2006 LAND ROVER FRELANDER 2 cooling

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Engine Cooling
Des cript ion and Operat ion
COMPONENT LOCATION
OVERVIEW
Becaus e of it s powerful engine, s ophi s ti cat ed transmis si on and t racti on s ys t em; the vehicle in the mos t demandingcondi ti ons will need t o cont inuall y dis s ipate as much as 120 kW of heat t o atmos phere. To compound the s i tuati on t hi st ypi call y occurs at low speeds when t here i s ins ufficient air being forced t hrough the radiat or t o ai d the cooli ng s ys t em.W i th thi s in mind and consi dering that t he majorit y of vehi cl es rarel y need to dis s ipate more t han 10 kW of heat , thecool ing s ys tem has been s peciall y devel oped t o cope wit h t he s everit y of off-road dri vi ng and variable ext remes of cl imat e.
The cool ing s ys tem functi ons us ing the cros s -flow pri ncipl e. The coolant is routed from t he cool ant pump int o the engi neblock on t he exhaus t s ide of t he engi ne and leaves the engine bl ock at t he rear edge, vi a t he t hermos tat housi ng, on theint ake si de.
The t hermos tat is a wax t hermos tat . The cool ant t emperat ure s ensor i s located i n t he thermost at hous i ng.
The cool ant i s pumped from the coolant pump t o t he engi ne through 2 connecti ons . After pass ing through t he engine,s ome of t he coolant exit s t he engi ne block at the rear edge of t he exhaus t s ide t o be routed t hrough t he pass engercompartment el ement and onwards to the coolant pump.

Coolant Flow - Open Thermostat
W hen t he t hermos tat opens, coolant is al so rout ed to the radiatorThe radi at or has an inl et on the Ri ght Hand (RH) s ide and 2 out let s on t he left-hand si deThe great er volume of cooled coolant is routed at the radi ator's l ower out let t o the coolant pumpAt t he upper outl et some of the coolant is routed t o t he automat ic t rans mi ss i on's oil cool er. Before t he coolantreaches the oi l cooler, it pas ses a 'choke' circuit t hrough t he radi at or wit h a lower (s lower) fl ow t han other cool ant s .This provi des opt imum cool ing of t he cool ant before i t reaches the oi l cooler, whi ch in turn, provi des effect ivecool ing of t he transmis s ion oil . The cool ant i s rout ed from t he oil cooler onwards to t he cool ant pump.
Bleeding
The engi ne has 2 bl eed ci rcuit s connected t o t he expans ion t ank. One is l ocat ed on the radiat or and the ot her on thecyl inder head.
Radiator and Cooling Fan(s)
The radi at or, whi ch di s si pat es heat from t he engine cool ant and engi ne mount ed oil cooler, i s manufactured from a 27 mmalumi num mat ri x wit h hi gh-pres s ure i nject ion molded end t anks .
ItemPart NumberDescription
A-Col d t o mi ld cli mat e radiat orB-Hot cl imat e radi at or
Dependant on cli mate condit ions t here are 2 s peci fi cat ions of radiat or fan avail abl e:
Cold t o mild cl imat es : a s ingle fan unit des igned around a 500W mot orHot climat es : a t win fan unit feat ures t wo motors del iveri ng a t otal of 750W
Common t o bot h fan types are:
Electric mot ors wit h brus hesThe Engi ne Control Module (ECM) controls t he fan speed via Pul s e W i dth Modulat ion (PW M) s i gnal s to the El ect ronicFan Cont rol Module (EFCM)The fan speed i s cont rol led at 4 l evel s:- Run-on occurs i n 3 s t ages (i.e. depres s ing the fan s peed)- The engine cool ing fan i s act ivated a cert ai n t ime aft er t he engine has been s wit ched off to prot ect vari ousengi ne component s from overheati ng- The t ime the fan is act ivated and the s peed of the fan i s dependent on the coolant t emperature and thedri ver's driving s t yle (engi ne load) when t he engi ne is swi tched off- The hott er the engine and the hot ter t he load, the hi gher t he fan speed and t he longer run-on ti me. The

