2006 LAND ROVER FRELANDER 2 engine

Publi s hed: 11-May-2011
Exhaust System - TD4 2.2L Diesel - 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

4. W ARNING: Thi s s tep requi res t he aid of
another technician.
4.
Vehicles with petrol engine Remove and dis card t he gas ket .
5.
All vehicles 6. NOTE: Do not dis ass embl e further if t he component i s removed
for acces s onl y.
Remove t he rubber mount s .
6.
Installation To i nst all , revers e t he removal procedure.
1.

8.
9. CAUTION: Before dis connecti ng or removing t he
component s, make sure t he area around t he joi nt faces
and connecti ons are clean. Plug open connecti ons to
prevent cont aminati on.
9. 10. CAUTION: Before dis connecti ng or removing
t he components , make s ure the area around t he joi nt
faces and connecti ons are cl ean. Plug open connect ions
t o prevent cont aminati on.
10.
Installation Apply ant i-sei ze compound t o t he s ens or and pipe union t hread.
Refer t o: Specificati ons (303-08B Engine Emis si on Control - TD4 2.2L
Di es el, Specifi cat ions ).
1.
Inst all t he temperat ure sens or.
T orque: 35 Nm 2.

Publi s hed: 11-May-2011
Fuel System - General Information - Fuel System BleedingTD4 2.2L Diesel
General Procedures
Special T ool(s) 310-163
Bl eeder, Fuel Sys t em
• W ARNINGS: Avoid flames , s parks or li ght ed s ubs t ances .
W ai t for a mini mum of 1 minute aft er the engine has s t opped before carryi ng out any
repair t o t he fuel inject ion
s ys t em. CAUTION: Make s ure that the area around t he component is cl ean and free of forei gn m
at erial .
This procedure is neces s ary if any of the foll owing fuel s yst em
component s are removed, di sconnect ed or replaced: Fuel tank, low
pres s ure fuel lines or t he fuel fi lt er.
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m and
Ornament ati on, Removal and Ins tal lat ion).
2. 3.
CAUTIONS: Ext reme cl eanli ness must be exerci sed when
handl ing t hese components . Be prepared t o collect es caping fuel.
Di sconnect t he fuel li ne.
3. 4. CAUTION: Be prepared to col lect escaping fuel .
• NOTE: Make s ure that t he fuel fl ow direct ion arrow on
t he s pecial t ool i s pointi ng t owards t he fuel fi lt er.
Inst all t he s pecial t ool between the fuel s upply
l ine and t he fuel fi lt er.
Speci al Tool (s ): 310-163 Pri me t he fuel fil ter by s queezing the hand
pump s everal ti mes unti l the pump is hard. 4.
Remove t he s pecial t ool s. 5.

5-Vapor pipe t o evaporat ive emis s ion cani s ter
6-Vapor purge pipe t o i ntake manifold
7-Fuel del ivery pi pe to engi ne8-Breat her pi pe
ItemPart NumberDescription1-Roll Over Valve (ROV)
2-Cros s over t ube as sembl y
3-Fil l li mit vent val ve4-Coars e fuel fil ter
5-Fuel gage s ender uni ts
6-Primary fuel fi lt er7-Fuel del ivery modul e
8-Fuel fil ter el ement
OVERVIEW
The 70 l it er s addle-t ype fuel t ank is l ocat ed bel ow t he rear s eat and as t ri de the drives haft.
The fuel t ank is manufact ured us ing t he lat est s i x-layer lami nat ed blow-moldi ng technol ogy providing bot h high mechanicals trengt h and complet e emis s ions i ntegri ty. The fuel fill er neck i s produced from aluminum t o balance high-st rength wit hlow-weight. In t he event of an accident damagi ng the fil ler neck, an i nlet check valve i n t he tank's fil ler s tub prevent s fueles caping.
A s i ngl e pump s uppl ies t he engine's fuel demands whil e als o s upplying t he fuel t o power the vent uri. The rapi d flow of fuelt hrough the venturi nozzle creat es a depres s ion whi ch draws fuel back across the s addle i nto the pump si de of the tank.
The fuel gage s enders are s ealed unit s whi ch us e magnet ic actuat ion i n place of electrical contact s; t his prevent s the

problem of chemi cal contami nat ion of el ect ri cal components .
To meet on-board refuel ing vapor recovery (ORVR) requi rements , t he fuel t ank and as soci ated component s are des i gned t omi ni mi ze fuel vapor los s duri ng refuel ing. This i s achi eved by prevent ing fuel vapor from t he fuel t ank vent ing direct ly tot he atmos phere. Ins t ead fuel vapor is di rected into the evaporati ve emis s ion (EVAP) canis t er where i t is s t ored beforebeing purged at i ntervals to the engine’s intake mani fold.For addit ional informat ion, refer t o: Evaporat ive Emi s si ons (303-13 Evaporat ive Emi ss ions , Descripti on and Operat ion).
Roll Over Valve (ROV)
The ROV i s connected vi a pipes t o a l iquid vapour separat or. The s eparator i s connected via a pipe to t he t ank breatheroutl et in t he pump module fl ange. The ROV contai ns a non-ret urn val ve, whi ch cl oses i n t he event of t he vehi cl eoverturning, prevent ing l iquid fuel escaping from the tank via the breat her pi pe.

