2006 LAND ROVER FRELANDER 2 steering

Publi s hed: 11-May-2011
Steering System - General Information - Steering System
Diagnosi s and Tes ti ng
Principle of Operation
For a detail ed descripti on of the st eering sys tem, refer t o t he rel evant Des cript ion and Operat ion s ecti on in the works hopmanual. REFER to:
Steeri ng Sys t em (211-00 St eering Sys tem - General Informat ion, Diagnos i s and Test ing),Power St eering (211-02 Power Steeri ng, Des cri pti on and Operati on),Steeri ng Linkage (211-03 St eering Li nkage, Descripti on and Operat ion),Steeri ng Column (211-04 St eering Col umn, Des cri pti on and Operati on).
Inspection and Verification
1. Verify t he cus t omer concern by operat ing t he s yst em.1.
2. Vis ually ins pect for obvious s igns of damage and s ys t em i ntegri ty.2.
Visual Inspection
MechanicalCheck the t ires for correct press ure, s ize and t read pat ternCheck for wheel rim and t ire damageCheck road wheel securi tyCheck the power s teeri ng fluid level and t he hydraulic ci rcuit for flui d leaksCheck the power s teeri ng pump drive belt condi ti on and t ens ionCheck the power s teeri ng pump for securi ty, wear, damage and exces s ive nois eCheck the s t eering gear as sembl y for damage, wear and s ecurit yCheck the hydrauli c pipes and cool er li nes for damage and correct rout ingCheck the s t eering joint s for damage, excess i ve play, wear and s ecurit yCheck the s t eering column and joi nt s for damage, exces s ive play, wear and securi ty
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 ep.3.
4. If t he concern is not vis uall y evi dent , verify t he s ymptom and refer t o t he Symptom Chart .4.
Symptom Chart
• NOTE: If a component is sus pect and t he vehicle remains under the manufact urer warrant y, refer t o t he W arrant y Policyand Procedures manual (s ect ion B1.2), or determine i f any prior approval programme is i n operat ion, prior t o t heins t al lat ion of a new component.
SymptomPossible CauseAction
St eering wandersExces s ive free pl ay in t hes teering s yst emSt eering geometryi ncorrect ly al igned
Check for excess i ve movement or play i n t he s teeri ng s yst em wit hthe engine running. Check for pl ay at several different s t eeringpos i ti ons . Carry out st eeri ng geomet ry and alignment checks .REFER t o: Four-W heel Al ignment (204-00 Sus pens i on Sys t em -General Informati on, General Procedures ).St eering pull s t o t hel eft or ri ghtSt eering/s us pens ioncomponent s damaged,bent, l oos eSt eering geometryi ncorrect ly al igned
Check s t eering and s us pens ion component s for damage/correctins tal lati on. Carry out s t eering geometry and ali gnment checks .REFER t o: Four-W heel Al ignment (204-00 Sus pens i on Sys t em -General Informati on, General Procedures ).
St eering feel snotchy when t urningfrom lock to lock
St eering or s uspens ions wivel joi nt s s eizedSt eering t ie rod end jointsor t rack rod i nner joint ss eizedSt eering column orunivers al joi nt s s eizedSt eering gear int ernalcomponent s mi sal igned,worn or damaged
Dis connect the s t eering gear from the s us pens ion. Check forfreedom of movement i n t he s us pensi on. Di s connect t he s teeringcol umn from the s t eering gear. Check t he st eeri ng col umn anduni vers al joint s for freedom of movement. Check the s t eeringgear for freedom of movement . Rect ify as neces s ary.
St eering feel s t ightand does nots elf-center
Power st eeri nghydrauli cs noi syoperat ion
Power st eeri ng fl uid l evell ow or cont aminatedPower st eeri ng fl uidaerat edPower st eeri ng hos est wis t ed or res tricted
Check and t op-up t he power st eering fl ui d l evel if requi red.REFER t o: Power St eeri ng Sys t em Bl eeding (211-00 St eeringSys t em - General Informat ion, General Procedures ).Check for contaminated flui d. Check for air i ngres s int o t hesys t em. Check t he power s t eering hos es for t wis t ing orres trict ions. Recti fy as neces sary.
Power st eeri ng pumpnois yPower st eeri ng fl uid l evell ow or cont aminatedPump i nternal component sworn or damaged
Check and t op-up t he power st eering fl ui d l evel if requi red.REFER t o: Power St eeri ng Sys t em Bl eeding (211-00 St eeringSys t em - General Informat ion, General Procedures ).Check for contaminated flui d. Check for exces s ive pump noi se.Ins tal l a new pump as required. Refer t o t he new componentins tal lati on note at t he t op of the Sympt om Chart

