2006 LAND ROVER FRELANDER 2 maintenance

Publi s hed: 11-May-2011
General Information - General Service Information
Des cript ion and Operat ion
Introduction
This manual has been wri tt en in a format t hat i s desi gned to meet the needs of Land Rover technicians worl dwide and t oas si st them in t he efficient repai r and maintenance of Land Rover vehi cl es .
This manual provides descripti ons and methods for accomplis hing adjust ment, s ervi ce and repair work usi ng t es t ed andeffect ive procedures . Fol lowi ng thes e procedures wil l hel p ens ure product rel iabil ity.
Special Tools
The Speci al Tool(s ) Tabl e provided at t he begi nni ng of each procedure li st s t he s pecial t ool (s ) requi red t o carry out repairoperati ons wit hin t hat specific procedure. W herever poss i bl e, ill ust rat ions are provided whi ch wil l as s is t t echnicians i nidenti fyi ng the s pecial tool(s ) required and als o s howing s uch tool (s ) in use.
Speci al t ools may be obt ained from the manufact urer, SPX Tool s, t he addres ses of t heir branches will be found in theSpeci al Tools Gl oss ary.For addit ional informat ion, refer t o: Special Tool Glos sary (100-00 General Informati on, Des cri pti on and Operati on).
Important Safety Instructions
Appropri at e s ervi ce methods and correct repai r procedures are es sent ial for t he s afe and reli abl e operati on of all mot orvehi cl es as well as ens uri ng the personal s afety of t he i ndi vi dual carryi ng out the work.
This manual cannot poss ibl y anti ci pat e al l s uch vari at ions and provi de advi ce or cauti ons as to each. Any pers on whodeparts from t he ins t ructi ons provi ded in this manual mus t firs t es tabl is h t hat t hey compromis e nei ther thei r personals afety nor t he vehicle i ntegri ty by their choice of met hods , tool s or parts .
Indi vi dual s who undert ake their own repai rs should have s ome skil l or training and limi t repairs t o component s which coul dnot affect t he s afety of t he vehicle or i ts pas s engers. Any repai rs requi red to s afet y cri ti cal i tems such as s t eering, brakes,s uspens ion or s uppl ement al res traint s yst em s hould be carri ed out by a Land Rover Dealer. Repairs t o s uch i tems s houldNEVER be at tempt ed by untrai ned indivi duals .
Warnings, Cautions and Notes which appear in this manual
As you read through t his manual, you wi ll come acros s W arnings, Caut ions and Notes . A W arning, Cauti on or Not e i splaced at the beginni ng of a s eries of s t eps . If the warning, caut ion or note onl y appl ies t o one s t ep, i t is pl aced at t hebegi nning of t he specific s t ep aft er the s t ep number.
Warnings, Cautions and Not es have the foll owing meanings :
Warning: Procedures which mus t be foll owed to avoid the pos s ibil it y of pers onal i njury.
Caution: Cal ls at tent ion t o procedures which mus t be foll owed to avoid damage to components .
Note: Gi ves hel pful informati on.
References
References t o the Left Hand (LH) or Right Hand (RH) si de given i n t hi s manual are made when vi ewing t he vehi cl e or unitfrom the rear.
Fault Diagnostic Equipment
The vehi cl e i s equi pped wit h a number of electroni c cont rol s yst ems t o provide opt imum performance of the vehicl e'ss ys t ems .
Land Rover approved diagnos t ic equipment is avai lable and mus t be us ed where s pecified. The use of this equi pment willas si st wit h t he fault di agnos ti c abili ti es of the Deal er workshop. In parti cul ar, t he equi pment can be us ed t o i nterrogat et he elect roni c s ys t ems for di agnos is of faul ts whi ch may become evident during t he li fe of the vehicle.
This manual is produced as a reference s ource t o s uppl ement Land Rover approved di agnos ti c equipment.
Feat ures of t he equi pment include:
a. Ful ly upgradeable s upport for t he t echnician
b. Struct ured di agnos ti cs to accommodate al l ski ll levels
c. Direct print-out of screen i nformati on and tes t res ult s
Testing the vehicle
Operat ions covered in t his manual do not include reference t o t es t ing t he vehicle after repai r. It is es s ent ial t hat work i sins pect ed and t es t ed aft er compl eti on and if neces s ary, a road tes t of the vehicle is carried out , part icul arl y where s afet yrel ated i tems are concerned.
