2006 LAND ROVER FRELANDER 2 Repair Manual

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Page 25 of 3229

LAND ROVER FRELANDER 2 2006 Repair Manual W ARNING: Do not use el ect ri cal t est equipment on t he SRS harnes s whil e i t is connected to any of t he SRScomponents , i t may caus e accidental depl oyment and i njury.
Handl ing and s

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LAND ROVER FRELANDER 2 2006 Repair Manual • W ARNINGS:
W hen handli ng a s ide curtain airbag modul e, hol d by t he gas generat or hous ing, DO NOT hold by the ai rbag. Do notwrap the t humb around t he gas generator whi le holdi ng. Do

• W ARNINGS:
W hen handli ng a s ide curtain airbag modul e, hol d by t he gas generat or hous ing, DO NOT hold by the ai rbag. Do notwrap the t humb around t he gas generator whi le holdi ng. Do not drape airbag over s houl der or around neck. For s eat buckl et ype pre-t ens i oners, hold by the pi s ton t ube, wit h the open end of t he pis t on tube point ing t owards t he ground and t hebuckle facing away from your body. Do not cover the end of t he pis t on tube. DO NOT hold buckl e t ype pre-t ensi oners byt he bracket as s embl y or cabl e. Never point t he pis ton t ube t owards your body or other peopl e.
Ai rbag modules and s eat bel t pre-tens ioners are clas sed as expl os i ve devices . For overnight and l onger t erms torage, t hey must be st ored in a secure st eel cabinet which has been approved as s ui tabl e for t he purpos e and has beenregi st ered wi th the local authorit y.
St ore ai rbag modules or s eat bel t pre-tens ioners i n a des ignated s t orage area. If there is no des ignated st oragearea avail abl e, st ore in t he l ocked luggage compartment of t he vehi cl e and i nform t he works hop supervi sor.
CAUTION: Improper handl ing or s torage can i nternal ly damage t he airbag module maki ng it i noperat ive. If yous uspect the ai rbag module has been damaged, ins tal l a new module and refer t o t he depl oyment /di spos al procedures fordis posal of t he damaged modul e.
SRS harnes s and connectors
Always obs erve t he fol lowing precaut ions wit h regards to SRS s ys t em el ect ri cal wiring:
Never at tempt t o modi fy, s pl ice or repai r SRS wiring.Never i nst all electrical equi pment such as a mobi le telephone, t wo-way radio or i n-car ent ert ainment s yst em i ns uch a way t hat i t coul d generate el ect ri cal i nt erference in the ai rbag harnes s. Seek s peci alis t advice whenins t al li ng s uch equipment .
• NOTE: SRS wi ri ng can be identi fi ed by a s peci al yell ow outer s leeve prot ect ing the wi res (black wi th yell ow s t ri peprot ect ive coverings are s ometi mes used).

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LAND ROVER FRELANDER 2 2006 Repair Manual W ARNING: Always make s ure SRS wiring i s rout ed correctl y. Be careful to avoi d trapping or pinchi ng t he SRS wiring.
W ARNING: Do not leave the connect ors hanging l oos e or al low SRS compone