Publi shed: 13-Jul-2011
Fuel Tank and Lines - I6 3.2L Petrol - Fuel Tank and Lines
Diagnosi s and Tes ti ng
Principles of Operation
For a detail ed descripti on of the fuel tank and l ines s ys t ems , refer t o t he rel evant Des cript ion and Operat ion s ecti on in theworks hop manual .REFER to: Fuel Tank and Lines (310-01A Fuel Tank and Lines - 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.
• NOTE: For di agnos t ic purpos es the cyli nders are divided i nt o t wo banks: Bank 1 - Cyl inder numbers 1, 2 and 3. Bank 2 -Cylinders 4, 5 and 6
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 Inspection
MechanicalElectricalFuel l eaksDamaged fuel l inesDamaged push connect fit t ingsFuel l evelFuel contami nati on/grade/quali tyDamaged fuel t ank fi ller pipe capDamaged fuel t ank fi ller pipe
FusesLoos e or corroded elect rical connect orsHarnes s esFuel Pump Dri ver Module (FPDM)Central Junct ion Box (CJB)Fuel pump relayEngine Control Modul e (ECM)
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, al ternat ively, check forDi agnos ti c Trouble Codes (DTCs) and refer t o t he DTC Index.4.
Symptom Chart
SymptomPossible CauseAction
Engine cranks , but does not fi reEngine breat her sys temdi sconnect ed/res trict edIgnit ion s yst emFuel sys temEl ect ronic engine controls
Ens ure t he engi ne breat her s ys tem is free fromres t ri ct ion and is correct ly i nst all edFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).
Engine cranks and fires , but wil lnot s tartEvaporati ve emis s ionspurge val veFuel pumpSpark pl ugsIgnit ion coil fai lure(s )
For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel pump t es t s . Check for DTCs and refert o DTC Index in t his s ecti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Di fficul t col d s t artCheck engi ne cool antl evel /anti -freeze cont entBat teryEl ect ronic engine controlsFuel pumpEvaporati ve emis s ionspurge val ve
Check the engine coolant level and condit ion.REFER to: Specifi cat ions (303-03A EngineCooli ng - I6 3.2L Petrol, Speci fi cat ions ).Ens ure t he batt ery i s in a ful ly charged ands erviceable condi ti onFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).

SymptomPossible CauseAction
Di fficul t hot st artInjector l eakEl ect ronic engine controlsEvaporati ve emis s ionspurge val veFuel pumpIgnit ion s yst emInjector l eak
Carry out inject or leak tes t s, i nst all newi nject ors as neces sary.REFER to: Fuel Inject or (303-04A Fuel Chargingand Controls - I6 3.2L Pet rol , Removal andInst all at ion).For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Di fficul t t o s tart aft er hot s oak(vehi cl e s tanding, engi ne off,aft er engi ne has reachedoperat ing t emperature)
El ect ronic engine controlsEvaporati ve emis s ionspurge val veFuel pumpIgnit ion s yst em
Carry out inject or leak tes t s, i nst all newi nject ors as neces sary.REFER to: Fuel Inject or (303-04A Fuel Chargingand Controls - I6 3.2L Pet rol , Removal andInst all at ion).For elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For purge valve t est s .REFER to: Evaporati ve Emis s ions (303-13Evaporati ve Emis s ions, Di agnos is and Tes t ing).For fuel s ys t em t est s . Read DTCs and refer t oDTC Index in t his secti onFor ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).
Engine s t al ls s oon after s tartBreat her sys temdi sconnect ed/res trict edECM relayEl ect ronic engine controlsIgnit ion s yst emAi r intake s ys temrest ri ctedAi r leakageFuel lines
Ens ure t he engi ne breat her s ys tem is free fromres t ri ct ion and is correct ly i nst all edFor ECM rel ay and electroni c engi ne cont rol st est s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).Check for blockage i n air cl eaner element andair i ntake s yst emCheck for leakage in ai r int ake sys temFor fuel li ne tes t s. GO to Pinpoint Test A.
Engine hes it at es /pooraccel erati onFuel pres sure, fuel pump,fuel l inesInjector l eakAi r leakageEl ect ronic engine controlsIgnit ion s yst emTrans mi ss i on malfunct ionRes trict ed pedal t ravel(carpet, et c)
For fuel pres sure t est s . GO t o Pinpoint Tes t B.For fuel li ne tes t s. GO to Pinpoint Test A. Forfuel pump t es ts , check DTCs and refer to DTCIndex i n t his s ecti onCarry out fuel inject or leak t es t s, i nst all newi nject ors as neces sary.REFER to: Fuel Inject or (303-04A Fuel Chargingand Controls - I6 3.2L Pet rol , Removal andInst all at ion).Check for leakage from ai r intake s ys temFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A EngineIgni ti on, Di agnos is and Tes t ing).For trans mi s si on s ys t em t es ts .REFER to: Di agnos ti cs (307-01 Aut omati cTrans mi ss ion/Transaxle, Di agnos is andTes ti ng).Ens ure accel erator pedal i s free from res t rict ion
Engine backfiresFuel pump, fuel l inesAi r leakageEl ect ronic engine controlsIgnit ion s yst emSt icking vari abl e cams haftt iming (VCT) hub
For fuel pump t es t s . Read DTCs and refer t oDTC Index in t his secti on. For fuel l ine t est s .GO to Pi npoi nt Tes t A.Check for leakage from ai r intake s ys temFor elect roni c engi ne cont rol t es t s .REFER to: El ect ronic Engine Cont rols (303-14AElectronic Engine Controls - I6 3.2L Petrol ,Di agnos is and Tes ti ng).For ignit ion s ys tem tes t s.REFER to: Engine Ignit ion (303-07A Engine