Repairs and Replacement Parts

Publi s hed: 11-May-2011
Maintenance Schedules - Maintenance Schedules - Gasoline Engines
Des cript ion and Operat ion
Under Bonnet View
ItemPart NumberDescription1-Coolant expans ion t ank
2-Brake flui d res ervoir (LH drive i llus t rated - RH dri ve on oppos i te si de)
3-Engine oi l fil ler cap4-Power s teeri ng res ervoir
5-Engine oi l l evel i ndi cat or
6-W indscreen washer fl uid res ervoi r
Maintenance Operations
CAUTION: Not e that t he 'A' and 'B' Service Interval s li s ted on the 'Maintenance Check Sheet' for vehicles operat ingunder arduous condi ti ons , vary from t hos e s pecifi ed for vehicles operat ing under normal condit ions . Reference mus tt herefore, always be made to the 'Arduous Condi ti ons secti on for vehicles operat ing under thes e condi ti ons .
Unles s s tat ed otherwis e, the foll owi ng operati ons mus t be carri ed out at every s ervice int erval.
Battery

Air Filtering
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 12 months or 15,000 miles (24,000 km).
Replace the ai r fi lt er el ement.For addit ional informat ion, refer t o: Air Cl eaner (303-12A Int ake Ai r Dis t ri but ion and Fi lt ering - I6 3.2L Petrol ,Removal and Inst all ati on).
Accessory Drive Belt
CAUTION: When vehicles are operating under arduous conditions, the following service item must be carried outevery 5 years or 75,000 miles (120,000 km).
Replace the access ory drive bel t.For addit ional informat ion, refer t o: Acces sory Drive Belt (303-05A Acces s ory Drive - I6 3.2L Pet rol , Removal andIns t allat ion).
Radiator and Cooling Fan
CAUTION: When vehicles are operating under arduous conditions, the following item must be carried out.
Vis uall y check radi at or for external obs truct ions , check cool ing fan blades for damage.
Continuous Use In Severe Off-Road Conditions
CAUTION: After 50 miles (80 km) continuous use in severe off-road conditions i.e. w ading, deep mud andabrasive grit/slurry, the following items must be cleaned and inspected.
The parking brake.The acces sory dri ve belt .
Vehicles used in dusty or field conditions or d eep wading:
More frequent att enti on to the ai r cl eaner wi ll be requi red.
Additional Items That May Require Attention
1. Every 6 years: It i s recommended t hat al l brake fl uid hydrauli c s eal s are replaced.
• NOTE: This i s in addi ti on to the maintenance requirement that fl exi ble brake hos es MUST be replaced at thi s s erviceint erval.

Publi s hed: 11-May-2011
Maintenance Schedules - Maintenance Schedules - Diesel Engines
Des cript ion and Operat ion
Under Bonnet View Item
Part Number Description
1 -Coolant expans ion t ank
2 -Brake flui d res ervoir (RH drive i ll us t rat ed - LH dri ve on oppos i te si de)
3 -W indshi eld was her res ervoir
4 -Power s teeri ng fl uid reservoi r
5 -Engine oi l fil ler cap
6 -Engine oi l l evel i ndi cat or
Maintenance Operations CAUTION: Not e that t he A and B Services li st ed on t he Maint enance Check Sheet , appl i
cabl e t o vehi cl es operati ng
under arduous condi ti ons , vary bot h i n period and mil eage (kil ometres) t o t he int erv als s pecifi ed for t hose vehi cl es
operati ng under normal condit ions. Reference mus t therefore, always be made t o t he ' Arduous Condit ions s ect ion' for
vehi cl es operati ng under t hese condit ions .
Unles s s tat ed otherwis e, the foll owi ng operati ons mus t be carri ed out at every s ervi ce int erval.
Battery

The parking brake.
The acces sory dri ve belt .
Vehicles used in dusty or field conditions or d eep wading:
More frequent att enti on to the ai r cl eaner wi ll be requi red. Fuel Filter
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 3 months or 3,750 miles (6,000 km).
Drai n wat er from t he fuel fi lt er. Poor Fuel Quality
CAUTION:
When vehicles are operating under arduous conditions, the following service item mus t be carried out
every 3 months or 3,750 miles (6,000 km).
W here vehi cl es are us ed i n t hes e areas , t he fuel fi lt er may require drai ning at more frequent i nterval s.Additional Items That May Require Attention
1. Every 6 years: It i s recommended t hat al l brake fl uid hydrauli c s eal s are replaced.
• NOTE: This i s in addi ti on to the maintenance requirement that fl exi ble brake hos es MUST be replaced at thi s s ervice
int erval.