W ARNING: Always make s ure SRS wiring i s rout ed correctl y. Be careful to avoi d trapping or pinchi ng t he SRS wiring.
W ARNING: Do not leave the connect ors hanging l oos e or al low SRS component s t o hang from their harnes s es . Lookfor pos si ble chafi ng points .
Side i mpact cras h sens or ins pecti on
Aft er any degree of si de body damage, i ns pect the s i de impact cras h s ens ors . Replace a cras h s ens or i f there is any s i gn ofdamage.
CAUTION: Take ext ra care when paint ing or carryi ng out bodywork repairs in the vi ci ni ty of the cras h s ens ors . Avoi ddirect exposure of the crash sens ors or l ink harnes ses to heat guns, wel di ng or s praying equipment. Take care not t odamage s ens or or harness when reins t al li ng components .
Clock s pri ng
CAUTION: Always foll ow t he procedure for i ns t alli ng and checking t he clock s pring as ins truct ed in the SRS repairss ect ion. Comply wi th all s afety and ins tal lati on procedures to make s ure t he s yst em funct ions correct ly. Obs erve t hefol lowing precaut ions :
Do not unlock and rot ate the clock s pri ng when it i s removed from t he vehi cl e.Do not t urn t he road wheel s when the cl ock s pring i s removed from the vehicle.Always make s ure the cl ock s pri ng is removed and ins t al led i n i ts central pos it ion and wit h t he front road wheels i nt he st rai ght ahead pos it ion - refer t o SRS repair s ecti on for t he correct removal and ins tal lat ion procedure.If a new clock s pring is being ins tall ed, make sure t he locki ng t ab hol ding t he coupl er's rotat ional pos i ti on is notbroken; uni ts wit h a broken l ocking tab mus t not be us ed.
Airbag and pre-tensioner deployment
W ARNING: During deployment part s of the ai rbag modul e become hot enough to burn you. W ait 30 minut es aft erdepl oyment before t ouching the ai rbag module.
Deployment procedures and precaut ions as detai led i n thi s manual s hould be st ri ctl y adhered to. Onl y pers onnel who haveundergone the appropriate training s hould undert ake depl oyment of airbag and pre-tens ioner modul es. The followi ngprecaut ions mus t be compli ed wi th:
Only us e deployment equi pment approved for the intended purpos e.Deployment of ai rbag / pre-t ens ioner modules mus t be performed in a well vent il ated area which has beendesi gnat ed for t he purpos e.Make s ure ai rbag / pre-t ens ioner modules are not damaged or rupt ured before at tempt ing t o deploy.W here local legis lat ion exis t s, not ify the relevant aut horit ies of i ntenti on t o deploy airbag and pretens ioner uni ts .W hen deploying ai rbag pre-t ens ioner unit s, make s ure that all personnel are at l eas t 15 met res (45 feet ) away fromt he depl oyment zone.

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LAND ROVER FRELANDER 2 2006 Repair Manual Make s ure deployment tool is connect ed correct ly, in compl iance wit h t he ins truct ions det ai led i n t he SRS s ect ion oft hi s manual. In part icular, make sure depl oyment t ool is NO