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Engine Cooling
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the cooli ng s ys t em, refer t o t he rel evant Des cript ion and Operat ion secti on in the workshopmanual.REFER to: Engine Cooli ng (303-03A Engi ne Cool ing - I6 3.2L Pet rol , Descri pti on and Operat ion).
Inspection and Verification
CAUTION: Di agnos is by s ubs ti tut ion from a donor vehicle is NO T acceptabl e. Subs ti tut ion of cont rol modules doesnot guarant ee confirmat ion of a faul t, and may als o caus e addit ional fault s i n t he vehi cl e being t est ed and/or t he donorvehi cl e.
1. Verify t he cus t omer concern.1.
2. Vis ually ins pect for obvious s igns of mechani cal or electrical damage.2.
Visual InspectionMechanicalElectrical
Coolant leaksCoolant expans ion t ankElectric fanRadiat or
FuseW i ri ng harnessLoos e or corroded connect or(s )Engi ne Coolant Temperature (ECT) s ensor
3. If an obvious cause for an obs erved or report ed concern is found, correct t he caus e (if pos s ible) beforeproceeding t o t he next s t ep3.
4. If t he caus e is not vis ually evi dent , verify t he sympt om and refer t o t he Sympt om Chart, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseActionCoolant los sHosesHose connect ionsRadi atorCool ant pumpHeat er coreGasketsEngi ne cas t ing cracksEngi ne block core plugs
GO t o Pinpoint Test A.
Engine overheati ngEngi ne cool ant (level/condit ion)Thermos tatFan motorFan motor fus es and/or circui tsECT s ens orEngi ne cont rol module (ECM)Fan speed module
GO t o Pinpoint Test B.
Engine not reaching normal operat ing t emperat ureThermos tatElect ric fanFan speed module
GO t o Pinpoint Test C.
DTC Index
• NOTE: If the control modul e or a component i s s us pect and the vehicle remains under manufacturer warrant y, refer t o theW arranty Pol icy and Procedures manual (s ect ion B1.2), or determine i f any pri or approval programme is in operat ion, pri ort o the ins tall ati on of a new module/component.
• NOTE: Generic scan t ool s may not read the codes li st ed, or may read only fi ve digit codes . Mat ch the five di git s from t hes can tool to the firs t fi ve di git s of the seven digi t code l is ted to ident ify t he faul t (t he las t t wo digi ts gi ve ext rainformat ion read by the manufact urer approved diagnos t ic s ys tem).
• NOTE: W hen performing volt age or res is t ance t est s , always use a digi tal mult imeter (DMM) accurat e t o t hree deci malplaces, and wi th a current cali brati on cert ifi cat e. W hen t est ing res is tance, al ways take t he res is t ance of t he DMM leadsint o account.
• NOTE: Check and recti fy bas ic faul ts before beginni ng diagnos t ic rout ines i nvol vi ng pinpoint t es t s.
• NOTE: If DTCs are recorded and, aft er performi ng the pi npoi nt tes ts , a fault is not present , an int ermi tt ent concern maybe t he caus e. Always check for loose connect ions and corroded terminals .
DT CDescriptionPossible CauseAction
P011600Engine coolant temperature s ens or 1circui t range/performanceEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: hi ghCheck t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l a