5-Brake shoe retai ni ng s pri ng
6-Brake shoe return s pri ng
7-Brake shoe mechanical adjust er8-Lower (l eadi ng) brake s hoe
9-Parki ng brake l ever cabl e
10-Parki ng brake cabl e equalizer11-Parki ng brake i nner cabl e
12-Equali zer fas t ener
13-Parki ng brake mi cros wit ch14-Parki ng brake l ever as sembl y
15-Parki ng brake outer cable
16-Brake dus t s hield
OVERVIEW
The parking brake is a manual ly actuat ed s ys t em t hat operat es brake s hoes located i n t he rear brake di scs . The ins idecent er of the rear brake dis c is manufact ured t o form the brake drum.
BRAKE SHOE ASSEMBLY
The brake s hoes are mount ed horizontal ly on an int egral brake dus t s hield and backplat e, and form an upper t rai li ng andlower l eading brake s hoe type s yst em. Retai ni ng pins pas s t hrough hol es in the dus t s hield and corres ponding hol es ineach brake s hoe bracket . Each pi n is secured t o t he brake s hoe wit h a ret ai ning cli p. The ret ai ning pins al low movement oft he brake s hoe toward the drum surface duri ng parking brake operat ion, but prevent si deways movement of the brake shoeaway from the dus t s hi eld.
An expander unit and manual adjust er are l ocat ed along t he hori zont al axis of t he dus t shi el d. The expander uni t isposi ti oned at the front of the dus t s hield and forms t he locati on for t he leading and t rai ling ends of t he brake s hoebracket s . The manual adjus t er i s mounted at t he rear of t he dust s hiel d and forms t he l ocati on and ful crum poi nt for theoppos it e ends of t he brake s hoe bracket s.
The manual adjus t er provides the means to adjust t he brake s hoe l ining t o drum clearance for maintenance purposes .Acces s t o t he manual adjus t er knurl ed wheel i s t hrough a formed hole in the front of the brake dis c. Adjust ment isrequired if t he brake s hoes or dis cs are renewed. A bedding-in procedure must al so be performed t o make s ure the drumbrakes operate sat is fact oril y.For addit ional informat ion, refer t o: Parking Brake Shoes Bedding-In (206-05 Parking Brake and Actuati on, GeneralProcedures).
The corres pondi ng ends of bot h t he upper and l ower brake shoe brackets are mai ntained i n contact wit h t he expander uni tand manual adjus t er by 2 ret urn springs . The return s pri ngs are l ocat ed bet ween t he ends of each upper and l ower brakes hoe and att ach to hol es formed in the brake shoe brackets . The ret urn springs pull t he brake s hoes away from t he drumwhen t he parking brake is released.
PARKING BRAKE LEVER
The parking brake lever is l ocat ed in t he floor cons ole bet ween the driver and pass enger s eats , and compri ses a toot hedquadrant , pawl and pres s-butt on rel eas e mechanis m. A si ngl e cabl e wi th a formed t hreaded rod-end connect s t he quadrantt o the equali zer unit , and is secured wit h eit her a locknut or a l ocking was her and nut.
The t hreaded rod all ows adjus tment s t o t he parking brake cable tens ion and parki ng brake lever travel t o be performed formaint enance purpos es.For addit ional informat ion, refer t o: Parking Brake Cabl e Adjus tment (206-05 Parki ng Brake and Actuat ion, GeneralProcedures).
The parking brake cable is routed from t he parking brake l ever equalizer, and al ong the chas si s t o t he rear parking brakeexpander uni t. The parki ng brake cabl e prot rudes t hrough t he brake dust s hiel d, and is formed wit h a nippl e that connectst o the expander unit . The oppos i te ends of each Left-Hand (LH) and Ri ght -Hand (RH) parking brake cabl e are formed wit h anipple that connect to the equali zer unit . The equal izer uni t makes sure t he LH and RH parki ng brake as s embl ies operat es imul taneous l y when the parking brake i s applied.
