t o when worki ng on t he SRS s ys t em:
T he correct procedures must always be used w hen working on SRS components.Persons w orking on the SRS system must be fully trained and have been issued w ith the safety guidelines.T he airbag modules contain extremely flammable and hazardous compounds. Contact with water, acids orheavy metals may produce harmful or explosive results. Do not dismantle, incinerate or bring into contactwith electricity before the unit has been deployed.Alw ays replace a seat belt assembly that has withstood the strain of a severe vehicle impact or if the webbing

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LAND ROVER FRELANDER 2 2006 Repair Manual shows signs of fraying.Alw ays disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with anSRS system.
CAUTION: Do not expos e ai rbag modules or s eat belt

shows signs of fraying.Alw ays disconnect the vehicle battery before carrying out any electric welding on a vehicle installed with anSRS system.
CAUTION: Do not expos e ai rbag modules or s eat belt pre-tens ioners t o t emperat ures exceeding 85° C (185° F).
It should be not ed t hat thes e precaut ions are not res trict ed to operat ions performed when s ervicing t he SRS s yst em. Thes ame care s hould be exerci sed when working on ancil lary sys t ems and components located i n the vi ci nit y of SRScomponents ; t hese include but are not l imi ted t o:
Steering wheel ai rbag, rot ary coupler.Pass enger front airbag.Side curt ain ai rbag modules - front and rear.Seat bel t pre-t ensi oners .SRS harnes ses , li nk leads and connectors.Side (t horax) ai r bags .
Making t he s ys t em s afe
Before working on or in t he vicini ty of SRS component s , make s ure t he s ys t em i s rendered safe by performi ng the foll owingoperati ons :
Remove the remot e cont rol .Dis connect batt ery, eart h lead first .W ai t 2 mi nut es for t he SRS power ci rcuit t o di scharge before commenci ng work.
• NOTE: The SRS us es energy res erve capaci tors to keep t he s yst em act ive i n t he event of electrical supply fail ure undercras h condi ti ons . It is necess ary to al low the capaci tors s uffi ci ent ti me t o dis charge (2 mi nut es ) in order t o avoid t he ris kof accidental deployment.
Ins t allat ion
In order to make s ure s ys tem int egrit y, it is ess enti al t hat the SRS sys tem is regularl y checked and mai nt ained s o t hat itis ready for effecti ve operat ion in t he event of a col lis i on. Carefully ins pect SRS component s before ins tal lati on. Do notins t al l a part t hat shows s i gns of being dropped or i mproperl y handl ed, s uch as dents , cracks or deformat ion.
W ARNING: The integrit y of the SRS sys tems is crit ical for safety reasons . Make s ure t he fol lowing precaut ions arealways adhered t o:
Do not install accessories or other objects to trim panels w hich cover airbags.Never install used SRS components from another vehicle or attempt to repair an SRS component.When repairing an SRS system, only use genuine new parts.Never apply electrical power to an SRS component unless instructed to do so as part of an approved testprocedure.Special fixings are necessary for installing an airbag module – do not use other fixings.Alw ays use new fixings w hen replacing an SRS component and make sure that all fixings are tightened to thecorrect torque.
• CAUTIO NS:
Take care not t o t rap airbag modules when i nst all ing i nt eri or trim components .
Make s ure SRS components are not cont aminat ed by oil or greas e.
• NOTE: Followi ng s eat bel t pre-t ensi oner deployment, t he s eat bel ts can s t ill be used as convent ional seat belt s but wil lneed to be replaced as s oon as poss i bl e t o make s ure full SRS protecti on. Do not us e t he s eat bel ts if t he ret racti onmechani sm i s not working correct ly.
• NOTE: If the SRS component s are to be repl aced, the part number/bar code of the new uni t mus t be recorded.
SRS component t es t ing precauti ons
The SRS component s are t riggered us ing relati vel y l ow operati ng current s, al ways adhere to the foll owing :
W ARNING: Never us e a mul ti meter or ot her general purpose equi pment on SRS components. Us e only Land Roverapproved diagnos t ic equipment t o diagnos e sys tem faul ts .

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