Make s ure deployment tool is connect ed correct ly, in compl iance wit h t he ins truct ions det ai led i n t he SRS s ect ion oft hi s manual. In part icular, make sure depl oyment t ool is NOT connect ed t o batt ery s upply before connecti ng t oairbag modul e connector.W hen deploying s eat belt pre-tens ioners , make s ure pre-t ensi oner unit i s s ecured correctl y t o t he s eat .W hen removing deployed airbag modul es and pre-tens ioner uni ts , wear protecti ve clothi ng. Us e gl oves and s ealdepl oyed uni ts in a pl ast ic bag.Followi ng depl oyment of any component of t he SRS s ys t em wi thi n the vehicl e, al l SRS components mus t berepl aced. DO NOT reus e or s al vage any parts of t he SRS s yst em.Do not lean over an airbag module when connect ing deployment equi pment .
If a vehi cl e i s to be s crapped, undepl oyed ai rbag modules and pre-t ens ioner unit s mus t be manually depl oyed. In thi s cas eairbags can be deployed i n the vehicl e. Before deployment, make s ure the ai rbag modul e is secure wit hi n i ts correctmounti ng posi ti on. Deployment of the driver's airbag in the vehicle may damage the st eering wheel ; if t he vehi cl e i s notbeing s crapped, deploy t he module out s ide of t he vehi cl e.
SRS Component Replacement Policy
• CAUTIO NS:
T he restraints control module (RCM) must be replaced after every time any SRS component has beendeployed.
The SRS s ide impact sens or mus t be replaced if t here are any s igns of phys i cal damage or if t he RCM i s regi st eri ng afaul t.
The fol lowing informati on detail s t he policy for replacement of SRS component s as a res ult of a vehicle accident.
Impacts w hich do not deploy the airbags or pre-tensioners
Check for s truct ural damage in t he area of the i mpact paying parti cular at tent ion t o bumper armat ures , longi tudi nal s andbracket ry.
Impacts w hich deploy the airbags or pre-tensioners
The repl acement and ins pect ion poli cy is dependent on t he t ype and severi ty of t he cras h condi ti on. The foll owingguideli nes are t he mi ni mum that s houl d be exercis ed as a res ul t of the deployment of s pecific SRS component s .
Check for structural damage in the area of impact paying particular attention to bumper armatures, longitudinalsand bracketry.
Front Airbag Deployment - Driver and Passenger
CAUTION: If the front airbags are deployed, the followi ng components mus t be replaced:
Dri ver ai rbag moduleSteering wheelPass enger ai rbag moduleIns t rument panelFly l eads (where appl icabl e) connect ing front ai rbag modules t o SRS harnes sAll s eat bel t buckle pre-t ensi onerAll occupied seat s at the ti me of t he crash s hould have their s eat bel ts replacedAny s eat bel t wit h a deployed ret ract or pretens ioner s hould be replaced.Rotary couplerAny front impact s ens ors that have been phys ically damaged or i f a faul t is being regis teredRCM
Additionally, the following items must be inspected for damage and replaced as necessary:
Front pass enger's seat belt retract or and webbi ng, t ongue l atching funct ion, 'D' loop and body anchorage poi ntRear seat belt buckl es, webbing, buckle covers , body anchorage point s and t ongue l atching funct ionFront s eat frames and head res trai ntsSteering column - if adjus tment i s los t or if t here are s igns of col laps eSeat bel t hei ght adjust ersRear seat belt s
Side Ai r Bags
CAUTION: If the s i de (t horax) air bags are deployed, the foll owi ng component s mus t be replaced on t he s ide of t hevehi cl e on whi ch the deployment occurred:
Side (t horax) ai rbagAny 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:
Front 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 sFront s eat frame and head res traint sDoor trim cas i ngSeat bel t hei ght adjust ers

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LAND ROVER FRELANDER 2 2006 Repair Manual 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 deploymen

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:

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LAND ROVER FRELANDER 2 2006 Repair Manual Air condi ti oning unit s mus t not be li ft ed by t hei r hos es , pipes or capil lary li nes .Hos es and lines mus t not be s ubjected t o any t wis t or s tress ; t he efficiency of the s ys