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DT CDescriptionPossible CauseAction
res is t anceEngi ne cool ant t emperat ure(ECT) s ens or fai lure
new s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011621Engine coolant temperature s ens or 1circui t range/performance - s ignalampl it ude les s than minimum
Engi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o groundEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: openci rcuitEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011622Engine coolant temperature s ens or 1circui t range/performance - s ignalampl it ude greater t han maxi mum
Engi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o powerEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011700Engine coolant temperature s ens or 1circui t lowEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o groundEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: openci rcuitEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P011800Engine coolant temperature s ens or 1circui t highEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: shortci rcuit t o powerEngi ne cool ant t emperat ure(ECT) s ens or 1 circui t: openci rcuitEngi ne cool ant t emperat ure(ECT) s ens or fai lure
Check t he ECT s ensor and circui ts .Refer to the el ect ri cal guides . Ins tal l anew s ens or as requi red.REFER to: Engine Coolant Temperature(ECT) Sensor (303-14A Electroni cEngi ne Cont rol s - I6 3.2L Pet rol,Removal and Inst all at ion).
P012500Insuffi ci ent coolant t emperature forclos ed-l oop fuel cont rolDamaged/Faul ty coolantthermost atCool ing fan faul tEngi ne cool ant t emperat ures ens or ci rcuit : highres is t anceEngi ne cool ant t emperat ures ens or fai lure
Check t he cool ing s ys tem operati on.Rect ify as neces s ary. Check for DTCsindicati ng a coolant temperat ures ens or fault .
P012800Coolant t hermos tat (coolantt emperat ure below thermost atregul ati ng temperat ure)
Damaged/Faul ty coolantthermost atCool ing fan faul tEngi ne cool ant t emperat ures ens or ci rcuit : highres is t anceEngi ne cool ant t emperat ures ens or fai lure
Check t he cool ing s ys tem operati on.Rect ify as neces s ary. Check for DTCsindicati ng a coolant temperat ures ens or fault .
P145C68Fan s yst em component errorCool ing fan cont rol moduletemperat ure fail ureNo acti on neces sary. Code forinformat ion only.
P145D68Fan s yst em component error BCool ing fan cont rol modulehigh t emperature i ndi cat ionNo acti on neces sary. Code forinformat ion only.
Pinpoint Tests
PINPOINT TEST A : LOSS OF COOLANT
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
A1: VISUAL INSPECT IONVis ually ins pect for l oss of coolant .
Carry out a s ys t em press ure tes t. See component t es ts i n t his s ecti on.
Is the engine cooli ng sys t em l eaking?YesRect ify t he leak as i ndi cat ed by t he tes t res ult . Top-up and fil l t he cooling sys tem t o the correctlevel wit h t he correct s pecificati on fl uid as necess ary.REFER to: Speci fi cat ions (303-03A Engi ne Cool ing - I6 3.2L Petrol , Specificati ons) /Cool ing Sys tem Drai ning, Fi ll ing and Bl eeding (303-03A Engine Cooli ng - I6 3.2L Pet rol, GeneralProcedures).TEST the s ys tem for correct operat ion.NoVeri fy t he cust omer compl aint.

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PINPOINT TEST B : THE ENGINE OVERHEATS
T ESTCONDIT IONSDET AILS/RESULT S/ACT IO NS
B1: CHECK CO OLANT
W ARNING: The cool ing s yst em is pres s uri zed! Ensure t he res ervoir cap i s never rel eased unt il t he sys t em has cool ed.Fail ure t o fol low thes e ins t ructi ons may res ult i n pers onal i njury.
Check t he cool ant l evel and condi ti on.
Does the s ys tem cont ai n s ufficient cool ant of t he correct s peci fi cat ion?YesGO t o B2.NoTop-up and fi ll t he cool ing s ys tem to the correct l evel wi th the correct s pecifi cat ion flui d asneces sary.REFER t o: Speci ficat ions (303-03A Engi ne Cool ing - I6 3.2L Pet rol , Specificati ons ) /Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03A Engine Cooli ng - I6 3.2L Pet rol, GeneralProcedures ).Check for coolant los s . GO t o B1.
B2: CHECK CO OLANT EXPANSION T ANK PRESSURE CAP
Check t he cool ant expansi on tank press ure cap for damage/correct operati on. REFER t o t he cool antexpans ion t ank pres sure cap pres sure t est i n t his s ect ion.
Is t he coolant expans ion t ank pres sure cap operati ng correctl y?YesGO t o B3.NoINSTALL a new coolant expans ion t ank pres s ure cap. TEST t he s yst em for correct operati on.
B3: CHECK T HERMOST ATCheck t he t hermos tat for correct operat ion. REFER to the t hermos t at component t es t in t hissect ion.Is t he t hermos tat operat ing correct ly?YesCheck for correct operat ion of cooli ng fans , ci rcuit s , sens ors , modules , et c.REFER t o: Electroni c Engine Controls (303-14A Electronic Engine Controls - I6 3.2L Pet rol , Diagnosi sand Tes t ing).NoINSTALL a new t hermos t at .REFER t o: Thermos tat (303-03A Engine Cooli ng - I6 3.2L Petrol, Removal and Ins tall ati on).TEST the s ys tem for correct operat ion.
PINPOINT TEST C : THE ENG INE DOES NOT REACH NORMAL OPERATING TEMPERATURE
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
C1: CHECK T HERMOST ATCheck the thermos t at for correct operat ion. REFER t o t he t hermos tat component t est in t hiss ecti on.
Is t he thermost at operati ng correctl y?YesCheck for correct operat ion of cool ing fans, circui ts , s ensors, modul es , et c.REFER t o: El ect roni c Engi ne Cont rol s (303-14A Elect roni c Engi ne Cont rol s - I6 3.2L Pet rol,Di agnos is and Tes t ing).NoINSTALL a new t hermos tat .REFER t o: Thermost at (303-03A Engi ne Cool ing - I6 3.2L Pet rol , Removal and Inst all at ion).TEST t he s ys t em for correct operati on.
Component Tests
Cooling System Pressure Test
W ARNING: Never, under any ci rcums tances, remove the coolant expans ion tank pres s ure cap whi le t he engine i soperati ng. To avoid havi ng s caldi ng hot water or s team bl ow out of the cooli ng s ys t em, use ext reme care when removi ngt he coolant expans ion tank pres s ure cap from a hot cool ing s ys tem. W ai t unti l the engine has cooled, then wrap a t hickcloth around t he coolant expans ion tank pres s ure cap and t urn it s lowl y unt il t he pres s ure begins t o releas e, s t ep backwhil e t he pres sure i s rel eas ed from the s ys tem. W hen certai n all t he pres s ure has been rel eas ed (s ti ll wit h a cl oth) t urnand remove t he coolant expans ion t ank pres sure cap. Fail ure t o follow thes e i ns t ructi ons may res ult i n damage t o t hecool ing s ys tem, engine and/or cause pers onal injury.
1. Swit ch the engine off.1.
2. Open the hood and i nst all prot ect ive fender covers .2.
3. Careful ly remove the coolant expans ion t ank pres s ure cap from the coolant expans ion t ank to rel ieve pres s ure i nt he cool ing s ys tem. Add coolant t o cool ant expans i on tank as necess ary.3.
4. Ins t al l the press ure tes t er equipment t o t he cool ing s yst em foll owing manufact urers i nst ruct ions. Rei ns t all t hecoolant expans ion t ank pres sure cap (if pres s ure t est equipment i s not ins tal led t o t he cool ant expans i on tank).4.
5. Pres surize t he cool ing s ys tem to the coolant expans ion t ank pres s ure cap lower l imi t.5.
6. Observe the gauge readi ng for approximat ely t wo minutes . Pres s ure s houl d not drop during t his t ime.
If sys tem holds pres s ure, cont inue from s tep 8.
6.