Publi s hed: 11-May-2011
Steering System - General Information - Power Steering System Bleeding
General Procedures
Clean power s teering fluid res ervoir around t he fi ll er cap and flui di ndi cat or.1.
Check the power s teeri ng fluid, if aerat ed, wait unti l fl ui d i s freefrom bubbles then t op-up res ervoi r to UPPER l evel mark wit hrecommended fluid.
2.
3. CAUTION: Flui d mus t always be pres ent in theres ervoi r during bl eeding.
Remove t he fi ll er cap and fil l t o t he MAX level mark.
3.
Inst all t he fi ll er cap.4.
St art t he engi ne and allow to run for 10 s econds, s t op t he engi ne.5.
Check the power s teeri ng fluid, if aerat ed, wait unti l fl ui d i s freefrom bubbles then t op-up res ervoi r to UPPER l evel mark wit hrecommended fluid.
6.
St art t he engi ne and turn s teering ful ly lock to lock, s t op the engine.7.
Check and top-up power s t eering fluid level.8.
St art and run the engine for 2 mi nut es , turn the st eeri ng full y l ock t ol ock.9.
Check and top-up power s t eering fluid level.10.

Publi s hed: 11-May-2011
Steering System - General Information - Power Steering System Flushing
General Procedures
• NOTE: If heavy s teering or cont aminat ion wi thi n t he power s t eering s ys tem is found, i t is necess ary to carry out t hes ys t em flus h procedure as det ailed bel ow. If any component s have been replaced in t he power st eeri ng s ys t em t heprocedure below must be carri ed out in full.
• NOTE: Some vari ati on in the i ll us t rat ions may occur, but the es s ent ial informat ion i s always correct .
1. Remove the power s teeri ng fl uid res ervoi r cap.
2. Usi ng a s uit able s yri nge, remove the power s teering fluid fromt he power s t eering flui d res ervoir.
3. CAUTION: Be prepared to col lect escaping fluids .
• NOTE: Not e t he orient ati on of the cli p.
Det ach the power s teering fluid res ervoir.
Det ach but do not remove the power s teeri ng fl uidres ervoi r.
Releas e t he power s t eering flui d ret urn hos e from thepower st eeri ng fl uid reservoi r.
If a quick rel eas e coupli ng is fit ted to the powers teering return hos e, rel eas e the power s teeri ng fl uidret urn hos e from t he coupli ng by removi ng the cl ip.
4. CAUTION: Be prepared to col lect escaping fluids .
• NOTE: Make s ure that all openi ngs are s ealed. Us e newblanking caps.
Usi ng a s uit abl e blanking cap, cap the power s teeri ngres ervoir ret urn pi pe.

Publ is hed: 05-Dec-2011
Power Steering -
Lubricants, Fluids, Sealers and AdhesivesItemspecificationCapacity
Recommended flui dPent ozi n CHF202Fil l to maxi mum mark on res ervoir
General Specification
ItemSpecification
PAS pump - 2.2 Di es elHit achi variable dis placement pump (VDP)PAS pump - 3.2 PetrolZF Conventi onal (fi xed di s pl acement ) pump wit h oi l cooler
PAS pump - 2.0 PetrolZF Conventi onal (fi xed di s pl acement ) pump wit h oi l cooler
PAS cooler - 3.2 Pet rolInt egral part of hos esSt eering gearW elded s t eel t ube des i gn for conventi onal gear (Vi st eon)
System operating pressure:
3.2 Pet rol125 Bar ± 5 (1813 ± 73 ps i)2.2 Dies el115 Bar ± 4 (1667 ± 58 ps i)
2.0 Pet rol115 Bar ± 4 (1667 ± 58 ps i)
Idle resi dual pres s ure4 bar ± 1 (58 ± 15 ps i)Flui d fl owCons tant
Maximum flow8.8 Lit ers per mi nute ± 0.5 l/min
Torque Specifications
DescriptionNmlb-ftHi gh-pres sure l ine t o power st eeri ng pump - 2.2 Dies el2015
Hi gh-pres sure l ine t o power st eeri ng pump - 3.2 Pet rol2518
Hi gh-pres sure l ine t o power st eeri ng pump - 2.0 Pet rol2720Power st eeri ng fl uid cooler107
Power st eeri ng fl uid l ine bolt s2720
Power st eeri ng fl uid pres s ure lines2518Power st eeri ng gear t o cros s member nuts10577
Power st eeri ng pump bolt s - All engines2418