Air condi ti oning unit s mus t not be li ft ed by t hei r hos es , pipes or capil lary li nes .Hos es and lines mus t not be s ubjected t o any t wis t or s tress ; t he efficiency of the s ys tem wil l be impai red by ki nksor res trict ions. Make s ure that hos es are correct ly pos it ioned before t ightening coupli ngs , and make s ure that allclips and support s are ut il is ed.Flexible hos es s houl d not be pos it ioned cl oser t han 100 mm (4.0 i n) t o t he exhaus t manifold unl es s protected byheat shi el ding.Complet ed ass embli es mus t be checked for refrigerat ion l ines t ouching met al panels . Any direct contact ofcomponents and panels may t rans mit nois e and s o must be el iminated.The appropri at e t orque wrench must be us ed when t ight eni ng refri gerant connect ions to t he s ti pul at ed value. Anaddi ti onal s panner mus t be us ed t o hold t he union t o prevent t wis ti ng of the pi pe when t ightening connect ions .Before connecti ng any hos e or pipe, make s ure that refri gerant oil is appli ed t o t he seat of t he new O-ri ngs , BUTNOT to the t hreads of the connect ion.All prot ect ive pl ugs or caps mus t remai n i n place in the component unt il i mmediat el y pri or to connect ion.Make s ure component s are at room temperat ure before uncappi ng/unpl uggi ng, t o prevent condens at ion of moi s turefrom the ai r that enters it .W hen di sconnect ing, immedi ately pl ug or cap all air condi ti oni ng pipes t o prevent ingres s of dirt and mois t ure i ntot he sys t em.Component s mus t not remain uncapped/unpl ugged, if a sys t em has been left uncapped/unpl ugged for 20 mi nut esor longer, a new recei ver/drier mus t be i ns t alled.The receiver/dri er contai ns des i ccant which absorbs mois t ure. It must be pos it ively sealed at al l ti mes . Areceiver/dri er t hat has been left uncapped for longer t han 20 mi nutes mus t not be used; i nst all a new uni t.The receiver/dri er s hould be the l ast component connect ed to the sys tem t o make s ure opt imum dehydrat ion andmaximum moi st ure protecti on of the sys tem.W henever a component of t he refrigerat ion s yst em is repl aced, it will al so be neces sary t o ins t al l a newreceiver/dri er uni t.Us e alcohol and a cl ean li nt -free cl oth to cl ean di rt y connecti ons.Make s ure t hat all new part s i ns t alled are marked for us e wit h R134a.W hen a major repai r has been complet ed, a leak t es t s hould be conduct ed; refer t o t he Repai rs Secti on of thi smanual for the correct procedure.
Refrigerant oil
CAUTION: Refrigerant oil eas il y absorbs water and mus t not be s tored for long periods. Do not pour unusedrefri gerant oi l back i nto the container. Always use an approved refrigerant oi l.
W hen replaci ng component s in the ai r condit ioning s ys tem, drai n t he refri gerant oi l from t he component being replacedint o a graduat ed cont ainer. On as s embly, add t he quant it y of refri gerant oi l drained t o t he new component - See Ai rCondi ti oni ng Compres s or Repl acement in this Sect ion.
Compres s or
A new compress or is sealed and press uris ed wit h Ni trogen gas . W hen i nst all ing a new compres sor, sl owly releas e thes eal ing cap; gas pres sure s houl d be heard to vent as t he s eal i s broken.
CAUTION: A new compress or s houl d always be s ealed and could be pres suris ed wit h ni trogen gas . To avoid pos si bleoil l os s , rel eas e t he s ealing cap(s ) s lowl y. Do not remove t he cap(s ) unt il i mmediatel y pri or to connect ing t he aircondi ti oni ng pipes t o the compress or.
Rapid refrigerant dis charge
If the ai r condit ioning s ys tem is i nvol ved in accident damage and t he s yst em is punct ured, t he refri gerant will di schargerapi dl y. The rapid di scharge of refrigerant wil l als o res ult in t he los s of mos t of the oi l from t he s yst em. The compres sormus t be removed and al l the remaining oi l in t he compres s or drained and refil led as i nst ruct ed in t he air condit ionings ect ion of t his manual.
Precaut ions for refrigerant recovery, recycl ing and rechargi ng
W hen t he air condit ioning s yst em is recharged, any exi s ti ng refri gerant i s first recovered from t he s ys t em and recycled.The s ys t em i s t hen charged wit h the required weight of refrigerant and volume of refrigerant oil .
W ARNING: Refri gerant mus t al ways be recycl ed before reus e t o make s ure that the purit y of the refrigerant i s highenough for s afe us e i n the ai r condit ioni ng sys t em. Recycl ing s hould al ways be carried out wit h equipment which i s des i gncert ifi ed by Underwrit er Laborat ory Inc. for compl iance wit h SAE J1991. Ot her equipment may not recycle refrigerant t o t herequired level of purit y.
• CAUTIO NS:
A R134a Refri gerant Recovery Recycli ng Rechargi ng Stat ion mus t not be us ed wit h any ot her t ype of refrigerant .Refrigerant R134a from domes ti c and commercial s ources mus t not be used i n mot or vehi cl e air condi ti oni ng s yst ems .
The s yst em must be evacuat ed i mmediat el y before recharging commences. Del ay bet ween evacuati on and rechargingis not permit ted.
Air Condit ioning Compress or Repl acement
A new compress or is suppli ed fi ll ed wit h a full charge (X cm³) of refrigerant oi l.
A calculat ed quant it y of oil mus t be drai ned from t he new compres s or before i nst all ing. To cal cul at e t he quant it y of oil t obe drai ned:
Remove the drain pl ug from the ol d compres sor.

