2006 LAND ROVER FRELANDER 2 engine

Publi s hed: 11-May-2011
Four-Wheel Drive Systems - Four-Wheel Drive Systems
Des cript ion and Operat ion
COMPONENT LOCATION
• NOTE: Manual t rans mi ss ion shown, automat ic t rans mis s ion si mil ar.
ItemPart NumberDescription1-Trans mis s ion
2-Power Trans fer Uni t
OVERVIEW
The power trans fer unit is l ocat ed at the rear of t he engine and i s att ached di rectly to the trans mi ss i on cas ing and to theengi ne cyl inder block via a bracket . The power t rans fer unit i s a common unit bet ween the pet rol and dies el engi nevariant s and als o aut omat ic and manual t rans mis s ions .

Publi s hed: 25-Nov-2011
Transfer Case -
Lubricants, Fluids, Sealers and AdhesivesItemLand Rover Part No.
Input s haft s pli nes grease6G92M1C27AA
Power trans fer uni t fl ui d - vehicles wi th 3.2 pet rol and 2.2 di eselLR003137Power trans fer uni t fl ui d - vehicles wi th 2.0 pet rolLR003136
C apacitiesDescriptionLubricantCapacity (liters/pints/US quarts)
Power trans fer uni tBOT 118 PLUS 75W -900.75/1.3/0.79
General Specification
ItemRatio3.2 Pet rol aut o3.750:1
2.2 Dies el manual4.533:1
2.2 Dies el aut o3.329:12.0 Pet rol aut o2.583:1
Torque Specifications
DescriptionNmlb-ft
Axle mount ing bracket bolt s2418Oi l drain pl ug3526
Oi l fil ler plug3526
Pini on nut4835Power trans fer uni t front mount ing bracket heat s hiel d107
Power trans fer uni t bracket t o engine block bolt s6548
Power trans fer uni t bracket t o power trans fer uni t bol ts6548Power trans fer uni t to trans mi s si on hous i ng bol ts6548

Publi s hed: 11-May-2011
Transfer Case - Power Transfer UnitTD4 2.2L Diesel, Vehicles With: M66
6-Speed Manual Transmission AWD
Removal and Inst all ati on
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e t he vehicle on a li ft .
1.
Remove t he dri ves haft .
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er(DPF) (205-01 Driveshaft, Removal and Ins tal lati on).
2.
Remove t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculateFil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removaland Inst all at ion).
3.
Remove t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2LPetrol, Removal and Ins tall ati on).
4.
Remove t he RH halfs haft.
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removaland Inst all at ion).
5.
6.

Publi s hed: 11-May-2011
Transfer Case - Power Transfer UnitTD4 2.2L Diesel, Vehicles With: M66
6-Speed Manual Transmission AWD
Removal and Inst all ati on
Removal
Rais e t he vehicle on a li ft .
1.
Remove t he dri ves haft .
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er (DPF) (205-01 Driveshaft, Removal and Ins tal lati on).
2.
Remove t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculate Fil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removal
and Inst all at ion).
3.
Remove t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2L
Petrol, Removal and Ins tall ati on).
4.
Remove t he RH halfs haft.
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removal
and Inst all at ion).
5. 6.

