2006 LAND ROVER FRELANDER 2 engine

9. CAUTIONS:
Be prepared t o collect es caping flui ds .
Do not al low the power s teeri ng fl uid l evel i n t he powers teering fluid res ervoir t o fal l bel ow t he mi ni mum powers teering fluid level. Failure t o fol low this ins truct ion may res ulti n damage to the power s teering s yst em.
Make s ure the engine is s wi tched off as s oon as t he ful l4 l it res of power s teeri ng fl uid has ent ered t he power s t eeringfluid res ervoir.
Fl ush the power s teeri ng s yst em.
St art t he engi ne
W it h ass i st ance turn the st eeri ng sl owly l ock to lock 3t imes at approximat ely 1 revolut ion every 5 seconds .
Conti nue to fl us h t he power s teeri ng s ys t em unt il 4l it res of power st eering fl ui d has been added to t hepower st eeri ng res ervoir. Thi s s houl d t akeapproximat ely 30 s econds .
10. CAUTION: Be prepared to col lect es caping fluids .
Remove t he s uit abl e funnel.

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

ItemPart NumberDescription
1-Fl ui d cool er2-Sucti on hose - res ervoir t o pump
3-Res ervoir
4-Fl ui d ret urn pipe - s t eering gear to cooler5-Ti e-rod
6-Hi gh pres s ure feed pipe - pump to s t eering gear
7-Power s teeri ng pump8-Val ve uni t
9-Bul khead s eal and gas ket
10-Bol t11-St eering gear
OVERVIEW
The power st eering sys tem compri ses a hydraul ic s t eering gear, a power s t eering pump, res ervoi r and a fl uid cooler onpetrol engine derivati ves .
The s teeri ng gear is a convent ional end take-off, rack and pi ni on power as s is t ed unit , mount ed on t he rear of t hes ubframe.
Different power s teering pumps are used on the TD4 di esel engine and t he i6 pet rol engine. A vari abl e dis placement vanepump i s used on the di esel engine t o give i mproved engine economy. A fi xed di s pl acement vane pump i s used on thepetrol engine to provi de refinement and res pons i venes s. Bot h pumps have high flow rates whi ch enhance t he s teeri ngperformance.
Petrol engine vehicles are fit ted wit h a fluid cooler t o cool t he power s teeri ng fl uid from t he fi xed di s pl acement pump.