A micros wit ch is locat ed on t he base of the parki ng brake lever. The micros wit ch operates t he parking brake warni ngindicat or l amp l ocat ed in t he i ns t rument clus ter, when the parki ng brake i s appl ied.For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
PRINCIPLES OF OPERATION
As t he parking brake lever i s applied, t he toot hed quadrant rotat es and pul ls on the t hreaded rod and cable equali zer. Theequal izer pul ls t he 2 parki ng brake cables and operat es the 2 expander uni ts s i mult aneous ly. Movement of t he expanderunit caus es t he upper and l ower brake s hoes t o pivot agains t the manual adjus ter fulcrum, and t he brake s hoes cont actt he brake drum agai nst t he t ens i on of the 2 ret urn s pri ngs .
As t he parking brake lever quadrant rot ates , t he teet h on t he pawl engage wit h corresponding t eeth on the quadrant . Int he appl ied pos it ion, the pawl t eet h are held under spring t ensi on agai nst the quadrant teet h t o prevent the l ever fromdis engagi ng.
W i th the parki ng brake appli ed and the i gnit ion i n power mode 6 (ignit ion), t he mi cros wit ch connect s a ground to theins t rument clus ter and il lumi nat es t he parking brake warning i ndi cat or lamp.For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
W hen t he parking brake lever pres s-butt on is pres sed and t he l ever moved t o rel eas e t he parki ng brake, t he pawl teet hare rais ed clear from the quadrant t eet h. As the parki ng brake l ever i s lowered, t he parking brake cable cl oses t heexpander uni t and the brake s hoes are immediatel y moved away from the brake drum by the 2 ret urn s pri ngs .

Publi shed: 14-Jul-2011
Battery and Charging System - General Information - Battery Care
Des cript ion and Operat ion
12V LEAD ACID BATTERY CARE MANUAL FOR DEALER / RETAILER USE
1. INTRODUCTION
2. GENERAL RULES FOR BATTERY CARE
3. EQU IPMENT (MINIMU M STANDARD)
4. HEALTH AND SAFETY PRECAUTIONS
5. DETERMINING BATTERY CONDITION
6. BATTERY CHARGING AND MAINTENANCE
7. CHARGING SYSTEM TEST AND DIAGNOSIS
8. VEHICLE QUIESCENT CURRENT TESTING
APPENDIX A: BATTERY TEST PROCESS
APPENDIX B: BATTERY REPORT FORM - IN SERVICE BATTERIES ONLY
1. INTRODUCTION
This publi cat ion s ets out , for t he benefit of dealers / ret ailers worl dwide, requirement s for the care and maint enance ofbatt eri es , from the vehicles hand-over to the dealer / retail er to the handover t o the cus t omer or i n t he cas e of a sparepart batt ery from i s delivery to the dealer / retail er to it s fi tment t o a cus tomer vehicle.
It appl ies t o all t ypes of 12 volt Lead Acid Bat teries us ed, whet her they are convent ional fl ooded t echnology or Abs orbedGlas s Mat (AGM) technol ogy and als o applies to bot h Pri mary and Secondary or Auxi li ary Bat teri es.
The clearl y lai d out and ill ust rat ed s ect ions guide dealers / ret ail ers t hrough each st age of the vehicl es or s pare partsreceipt , st orage, pre-del ivery and cus tomer hand-over. This publi cat ion can be us ed as a gui de to the handli ng and care ofbatt eri es in s ervi ce. It is vi tal t o appreci ate that unles s each proces s i s ri gorousl y appl ied on al l vehi cl es, t he cust omer wil lreceive a vehicl e wit h a bat tery or a s pare part bat t ery which will not provide a s at is fact ory s ervi ce life.
It is very import ant that all t est s quoted throughout this publ icat ion are adhered to. If t hey are appli ed incorrect lybatt eri es could be s crapped unneces s ari ly. Refer to the bat tery tes t ing s ect ion for detail ed informat ion.