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Cooling System Draining, Filling and
Bleeding
General Procedures
W ARNING: Si nce injury s uch as scaldi ng coul d be caus ed by es capi ng s team or coolant, do not remove the fi ller capfrom the coolant expans ion t ank while the sys tem is hot .
Pos it ion t he vehi cl e on a lift .1.
Set the heat er controls t o maxi mum.2.
Remove t he engi ne undershi eld.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,Removal and Ins tall ati on).
3.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
4.
5. W ARNING: Si nce injury s uch as scaldi ng coul d be caus ed byes caping st eam or coolant, do not remove the fil ler cap from t hecool ant expansi on t ank whi le the s ys tem is hot .
Remove t he cool ant expans i on tank cap.
5.
Pos it ion a contai ner t o coll ect t he fl uid.6.
At tach a hos e t o t he radiat or drain tap. Open the tap.7.
Loosen t he engine drai n t ap.8.
Clos e t he radi ator drai n tap and remove t he hose.9.Tight en the engine drain tap.10.

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Thermostat
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he int ake mani fol d as sembl y.
Refer t o: Int ake Mani fol d (303-01A Engi ne - I6 3.2L Petrol, Removal
and Inst all at ion).
2.
Drai n t he cool ing s ys tem.
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03A
Engine Cooli ng - I6 3.2L Petrol, General Procedures).
3. 4.
T orque:
10 Nm 5.
Remove t he thermost at.
6.
Remove and dis card t he gas ket .
7.

Publi s hed: 11-May-2011
Engine Cooling - I6 3.2L Petrol - Coolant Pump
Removal and Inst all ati on
Removal
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - I6 3.2L Pet rol (501-05 Int eri or Trim andOrnament ati on, Removal and Ins tal lat ion).
2.
Remove t he bat t ery t ray.
Refer t o: Bat t ery Tray (414-01 Bat tery, Mount ing and Cables ,Removal and Ins tall ati on).
3.
Remove t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -I6 3.2L Pet rol, Removal and Ins t al lat ion).
4.
Drai n t he cool ant .
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03AEngine Cooli ng - I6 3.2L Petrol, General Procedures).
5.
Remove t he A/C compress or, l ower support bracket.6.
Us ing s uit able t ools , rel eas e t he acces s ory drive beltt ens i on.7.