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

3-Pres s ure out put port (t o s t eering gear val ve unit )
The pump i s a fixed dis placement, vane type pump which s uppl ies hydrauli c pres sure to t he st eeri ng gear valve unit . Thepump i s located at t he rear of t he engi ne and is driven by t he Rear Engi ne Auxi liary Drive (READ) Poly Vee bel t which i sindirect ly driven from t he cams haft s . The pump s uppl ies a cons tant fl ow rate, t herefore the out put i s i ndependent ofpump/engine s peed. A s el f-adjus ti ng tens ioner is fit t ed to maint ai n t he correct t ension on the bel t.
The pump contains a number of vanes which rot ate wit hin a cam ri ng and are driven by t he i nput s haft . As the vanesrot ate, t he cam ring causes t he s pace bet ween the vanes t o increas e. Thi s caus es a depres s ion bet ween the vanes andfl 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 t he pres surized fluidpass es from the pump out let port into the press ure hose to the s t eering gear.
The pres s urized fluid is s ubject t o cont rol by a flow cont rol and pres s ure relief valve. The fl ow control valve maintai ns acons t ant flow of flui d s uppl ied t o t he s teeri ng gear irres pecti ve of engi ne s peed variati ons . The pres s ure reli ef val ve limit st he maximum pres sure on t he output s ide of t he pump. A met eri ng orifice i s included i n t he dis charge port of the pump.
If the pres s ure in t he ori fi ce reaches a predetermined l evel , a s pring loaded bal l in t he cent re of the flow cont rol valve isli ft ed from it s s eat and al lows pres s uri zed flui d t o recircul ate wit hi n t he pump. The pres sure rel ief valve wi ll operate if t hedis charge from the pump is rest ri ct ed, for example, s teeri ng held on full l ock. If the output from the pump is bl ocked, al loutput is recirculat ed t hrough the pump. In t his condi ti on, as no fresh fl ui d i s drawn i nto the pump from t he res ervoir, thefl uid t emperat ure i nsi de t he pump wil l increas e rapi dl y. Cons equent iall y, periods of operati on of the s t eering gear on ful llock s houl d be kept to a mi nimum to prevent overheati ng of the pump and the flui d within it .
The pump has an i nternal pres s ure reli ef valve whi ch als o i ncorporat es a flow cont rol val ve. The press ure rel ief val ve li mit s
t he maximum pres sure s uppl ied t o t he s teering gear to 125 bar (1812 lbf in2) ± 4 bar (58 l bf in2). The flow control val ve
li mit s t he maximum flow t o 8.8 l/mi n (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 11 cc/rev (0.67 i n3/rev).
RESERVOIR
ItemPart NumberDescription1-Cap
2-Body
3-Ret urn connect ion (DW 12 - from s teering gear) (i6 - from fluid cool er)4-Sucti on connecti on (t o power s teeri ng pump)
5-Bracket att achment moul dings
The fl uid res ervoi r is locat ed on a bracket in the RH s ide of t he engi ne compartment, behi nd t he headl amp as sembl y. Theres ervoir compri s es a body, cap and filt er. The purpos e of t he res ervoir i s t o cont ain a surplus of t he hydraul ic fluid in thes ys t em t o al low for expans ion and cont ract ion of t he fl uid due t o t emperature vari ations .
The fl uid l evel ens ures t hat t he s uppl y connecti on on t he bot t om of t he res ervoir i s covered wit h fluid at al l operat ingvehi cl e at ti tudes. Any ai r which is pres ent i n t he s ys t em i s exhaus ted from t he s ys tem i n t he res ervoir.
The body is a plas ti c moulding wit h two port s at the bot tom which provi de for t he connecti on of the s ucti on supply andret urn hos es . Moul ded markings on the s ide of t he reservoi r denot e the upper and lower fluid level s . A non-s erviceable,100 mi cron nylon mes h fil ter is fi tt ed in the body. The fi lt er removes parti cul ate matt er from t he fl uid before i t is drawnint o t he pump s uppl y connecti on. Maximum and minimum fluid level s are moulded int o the body and ass is t checking fl ui dlevels when the hydrauli c fl uid i s cold.
The cap is rotat ed count erclockwi s e t o rel eas e from t he body. The cap is fit t ed wit h an O-ri ng t o prevent fl ui d l eakage andincorporat es a breat her hol e to allow for changes i n fluid level duri ng operati on and prevent vacuum or pres s uri zat ion oft he res ervoir.
FLUID COOLER (i6 ONLY)

ItemPart NumberDescription
1-Res ervoi r2-Fl uid cooler
3-Val ve unit
4-Steeri ng rack and pini on5-Fl ow control/press ure rel ief - ret urn
6-Fl ow control/press ure rel ief val ve
7-Output port8-Power s t eering pump
9-Low pres s ure s uct ion line
W hen t he engine i s s tarted t he power st eeri ng pump draws flui d from the reservoi r int o the low press ure s uct ion l ine. Thefl uid pas s es through t he pump and emerges as pres s urized fluid at the out let port . The high pres s ure hos e pas ses t hepres s urized fluid to the s t eering gear valve unit .
If no st eeri ng effort is appl ied, there is minimal rest ricti on wit hin t he s yst em and the s upply pres s ure from t he pump i slow. Mi nimal pres s ure i s applied, via the valve unit , t o each si de of the pi s ton i n t he hydraul ic cyli nder and t he ful l flowfrom the power s teeri ng pump returns to t he reservoi r vi a t he fl uid cooler.
W hen s t eering effort is appli ed in ei ther direct ion, t he ret urn flow of flui d t o t he res ervoir i s res trict ed by the val ve uni t,caus ing the s upply pres s ure from t he pump t o i ncreas e. The pres surized fluid is di rected by t he valve unit t o t he applicables ide of t he pis ton in t he hydrauli c cyl inder, providi ng the power as si s tance required to reduce the st eering effort. Fl ui ddis placed from t he l ow pres s ure s i de of the cyli nder is ret urned via t he valve unit and flui d cool er to t he reservoi r. The fluidcool er reduces t he fluid temperat ure i mproving fl ui d performance and als o prolongs the l ife of hoses and s eals in t hes ys t em.

