2006 LAND ROVER FRELANDER 2 engine

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Engine Emission Control
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the engine emis s ion control s ys tems , refer to the relevant Des cri pt ion and Operati on s ect ionin the workshop manual.REFER to: Engine Emi s si on Cont rol (303-08B Engine Emi ss i on Cont rol - TD4 2.2L Dies el, Des cript ion 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
EGR valveEGR pi pes /hos esVacuum s ys t emEngine breat her s ys tem
W i ring harnes sElect rical connect or(s)Fus es (s )
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 CauseActionRough idl e, l ack of power under accel erati on,exces s ive fuel consumpt ion, exces s ive blacks moke
EGR valve s t uckCheck EGR valve for correct operati on.Check for relat ed DTCs and refer t o t he DTCIndex
Exces s ive engine bl ow-by/crankcas e press ureEngine breat her s ys temblocked/res trict edExces s ive engine wear
Check engine breat her s ys tem forbl ockage/res t ri ct ion. Check for exces si veengine wearREFER t o: Engi ne (303-00 Engi ne Sys t em -General Informati on, Di agnos is andTes t ing).
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 addi ti onalinformat 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 an up-t o-date cal ibrat ion cert ificate. W hen tes ti ng res is t ance al ways take t he res is t ance of t he DMMleads i nt 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: Ins pect connect ors for s igns of water ingres s , and pins for damage and/or corros ion.
• 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
P040500Exhaus t Gas Recirculat ionSensor A Circuit LowEGR Valve pos it ion s ensorvol tage below lower li mitCarry out t he pinpoint t est s as sociat ed wit hthis DTC usi ng t he manufacturer approveddi agnos ti c s yst emP040600Exhaus t Gas Recirculat ionSensor A Circuit Hi ghEGR Valve pos it ion s ensorvol tage above upper l imi tCarry out t he pinpoint t est s as sociat ed wit hthis DTC usi ng t he manufacturer approveddi agnos ti c s yst em
P042E00Exhaus t Gas Recirculat ionControl St uck OpenEGR Valve s tuck duri ng normalengi ne running - at tempt t ouns t ick valve unsucces s ful
Check/clear EGR valve fromobs t ructi on/s ti cking

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Exhaust Gas Recirculation
(EGR) Valve
Removal and Inst all ati on
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he EGR cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi neEmi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
2.
Installation
Inst all t he EGR cool er.
Refer t o: Exhaus t Gas Reci rculati on (EGR) Cooler (303-08B Engi neEmi ss i on Cont rol - TD4 2.2L Dies el, Removal and Ins tall ati on).
1.

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Exhaust Gas Recirculation
(EGR) Cooler
Removal and Inst all ati on
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - TD4 2.2L Dies el(501-02 Front End Body Panel s, Removal and Ins tal lati on).
2.
Drai n t he cool ant .
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03BEngine Cooli ng - TD4 2.2L Di esel , General Procedures ).
3.
Remove t he heat ed oxygen s ens or (HO2S).
Refer t o: Heat ed Oxygen Sens or (HO2S) (303-14B Electroni c EngineControls - TD4 2.2L Dies el, Removal and Ins tal lati on).
4.
5.
6.

T orque:
10 Nm Connect t he EGR valve elect rical connector.
4.
Inst all t he exhaus t manifol d heat shi eld.
T orque: 10 Nm 5.
6. CAUTIONS: Make s ure that t he component is cl ean, free of foreign
mat eri al and l ubricant. "Make s ure t hat a new component i s ins t al led. "
Inst all t he cool er t o i nlet manifold EGR pi pe.
T orque: 10 Nm 6.
Connect t he cool ant hos es and s ecure wit h t he clips .
7.
Inst all t he HO2S wi ring harnes s bracket.
T orque: 8 Nm 8.
Inst all t he HO2S.
Refer t o: Heat ed Oxygen Sens or (HO2S) (303-14B Electroni c Engine
Controls - TD4 2.2L Dies el, Removal and Ins tal lati on).
9.
Fil l and bl eed the cooli ng s ys t em.
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03B
Engine Cooli ng - TD4 2.2L Di esel , General Procedures ).
10.
Inst all t he s econdary bulkhead cent er panel.
Refer t o: Secondary Bulkhead Cent er Panel - TD4 2.2L Dies el (501-02 Front End Body Panel s, Removal and Ins tal lati on).
11.