5-Gasket
6-Tailpi pe fi nis her (opti onal )
7-Mount ing rubber (6 off)8-Rear muffler
9-Cent re muffler
10-Flange11-Bracket
12-Catalyt ic converter (2 off)
13-Flange14-Catalyt ic converter (2 off)
15-Exhaus t manifol d gas ket s
OVERVIEW
The 3.2L SI6 exhaus t s yst em i s fabricated from s tai nl ess st eel and is s upplied as two separat e as sembl ies ; a front s ect ionincorporat ing t wo catal yt ic convert ers and a rear sect ion i ncorporat ing centre and rear s i lencers.
EXHAUST MANIFOLDS
The exhaus t manifold compri s es two separat e manifold as s embli es . One mani fol d is us ed for cyli nders 1 t o 3 and thes econd mani fold is us ed for cyli nders 4 t o 6. The manifolds are s eal ed to the cyli nder head wi th a gas ket and s ecured wit h14 bolt s .
Each manifol d compri ses t hree fabri cat ed branches whi ch merge i nto an int egral cat alyti c convert er. A threaded bos s isposi ti oned where t he t hree branches merge and provi des for t he fi tment of a pre-catalys t HO2S. The cat alyti c convert eroutl et s have offs et flanges which mat e wi th corres pondi ng fl anges on t he front s ect ion exhaus t s ys tem.
A bracket on each out let flange all ows for t he att achment of an exhaus t mani fold heat s hield.
FRONT SECTION
The front sect ion has t wo flanged pi pes which mat e wi th the offs et fl anges of t he exhaus t manifol ds. The flanges ares eal ed wit h gas ket s and s ecured wit h bolt s . The fl anges are connected vi a curved pipes t o decouplers which provide afl exi ble joint i n the sys tem. The out let from each decoupl er compris es a curved pipe wit h a t hreaded bos s whi ch providesfor t he fit ment of a pos t -catal ys t HO2S.
Each pi pe is connect ed i nt o a smal ler catalyt ic converter whi ch in t urn is connected to a doubl e fl ange which mat es wit ht he rear s ect ion of t he exhaus t s ys t em.
Two mount ing rubbers are l ocat ed at the rear of the flexible coupli ng and are at t ached t o a bracket mounted on the fronts ubframe.
REAR SECTION
The rear s ect ion has a doubl e fl ange which mat es wit h t he doubl e fl ange of the front s ect ion. The doubl e flanges of eachs ect ion are s eal ed wi th a gas ket and s ecured wit h s tuds , washers and nuts . Two s hort pipes from the double fl angeconnect int o the cent re muffl er.
The cent re muffler is a fabricated unit wit h a capaci ty of 7.6 li ters. The muffl er compris es a pair of perforat ed baffle t ubescont ained wi thin the muffler body. The t wo baffle tubes merge into one s ingle t ube which provi des the out let from t hemuffler. A rubber mounti ng is at t ached t o t he rear of the muffler and att aches t o a hanger bracket l ocat ed on theunders ide of t he vehi cl e fl oorpan.
A s i ngl e pipe from t he rear of the centre muffl er is rout ed along t he unders ide of the vehi cl e body to the rear muffler. Thepipe ent ers t he rear muffl er t hrough a connect ion i n t he forward face of the muffl er.
The rear muffl er i s a fabri cat ed uni t wit h a capacit y of 29.3 l it ers . The rear muffler i s pos i ti oned t rans vers ely at t he rear oft he vehi cl e, forward of the rear bumper. The muffler compri ses baffl e plat es and perforated baffle tubes . Each end of t hemuffler body has an outl et which direct exhaus t gas ses to exit at t he rear of t he vehi cl e. The muffler is support ed by as ingle rubber mount ing on t he Left Hand (LH) s ide and by t wo rubber mounti ngs on the Right Hand (RH) s ide.
CATALYTIC CONVERTERS
The cat alyt ic converters are fit t ed in t he front s ect ion of t he exhaus t s ys t em, aft er the HO2S.
The HO2S moni tors the exhaust gas s es leavi ng t he engi ne. The engine management s ys t em us es t hi s informat ion t oprovide accuratel y met ered quant it ies of fuel t o t he combus t ion chambers t o ens ure the mos t efficient us e of fuel and t omi ni mi se the exhaus t emi s si ons .
In the cat alyti c convert ers , t he exhaus t gas es are pas s ed t hrough honeycombed ceramic el ement s coated wi th a s peci als urface t reat ment cal led 'was hcoat '. The was hcoat i ncreas es t he s urface area of the cerami c element s by a fact or ofapproximat el y 7000. O n top of t he was hcoat i s a coat ing cont ai ning plat inum, whi ch is t he act ive cons ti tuent forconvert ing harmful emi ss i ons into inert by-product s. The pl at inum adds oxygen t o the carbon monoxi de and thehydrocarbons i n t he exhaus t gases , to convert t hem i nto carbon di oxi de and water respecti vel y.

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Exhaust System
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the exhaust s ys tem, refer t o t he relevant Descripti on and Operat ion s ect ion in t he works hopmanual. REFER to:
Exhaus t Sys t em (309-00A Exhaus t Sys t em - I6 3.2L Pet rol , Descri pti on and Operat ion),Exhaus t Sys t em (309-00B Exhaus t Sys t em - 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 s ys tem int egrit y and obvi ous s igns of mechanical damage.2.
Visual InspectionMechanical
LeaksMet al fati guePipes , mufflers and cat alyt ic convertersJointsMounti ngsClearance around component 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 ep.3.
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.4.
Symptom Chart
SymptomPossible CauseAction
Exces s ivelynois y/l eaki ng exhaus tExhaus tsys t em/component sInspect exhaus t sys t em, refer t o Vi sual Ins pect ion aboveRecti fy l eaks or Inst all new component s as neces s ary. Refert o Removal and Ins tall ati on ins truct ions i n t his s ect ion
Loss of powerRes t ri ct ed exhaus tsys t emFuel s yst emIgnit ion sys temElect roni c engi necont rol
Inst all new exhaus t component s as neces s ary. Refer t oRemoval and Ins tal lati on ins t ructi ons i n t his s ecti onFor fuel s ys t em t est s .REFER t o: Fuel Tank and Li nes (310-01A Fuel Tank and Li nes -I6 3.2L Pet rol , Diagnos is and Tes t ing).For ignit ion s ys tem tes t s.REFER t o: Engine Ignit ion (303-07A Engine Igni ti on, Diagnos isand Tes ti ng).For electroni c engi ne cont rol t est s .REFER t o: El ect ronic Engine Cont rol s (303-14A El ect ronicEngine Controls - I6 3.2L Petrol , Diagnosi s and Test ing) /Elect ronic Engine Cont rols - 2.2L Durat orq-TDCi (DW ) Di esel(303-14 Electronic Engine Controls - 3.2L, Di agnos is andTes ti ng).

5. CAUTION: Di scard the bolt s .
T orque: 27 Nm 5.
Speci al Tool (s ):
310-121 T orque:
M18 45 Nm M5
6 Nm 6.
Installation To i nst all , revers e t he removal procedure.
1.
2. NOTE: For NAS vehicl es onl y.
If required, carry out a l ong drive cycl e.
Refer t o: Powertrain Cont rol Modul e (PCM) Long Drive Cycle Sel f-Tes t
(303-14 Electroni c Engine Controls - 3.2L, General Procedures).
2.

Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Exhaust System
Removal and Inst all ati on
Removal W ARNING: Observe due care when worki ng near a hot exhaust s ys tem.
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
All vehicles
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.
Vehicles with petrol engine T orque:
25 Nm 2.
Vehicles with diesel engine T orque:
40 Nm 3.
All vehicles