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.
• NOTE: Some flui d s pill age is i nevi table during t his
operat ion.
• NOTE: Care mus t be taken t o avoid contami nat ion of
t he acces sory dri ve bel t.
Di sconnect t he power s t eering hi gh-pres s ure pi pe
union.
9.
Inst all t he O-ring seal. Inst all t he s pecial t ool s.
Speci al Tool (s ): 211-011-12 ,
211-011-02 ,
211-011-02 ,
211-011-01 ,
211-287 Tie the press ure gauge as ide under t he hood.10.
11. CAUTION: Only us e new fl uid from a s ealed container.
Refi ll and bleed t he power st eeri ng.
Refer t o: Power St eering Sys tem Bleeding (211-00 St eering Sys tem -
General Informat ion, General Procedures ).
11.
Connect t he batt ery ground cable.
12.
13. NOTE: Make sure t he s teeri ng components and tes t equi pment
are free from leaks .
• NOTE: Mai nt ain the maxi mum flui d level during t he t est .
• NOTE: Make s ure the s t eering i s i n the st rai ght ahead pos it ion. W it h the tes t val ve open s tart the engine. Turn the s t eering full y lock t o lock, st op t he engi ne.
Top-up t he power st eeri ng fl uid reservoi r.13.
For power s t eering press ures , refer to the s t eering s peci fi cat ion
s ect ion.
Refer t o: Specificati ons (211-02 Power Steering, Specificati ons ).
14.
15. CAUTION: Do not hold st eering at full l ock for longer t han
15.

Refer t o:
Air Cleaner (303-12A Intake Ai r Dis tribut ion and Fil tering -
I6 3.2L Pet rol, Removal and Ins t al lat ion).
3. CAUTION: Di scard fl ui d s iphoned from t he power st eeri ng
s yst em.
Siphon t he fl uid from t he power s t eering res ervoi r.
3.
Pos it ion an abs orbent cl oth t o coll ect fluid s pi ll age.
4. 5. CAUTION: Before di s connect ing or removi ng
the component s , make s ure t he area around the joint
faces and connect ions are clean. Pl ug open
connect ions t o prevent cont aminat ion.
• NOTE: Some fluid spi llage i s inevit able duri ng t hi s
operati on.
• NOTE: Care mus t be t aken to avoi d cont aminat ion of
the acces s ory drive belt .
Dis connect the power s teeri ng high-press ure pipe
uni on.
5.
Inst all t he O-ring seal. Inst all t he s pecial t ool s.
Speci al Tool (s ): 211-313 ,
211-011-02 ,
211-011-11 ,
211-011-01 ,
211-287 ,
211-325 Tie the press ure gauge as ide under t he hood.6.
7. CAUTION: Only use new fl uid from a s ealed container.
Refi ll and bleed t he power st eeri ng.
Refer t o: Power St eering Sys tem Bleeding (211-00 St eering Sys tem -
General Informat ion, General Procedures ).
7.
Connect t he batt ery ground cable.
8.
9. NOTE: Make s ure t he s teeri ng component s and tes t equipment
are free from leaks .
• NOTE: Mai nt ain the maxi mum flui d level during t he t est .
• NOTE: Make s ure the s t eering i s i n the st rai ght ahead pos it ion. W it h the tes t val ve open s tart the engine. 9.