Publi s hed: 11-May-2011
Power Steering - Power Steering
Des cript ion and Operat ion
COMPONENT LOCATION - TD4 DIESEL
• NOTE: Right Hand (RH) drive shown, Left Hand (LH) drive s imil ar
ItemPart NumberDescription1-Sucti on hose - res ervoir t o pump
2-Res ervoir
3-Fl ui d ret urn pipe - s t eering gear to res ervoir4-Hi gh pres s ure feed pipe - pump to s t eering gear
5-Power s teeri ng pump
6-Ti e-rod7-Bul khead s eal and gas ket
8-Val ve uni t
9-St eering gear10-Bol t
COMPONENT LOCATION - i6 PETROL
• NOTE: LH drive s hown, RH dri ve si mi lar

STEERING GEAR
ItemPart NumberDescription
1-Locknut2-Tie-rod end
3-Locknut
4-Tie-rod5-Steering gear boot
6-Steering gear cas ing at t achment lugs
7-Pres s ure/return pipes8-Valve unit hous ing
9-Input s haft
10-Pres s ure/return connecti on to/from pump11-At tachment bol ts
The s teeri ng gear, manufactured by Vis t eon, i s located at t he rear, top face, of t he front subframe. It is s oli dl y bolt ed t ot he subframe wit h t wo bolt s. The bolt s are pass ed t hrough from the unders ide of t he s ubframe, t o i mprove s ervi ce access ,and are screwed into threaded bos s es on the st eering gear body.
The s teeri ng gear is a convent ional end take-off, rack and pi ni on power as s is t ed unit wi th l ock to lock requiring 2.6 turnsof the st eering wheel . Thi s gives a s t eering rati o (rat io of s t eering wheel angl e t o road wheel angl e) of 16.7:1 whi chprovides very qui ck and res pons ive react ion t o driver inputs . The s teeri ng gear features large di ameter t ie-rods whichopti mize feedback and feel t o t he driver.
The s teeri ng gear compris es a s t eel , welded and machined, one pi ece hous ing whi ch cont ai ns a mechanical s t eering rack, avalve unit and an i ntegrat ed hydraulic power unit . The s teeri ng gear us es a rack with an i nt egrat ed pis ton whi ch is gui dedon plai n bearings wi thi n t he rack hous i ng. The pi ni on, whi ch is at tached t o the val ve uni t, runs in bearings and mes heswit h t he rack t eeth. The rack i s pres s ed agai nst t he pini on by a s pri ng loaded yoke which ensures that t he teet h mes hwit hout any pl ay. The pi ni on is connect ed t o t he val ve unit via a tors ion bar. The rotary moti on of the st eeri ng wheel i sconvert ed i nt o l inear movement of t he rack by t he pinion and is i nit iated by the valve uni t. This movement i s transferredint o movement of the road wheel s by adjus t abl e t ie-rods.
The pis t on of the hydrauli c power uni t is l ocat ed at one end of the gear hous ing. Each s ide of t he pis ton i s connected tofl uid press ure or fl ui d ret urn vi a external met al pipes which are connected t o t he valve unit . Each end of t he gear has at hreaded hol e which provi des for the fi tment of t he ti e-rod. The external ends of t he st eeri ng gear are s eal ed wit h bootswhich prevent t he ingres s of dirt and mois t ure and al low for verti cal movement of the t ie-rods wi th the s us pens ion inaddi ti on t o li near movement when t he s teeri ng wheel i s t urned. The boot s are s ervi ceable it ems and are ret ai ned on t hegear hous ing and t he t ie-rod wi th ti es .
Valve Unit
• NOTE: Typi cal valve unit shown

