2006 LAND ROVER FRELANDER 2 engine

Publi s hed: 11-May-2011
Climate Control - Heater Core
Removal and Inst all ati on
Removal
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.
Drai n t he cool ing s ys tem.
Refer t o: Cool ing Sys tem Drai ni ng, Fi lli ng and Bleeding (303-03AEngine Cooli ng - I6 3.2L Petrol, General Procedures).
2.
Remove t he s el ect or lever.
Refer t o: Sel ect or Lever As sembl y (307-05 Aut omat icTrans mi ss ion/Transaxle Ext ernal Cont rol s , Removal andInst all at ion).
3.
4.
Remove t he cowl s ide trim panel .
Refer t o: Cowl Si de Tri m Panel (501-05 Interior Tri m andOrnament ati on, Removal and Ins tal lat ion).
5.

ItemPart NumberDescription
1-Automat ic Temperat ure Cont rol (ATC) modul e2-Fuel Fi red Boos ter Heater (FFBH)
3-Auxili ary coolant pump
4-Ambi ent ai r temperat ure s ens or5-Auxili ary fuel pump
6-FFBH Recei ver
7-FFBH antenna mat chi ng unit
OVERVIEW
The Fuel fired Boos t er Heat er (FFBH) is rated at 5 kW and compensat es for t he rel ativel y low coolant t emperaturesinherent i n the di esel engine. The uni t is locat ed behind t he Right Hand (RH) front fender s plas h s hield and heat s enginecool ant downs tream of t he heat er core.
Operat ion of t he FFBH is controlled by the Aut omati c Temperature Control (ATC) module via the medi um s peed ControllerArea Net work (CAN) bus . Operati on of the FFBH i s influenced by:
Ambient air t emperat ureEngi ne cool ant temperat ure.
The FFBH wil l operate i f the ambient air t emperature is lower than 5 °C (41 °F) and s top if ambient t emperature reaches 8°C (46 °F). Operat ion of t he FFBH may als o be inhibit ed if t he fuel l evel drops below a predet ermi ned level .
Remote Operation - Vehicles from 2009MY
On vehicles from 2009MY the FFBH has remote operati on. The remote sys tem includes t he addi ti on of a FFBH receiver,

FFBH antenna mat chi ng uni t and a remote hands et for operati on of the s ys tem. The FFBH unit remains as previ ous l y fi tt edbut has upgraded s oftware. The Engine Cont rol Modul e (ECM) als o has a s oft ware cal ibrat ion upgrade. The ins trumentclus ter mes s age cent er di spl ays FFBH mes s ages when required.
AUTOMATIC TEMPERATURE CONTROL MODULE
The ATC module is mount ed in the center cons ole and is i ntegral wi th the control panel. The module works i n conjunct ionwit h t he ECM t o control al l aspects of heati ng, venti lat ion, and Air Condit ioning (A/C).For addit ional informat ion, refer t o: Cont rol Component s (412-01 Cli mat e Cont rol , Descripti on and Operat ion).
AUXILIARY FUEL PUMP
ItemPart NumberDescription
1-Fuel li ne connect or2-Non return valve
3-Solenoid coi l
4-Pl unger5-Fi lt er i nsert
6-Fuel li ne connect or
7-O-ring s eal8-Spring
9-Pi st on
10-Bus hThe auxi li ary fuel pump is mount ed on the RH s ide of t he fuel t ank and regulates t he fuel s upply t o t he FFBH. The pump isa s elf primi ng, s olenoid operat ed plunger pump, controll ed by a Puls e W idt h Modulation (PW M) s ignal from t he cont rolmodule i n t he FFBH. W hen the pump is de-energized, i t provides a pos it ive s hut-off of t he fuel s uppl y.