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LAND ROVER FRELANDER 2 2006 Repair Manual Invert the compres s or and gravi ty drain the oi l into a calibrated meas uri ng cyl inder. Rotat e t he compres sor clut ch tomake s ure the compres s or is complet el y drai ned.Note the quanti t

Invert the compres s or and gravi ty drain the oi l into a calibrated meas uri ng cyl inder. Rotat e t he compres sor clut ch tomake s ure the compres s or is complet el y drai ned.Note the quanti ty of oi l drained (Y cm³).Calculate the quanti ty of oi l to be drained from t he new compres sor us ing t he fol lowi ng formula:X cm³ — (Y cm³ +20 cm³) = Q cm³Remove the drain pl ug from the new compres s or and drain Q cm3 of oi l. ins t al l and tight en t he compres sor drai nplug.
Vehicle Weights
Itemkglb
Maximum Gros s Vehicle W eight (GVW ) - Al l model s (1)25055511Approximate unladen w eight (2):
3.2 Petrol18254015
2.2 Diesel18204004Maximum weight of unbraked trailer:
On-road7501650
Off-road7501650Maximum towable weight (mass) - T railers with overrun brakes:
On-road20004400
Off-road20004400Gross train weight - T railers with overrun brakes (3):
On-road45059911
Off-road45059911Nose w eight:
On-road150330
Off-road150330Maximum front axl e l oad - All models (4)13102882
Maximum rear axle load - All models (4)13602992
Maximum roof rack l oad - All models (5)75165(1) T he maximum permissible weight of the vehicle including passengers and load.
(2) T his figure includes the toolkit, all fluids to the correct levels and spare w heel but excludes the driver andpassengers.
(3) T he maximum permissible weight of the vehicle and braked trailer and their respective loads.
(4) T he front and rear maximum loads cannot be reached simultaneously as this will exceed the GVW limit. Whencalculating rear axle loading, remember that the trailer nose w eight, the load in the vehicle' s luggage area, w eighton the roof rack, and the weight of rear seat passengers must all be added together.
(5) T his figure includes the weight of the roofrack.
Vehicle Dimensions
ItemmminLengt h - excluding l icens e pl ate pl int h - All models4500177.2
Width - All models:
Mirrors extended218085.83Mirrors folded200578.95
Maximum height - including roof rail s - Al l model s182071.65
W heelbas e - Al l model s2660104.7T rack:
Front w ith 16" wheels161163.43
Front w ith 17"/18"/19" wheels160163.03Rear with 16" wheels162463.94
Rear with 17"/18"19" wheels161463.54
Vehicle ride height (1):Front490.7±1219.32±0.47
Rear504.6±1219.87±0.47
Underbody running cl earance t o exhaus t - Mi nimum - Kerb wei ght2299.0Front axle t o underbody clearance2168.5
Rear axl e t o different ial cas i ng cl earance26710.5
Suspension travel from kerb - ROW (unladen):2278.9Front (bump/rebound)105/804.13/3.15
Rear (bump/rebound)130/905.12/3.54
T otal articulation33513.2Suspension travel from kerb - NAS (unladen):
Front (bump/rebound)102/764/3
Rear (bump/rebound)127/895/3.5T otal articulation33013.2
W adi ng dept h50019.7
Depart ure angle - Towbar NOT ins tall ed34°Depart ure angle - Fi xed hei ght towbar - NOT NAS vehicles19°
Depart ure angle - Detachabl e towbar ins t al led - NOT NAS vehicle18°
Depart ure angle - Towbar i ns t alled - NAS vehi cl es19°Approach angl e31°
Breakover angle157°
Maximum gradient for conti nuous operat ion30°Maximum gradient for drive t hrough operat ion (2)45°

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LAND ROVER FRELANDER 2 2006 Repair Manual (1) Ride height is measured vertically from wheel center to underside of wheelarch. All figures are with vehicle at'Show room' height - full fluids, full tank of fuel, no occupants/luggage, t

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