diamet er in i ts central sect ion. The smal ler diamet er allows the t ors ion bar t o t wist in res pons e t o t orque appli ed from t hes teeri ng wheel in relati on t o t he grip of the t yres on t he road surface. The pi nion s haft has machined t eet h on it s cent raldiamet er whi ch mat e wit h t eeth on the s t eering gear rack. A s lot , machi ned in t he upper end of t he pini on s haft mateswit h t he dog-t oot h on the i nput s haft . The pinion s haft l ocat es in the pi ni on housi ng and rot ates on bal l and roll erbearings .
POWER STEERING PUMP - TD4
ItemPart NumberDescription1-Pres s ure out put port (t o s t eering gear val ve unit )
2-Pull ey
3-Sucti on port (from res ervoi r)The pump i s a vari abl e dis placement, vane t ype pump which s uppl ies t he required hydraulic pres sure t o the st eeri ng gearvalve unit . The pump is locat ed at t he front of t he engine and i s dri ven by the Front Engine Auxil iary Dri ve (FEAD) Poly Veebelt which i s direct ly driven from the cranks haft . The out put from t he pump i ncreas es proporti onall y wi th the l oad appl iedt o the st eeri ng val ve uni t. A s el f-adjus ti ng tens ioner is fit t ed to maint ai n t he correct t ens ion on the bel t.
The pump consi st s of a cart ridge s et which cons is t s of 11 vanes and a rot or. These are mount ed on t he input s haft and ares urrounded by a variable di spl acement cam ring. The vanes rotat e wit hin the cam ri ng and are driven by t he s haft. As thevanes rotat e, the cam ri ng caus es the space between t he vanes to increase. This causes a depres si on between t he vanesand fl uid i s drawn from t he res ervoir vi a t he suct ion hos e int o t he s pace between the vanes. As t he s haft rotat es , t he inl etport i s clos ed to the vanes which have drawn in fluid, t rapping t he fluid bet ween t he vanes . The cam ring caus es t he s pacebetween t he vanes to reduce and cons equenti ally compress es and pres s uri zes t he hydrauli c fl ui d t rapped between t hem.Furt her rotat ion of t he s haft moves the vanes t o the out let port . As t he vanes pas s t he port plat e, the pres s uri zed fl ui dpass es from the pump out let port into the press ure hose to the s t eering gear.
The cam ring can move wi thi n t he val ve body. By moving the cam ri ng it i s poss ibl e to vary t he eccentricit y of t he s haftand t he vanes i n rel ati on to the cam ri ng. As t he eccent rici ty i s decreased, t he volume of hydraulic flui d t rapped bet weent he vanes decreases , mai nt aining a cons t ant flui d output. This reduces t he power and torque required to turn t he pumpand t herefore improves engine economy. The pump has an int ernal regulati ng valve which controls t he eccentricit y of t hecam ring and t herefore vari es the flow rat e accordi ng to demand.
At low engi ne s peeds , the i nternal dis placement of the vari able di spl acement pump i s at it s maximum t o generate thecont rol led fluid out put. As t he pump s peed increas es wit h engine s peed, t he i ncreas ed flow ins ide t he pump generates aback press ure wit hin the pump. This back pres s ure causes an internal regul ati ng val ve to move t he the cam ri ng andreduce t he int ernal di spl acement of the pump to maint ian t he cons t ant flui d fl ow from the pump.
A regul ati ng, pres s ure reli ef val ve wit hin t he pump l imi ts the maxi mum press ure s uppl ied t o t he s teeri ng gear t o 115 bar
(1667 l bf in2) ± 4 bar (58 lbf i n2) and al so li mit s t he maximum fl ow t o 8.8 l/min (1.93 gal/min) ± 0.5 l /min (0.1 gal /min)
at 10 bar (145 bf i n2). The pump has a dis placement of 9.6 cc/rev (0.58i n3/rev).
POWER STEERING PUMP - i6
ItemPart NumberDescription
1-Sucti on port (from res ervoi r)
2-Pull ey

Publi s hed: 11-May-2011
Power Steering - Power Steering
Diagnosi s and Tes ti ng
For addit ional informat ion.REFER to: St eering Sys tem (211-00 Steeri ng Sys t em - General Informati on, Di agnos is and Tes ti ng).