ItemPart NumberDescription
1-Combus t ion ai r fan2-Cool ant out let
3-Cool ant inlet
4-Burner ins ert5-Heat exchanger
6-Temperature s ens or
7-Exhaus t8-Fuel i nl et
9-Evaporat or
10-Air i nl et
Combustion Air Fan
The combus t ion ai r fan regul at es t he fl ow of air i nto t he FFBH t o s upport combus ti on of the fuel suppli ed by t he auxi liaryfuel pump. It i s als o us ed t o purge and cool the FFBH.
Burner Housing
The burner hous ing cont ai ns the burner i nsert and als o i ncorporat es connecti ons for t he exhaus t pipe, the coolant inl etfrom the auxil iary coolant pump and t he cool ant out let t o t he vehi cl e heater.
The burner ins ert i ncorporat es t he fuel combus t ion chamber, an evaporator and a gl ow pin and fl ame s ens or. Fuel from t heauxi li ary fuel pump is s uppl ied t o a vent uri, where it evaporat es and ent ers t he combust ion chamber to mix wit h air fromt he combus ti on air fan. The gl ow pin and fl ame s ens or provides t he igni ti on source for t he fuel:air mi xture and, oncecombus t ion i s es tabli shed, monit ors t he flame.
Heat Exchang er
The heat exchanger t ransfers heat generated by combus ti on t o the coolant . Two s ens ors are i nst all ed in t he heatexchanger cas ing t o provide the control modul e wi th i nput s of Engine Coolant Temperature (ECT). The cont rol module us est he temperat ure inputs t o control s ys tem operati on.
Air Inlet Hose and Muffler
A canis ter t ype muffler i s included in the ai r inlet s upply l ine. The muffler reduces the noi se caus ed by inducti on roar.
Exhaust Pipe and Muffler
The exhaus t pipe and muffl er di rects exhaus t combus ti on gases t o at mos phere below t he front RH wheel arch. Exhaus tvapor may be vi s ible when the FFBH i s running, dependi ng on atmos pheri c condit ions .
Control Module
The cont rol module cont rols and moni tors operati on of the FFBH sys tem. An int ernal flow of ai r from t he combust ion ai r fanvent il ates t he cont rol module to prevent i t overheat ing.

The cont rol module is powered by a permanent feed from the Bat t ery Junct ion Box (BJB), and communi cat es wi th t he ATCmodule over the medium speed Controller Area Network (CAN) bus .
AUXILIARY COOLANT PUMP
The auxi li ary coolant pump is mount ed on t he heater cas i ng and is us ed t o as si s t coolant flow through t he FFBH and t heheat er core.
The auxi li ary coolant pump runs conti nuous ly whi le the FFBH i s act ive. W hen t he FFBH is inact ive, cool ant flow is reli ant ont he engi ne cool ant pump. Operat ion of t he auxi li ary cool ant pump is controll ed by a power feed di rect from t he cont rolmodule wit hi n t he FFBH.
Stop/Start Vehicles - From 2010 MY
Duri ng a St op/Start cycle when the engine i s s hutdown and consequent ly the engine-driven coolant pump is st ati onary, thedesi red s et cabi n t emperature cannot be mai ntai ned for a prol onged period, especially in col d ambient t emperatures . Tocount eract this an auxi li ary electric coolant -pump, cont rol led by t he ECM (engi ne cont rol module), has been i ntegrat ed int ot he cooli ng s yst em t o mai ntai n the coolant flow t hrough t he cabi n’s heater core. This s upporti ng circulat ion prolongs thes et temperat ure set ti ng in the cabin and accordingly prevent s an earl y engi ne res t art .
On vehicles fit ted wit h a Fuel Fi red Boos ter Heat er (FFBH) t he addit ional auxil iary cool ant pump is not ins t al led. In it splace t he FFBH auxi liary cool ant pump is ut il ized t o circulat e t he cool ant i n an engine s hutdown s i tuati on. The pump isact ivat ed via t he FFBH by t he CJB (central junct ion box).For addit ional informat ion, refer t o: Starti ng Sys t em (303-06C Starti ng Syst em - TD4 2.2L Di es el, Vehicles Bui lt From:01-03-2009, Descripti on and Operat ion).
AMBIENT AIR TEMPERATURE SENSOR

ItemPart NumberDescription
1-Bat tery2-Fus e 17, BJB
3-Fus e 27, CJB
4-ATC modul e5-CJB
6-Engine Cont rol Modul e (ECM)
7-Ambi ent ai r temperat ure sens or8-Auxil iary fuel pump
9-Auxil iary coolant pump
10-FFBH Receiver (Vehicles from 2009MY )11-Ant enna matching unit