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Crankcase Vent Oil Separator
Removal and Inst all ati on
Removal
• CAUTIO NS:
Make s ure that all openi ngs are s ealed. Us e new bl anking caps .
Make s ure that t he area around t he component i s cl ean and free of foreign mat eri al .
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).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he thrott le body.
Refer t o: Thrott le Body (303-04B Fuel Chargi ng and Controls - TD42.2L Dies el , Removal and Inst all at ion).
3.
4.
5.

Publi s hed: 11-May-2011
Engine Emission Control - TD4 2.2L Diesel - Valve Cover Vent Oil Separator
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.
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).
1.
2. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
2.
Remove t he fuel rai l.
Refer t o: Fuel Rail (303-04B Fuel Chargi ng and Cont rol s - TD4 2.2LDi es el, Removal and Ins tal lat ion).
3.
4.

Publi s hed: 11-May-2011
Intake Air Distribution and Filtering - I6 3.2L Petrol - Intake Air
Distribution and Filtering
Des cript ion and Operat ion
COMPONENT LOCATION
ItemPart NumberDescription
1-Air i ntake duct - dirt y ai r
2-Air fil ter housi ng3-Res onat or
4-Air i ntake duct - cl ean air
5-Throt tl e body6-Intake manifold
OVERVIEW
The air i nt ake s ys t em has been des igned to:
make available the appropriat e air s uppl y t o t he engi ne,whil e providi ng a wade-proof s ys tem to ens ure vehi cl e off-road durabil it y
Fres h air i s s uppl ied i nto t he s yst em, t hrough the Left Hand (LH) vent locat ed on t he front fender. The vent is pos it ionedabove the vehicle's wade li ne to mini mize t he ris k of water entering t he s yst em. This pos it ioning of t he vent al so prevent shot air from the engine-compart ment being drawn int o t he engi ne.

A polyfibre porous duct provi di ng low int ake noi se, di rects ai r into the bas e of t he ri gid i njecti on-molded ai r fi lt er hous ing.The fi lt er hous ing is s upported on 4 elas tomer mount ings t o mi ni mi ze noi se transmis si on t o t he vehi cl e's body s truct ure. Aone-way drai n valve, incorporat ed in t he bas e of the fil ter hous ing, releas es any water t hat may have ent ered t he s yst em.Int ake air i s cl eaned as it pas ses t hrough an oi l-soaked fi lt er el ement which offers minimal obs truct ion to t he flow of ai r.
Clean ai r pas s es through the Mas s Ai r Fl ow (MAF) sens or and al ong a s ealed polypropylene duct to t he t hrot tl e body andint ake manifol d. The cl ean air duct features a s ingle quart er-wave res onator t ube to enhance engi ne sound quali ty duringint ake manifol d t ract s wit chi ng event s.
Computat ional flui d dynami cs were ext ens i vel y used in t he desi gn and refinement of the sys tem t o mi ni mize ai r-pres s uredrop.
The int ake manifol d i s capable of varyi ng bot h i ntake t ract length and pl enum volume. Two s eparate val ves cont rol thes efeat ures :
t he variable tract valve, andt he variable pl enum valve
Int ake Manifol d
ItemPart NumberDescription
1-Int ake manifol d2-Variable plenum valve
3-Variable tract valve
At low engi ne s peeds , long i nt ake tract s are functi oned to provi de opti mum engine torque; s hort er t ract s are us ed atmedium s peeds , agai n t o opti mize engine t orque for the exis t ing engine s peed range.
At higher engi ne s peeds t he benefit s of opt imizing t he t ract lengths are outwei ghed by neces si ty of mai ntai ni ng anappropri at e s upply of air t o meet t he engi ne's requi rements . Therefore, the pl enum val ve is opened t o create a s ingle,large plenum volume to provide t he maximum quant it y of air t o charge t he engi ne's cylinders .
Variable Induction System Functionality
Engine SpeedT ract ValvePlenum ValveEffectBelow 3800 rev/mClos edCl os edLong t racts
Between 3800 – 4800 rev/mi nOpenCl os edShort tract s
Above 4800 rev/minOpenOpenOpen pl enum
PRINCIPLE OF OPERATION
Low Engine Speed
• NOTE: Both throt t les clos ed. The ai r is routed t he long way.