It is equally important therefore to not e t he fol lowing key point s :
Mos t new vehi cl es leave t he factory wi th ei ther a t rans it relay i ns t alled and/or have a trans it mode programmedint o t he vehi cl e cont rol modules . The t rans it rel ay mus t be removed and t he t rans it mode di sabled (whereappl icable) us ing an approved diagnost ic sys tem, NOT MO RE T HAN 24 HOURS before t he cust omer t akes deli very.12 Volt Lead Acid Bat teries rely on i nternal chemical proces s es to create a vol tage and deli ver current. Theseprocess es and t he int ernal chemi cal s truct ure of the bat tery can be damaged i f the bat tery is allowed t o di schargeover a number of weeks / months , or is left i n a di scharged s t at e for a lengt hy ti me peri od. For t hi s reas on t hebatt ery mus t be t es ted / re-charged i f neces sary every mont h, and MUST BE re-charged after every t hree mont hperi od of st orage. Refer to the vehicle st orage manual and updat e t he vehi cl e his t ory s heet.Under no ci rcums tances should the bat tery be dis connected wit h the engi ne running becaus e under thes e condi ti onst he alt ernator can give a very high output volt age. This hi gh t rans ient vol tage wi ll damage t he electroni ccomponents in t he vehicle. Loos e or i ncompl et e bat tery connect ions may al s o caus e high transi ent volt age.On vehicles wi th conventi onal ignit ion keys , thes e mus t not be left in t he i gni ti on lock barrel when the t rans it relayhas been removed, ot herwi se qui escent current wi ll increas e and t he bat t ery wi ll discharge more rapi dl y.Two t ypes of Lead acid bat teri es are us ed; s tandard Fl ooded t ype and AGM (Absorbed Glas s Mat) or VRLA (Valveregulat ed Lead Aci d) types. AGM batt eries offer i mproved res is t ance t o cycl ing as seen i n s top st art appli cat ions .AGM Bat teries are ful ly s ealed and cannot have t he electrolyte level t opped up.
Dealers and retailers involved in the storage, handling of vehicles and spare parts batteries have a responsibility toensure that only vehicles and spare parts having a fully satisfactory battery may be processed further through thedistribution selling chain.
• NOTE: It is very important that t est proces s es quot ed t hroughout t hi s publicati on are adhered to.
If they are not adhered t o correct ly bat teries could be scrapped unneces saril y or a batt ery wit h an is s ue remains in use.Refer t o t he bat t ery t est ing s ecti on for detai led i nformat ion.
2. GENERAL RULES FOR BATTERY CARE
Frequency of Battery Cond ition Checks.
Any batt ery i n s torage whether it i s in a vehi cle or i n s pare part s i nventory mus t have it s charge s tat us checked every 30days as des cri bed in Appendix A, and mus t be recharged every 90 days as des cribed i n t he "Bat tery Charging andMaint enance" secti on of thi s manual.
Dealer Demonstration Vehicles

6. BATTERY CHARGING AND MAINTENANCE
BATTERY CHARGING
It is es s ent ial t hat a sui tably vent ilat ed defi ned area exis ts in each dealers hip / ret ailer for bat tery charging. Li kewis e, anarea s hould be al lot ted for s crap batt eries , and clearl y indicat ed as s uch. It is recommended t hat dealers / ret ail ers al wayshave full y charged batt eri es ready for us e. However t he bat t ery MUST BE tes ted and charged i f neces sary every mont h, andcharged aft er three months i rres pecti ve of any t es t.
• CAUTIO NS:
Bat teri es mus t be re-charged aft er a maximum of 3 mont hs st orage (s ee Storage His tory s heet i n t he New VehicleStorage Manual ).
It is very important t hat when chargi ng bat t eries us ing the t racti on charger or ot her s t and-alone chargers t hat thecharger i s s et for t he correct t ype of bat tery before chargi ng commences . If t he wrong swi tch i s s elected t he res ult woul dbe a bat tery that i s not charged full y and / or overheat ing can occur. Fol low the manufact urers operat ing ins truct ions .
Do not charge AGM bat t eries wit h vol tages over 14.8 volt s as t hi s wi ll damage the bat tery.
To bri ng a s ervi ceable but di scharged batt ery back t o a full y charged condit ion proceed as follows :
Check and i f neces s ary t op-up t he batt ery el ect rolyt e level.Charge t he batt ery us ing the Mi dtroni cs Diagnos t ic Charger (USA) or Tract ion Charger (all other market s) foll owingt he manufact urers operati ng ins t ructi ons .
• NOTE: W hen us ing the Mi dtroni cs Diagnost ic Charger, aut omati c mode mus t always be us ed. Aft er chargi ng and anal ysi s,t he charger may di s pl ay ‘Top-Off Charging’, pres s STOP t o end. Do not s top chargi ng unt il t he current falls to 5A or les s,otherwis e t he batt ery wi ll not be ful ly charged.
POST-CHARGE TEST METHODS
New Batteries, Batteries in Storage and In-Service Batteries
The purpos e of thi s tes t is to ens ure that t he chargi ng process has full y charged the bat tery.
• NOTE: IT IS RECOMMENDED THAT THIS TEST IS CO NDUCTED AT LEAST 24 HOURS AFTER THE CHARGE CY CLE ISCOMPLETED.