s tart fail ure or flameout, and decreas ed by one if a subs equent s tart is succes s ful . If t he event t imer i ncreas es t ot hree (over any number of drive cycl es), the cont rol module ent ers t he error lockout mode.Heat exchanger casing overheat: To prot ect t he s ys t em from exces s ive t emperatures , t he cont rol module ent erst he error l ockout mode if t he heat exchanger coolant temperat ure exceeds 125 °C (257 °F).Battery voltage out of limits: Error lockout wi ll occur if bat tery vol tage fall s bel ow 10.25 or ris es above 15.5 volt s .
The error lockout mode can be cleared usi ng the Land Rover approved di agnos ti c s ys t em, or by dis connect ing the bat terypower supply for a mi nimum of 10 s econds.
Remote Operation - Vehicles from 2009MY with FFBH Remote Control
The 868.3 MHz Radi o Frequency (RF) si gnal s t ransmit ted by the remote hands et are recei ved by the DAB/FFBH ant ennalocated i n t he LH rear s i de window. The s ignal s received by t he antenna are detected by t he FFBH receiver. A 'handshake's ignal is s ent back from the recei ver t o t he hands et t o confirm a val id on or off reques t and act ivate the handset LEDaccordi ngl y. The recei ver proces s es the s i gnal it recei ved and trans mi ts the appropriate si gnal s via a dedi cat ed bus t o theFFBH cont rol module.
• NOTE: The ‘handshake’ si gnal only confi rms hands et-receiver communi cat ions were s uccess ful , and not that t he FFBH hast urned on.
W hen t he FFBH is act ivated by the remote hands et, t he FFBH cont rol module will al low t he FFBH t o operate for 30 minutesor unt il an off request is received from t he remot e hands et or CJB. During t he 30 minut e period, the FFBH may operat e i neit her full l oad combus ti on, part load combus t ion or a controll ed idle phas e of operat ion, depending on t he t emperature oft he coolant i n t he heat exchanger.
Pre-burn Thresholds
The FFBH unit wi ll only acti vat e remotely if t he fol lowing thres hold condit ions are met:
Pre-burn batt ery vol tage check: ≥11.5V (volt age at FFBH terminals )Pre-burn coolant temperat ure check: ≤15°C (int ernal FFBH measurement )Pre-burn fuel l evel check: ≥7.5 lit ers (value s t ored i n FFBH at ignit ion off)
The fuel level val ue s tored wit hin t he FFBH unit i s only updated when t he engine i s running. W hen s t art ing t he FFBH viaremot e control wit h the engi ne off, the fuel l evel value us ed in the FFBH calculat ions wi ll be t hat s t ored at t he las t key offevent . It i s t herefore poss ibl e for t he FFBH t o fai l to operat e remotel y if t he engine was s t opped wi th a low fuel level; i ft he fuel tank i s s ubs equent ly refuell ed, the FFBH s t ored fuel l evel wil l st il l read l ow i f the engine has not been s tarteds ince refuel li ng.
If the FFBH does not act ivate due to low bat tery vol tage or l ow fuel l evel, t he FFBH cont rol module transmit s a mes s age ispass ed on t he medi um and high speed CAN bus es, vi a t he CJB to the i nst rument clus ter mes s age cent er which wil l dis playone of the foll owing mes s ages at i gnit ion on:
AUXILIARY HEATER UNAVAILABLE LOW FUELAUXILIARY HEATER UNAVAILABLE LOW BATTERY .
If bot h l ow fuel and low batt ery volt age mes sages are val id, t he ins trument cl ust er mes sage center wi ll alt ernate bet weent he two mes sages .
Remote Control ‘Park Heat’ to ATC ‘Supplementary Heat’ Transitions
• NOTE: The FFBH can s ti ll be acti vat ed by t he ATC module as previ ous l y descri bed
If the FFBH has been operated remot el y (‘park heat’) and the vehicl e is st art ed whilst the FFBH i s s ti ll act ive, it willt ransi ti on int o t he ATC-control led ‘s upplement ary heat’ mode if t he ATC request s i t.
Shoul d t he ATC t hen send a mess age t o t he FFBH to turn off, the FFBH will remain active if 30 minut es has not yetelaps ed from t he ori ginal remot e cont rol ‘park heat ’ request . Once t he remai nder of 30 mi nut es has elaps ed, t he FFBH wil lt urn off.
Swit chi ng Point Temperatures
W hen remotel y s tarted t he FFBH us es a different s et of s wit chi ng poi nt temperat ures t o t he normal ‘supplement al heat’mode. Thi s is because the remot e s tart feature can s tart the FFBH wi th the engine off – t hus different t hres hol ds arerequired t o opti mis e t he heati ng of the engine coolant.
Swit chi ng Point Temperatures

Publi s hed: 11-May-2011
Auxiliary Climate Control - Fuel Fired Booster Heater
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 axle
s tands .
Rais e and s upport t he vehi cl e.
2.
Drai n t he cool ant .
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 ).
3.
Remove t he RH fender s plas h s hield.
Refer t o: Fender Spl ash Shi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
4. T orque:
10 Nm 5.