Frelander 2. Manual — part 188
Secure the A/C and power steering lines.
24.
Install the A/C compressor.
Torque: 25 Nm
25.
Install the A/C compressor, upper support bracket.
Torque:
M10 45 Nm
M8 25 Nm
M6 10 Nm
26.
Install the A/C compressor, lower support bracket.
Torque: 25 Nm
27.
Connect the brake booster vacuum hose.
28.
Connect the ECM electrical connectors.
29.
Install the starter motor.
Refer to:
Starter Motor
(303-06A Starting System - I6 3.2L Petrol,
Removal and Installation).
30.
Remove the front subframe assembly.
Refer to:
Front Subframe
(502-00 Uni-Body, Subframe and Mounting
System, Removal and Installation).
31.
Install the lower engine stabilizer bar.
Refer to:
Engine Lower Support Insulator
(303-01B Engine - TD4 2.2L
Diesel, Removal and Installation).
32.
Remove the catalytic converters.
Refer to:
Catalytic Converter
(309-00A Exhaust System - I6 3.2L
Petrol, Removal and Installation).
33.
Refill and bleed the cooling system.
Refer to:
Cooling System Draining, Filling and Bleeding
(303-03A
Engine Cooling - I6 3.2L Petrol, General Procedures).
34.
Install the air cleaner assembly.
Refer to:
Air Cleaner
(303-12B Intake Air Distribution and Filtering -
TD4 2.2L Diesel, Removal and Installation).
35.
Remove the battery tray.
Refer to:
Battery Tray
(414-01 Battery, Mounting and Cables,
Removal and Installation).
36.
Remove the plenum box access panel.
Refer to:
Plenum Chamber
(412-01 Climate Control, Removal and
Installation).
37.
Remove the engine cover.
Refer to:
Engine Cover - I6 3.2L Petrol
(501-05 Interior Trim and
Ornamentation, Removal and Installation).
38.
Connect the battery ground cable and install the cover.
Refer to:
Specifications
(414-00 Battery and Charging System -
General Information, Specifications).
39.
Refill and bleed the power steering.
Refer to:
Power Steering System Bleeding
(211-00 Steering System -
General Information, General Procedures).
40.
Carry out the final halfshaft and suspension tightening with the
vehicle on its wheels.
41.
Engine - TD4 2.2L Diesel -
Lubricants, Fluids, Sealers and Adhesives
Description
Description and part number.
‘T’ joints - ladder frame to engine block
sealant
Three bond TB 1215J
Oil pan to block sealant
Three bond TB 1215J
Camshaft ladder sealant
Loctite 518 (8510302)
Engine Oil
SAE 5W-30 oils conforming to Ford WSS-M2C13B specification or ACEA A1 or
B1
Capacities
Item
Capacity (liters/pints/US quarts)
Dry fill including filter
6.5/11.4/6.7
Service fill
5.9/10.4/6.2
Amount of oil required to bring level from the lower to the upper mark on the dipstick 1.5/2.6/1.6
Cylinder Head Gasket Selection
Piston Protusion
Thickness of Compressed Gasket
Number of holes at 'a'
Number of holes at 'b'
0.55 to 0.60 mm
1.25 ± 0.04 mm
1
1
0.61 to 0.65 mm
1.30 ± 0.04 mm
2
2
0.66 to 0.70 mm
1.35 ± 0.04 mm
3
3
0.71 to 0.75 mm
1.40 ± 0.04 mm
4
4
'a' and 'b' = Thickness identification
General Specification
Item
Specification
Type
2.2 litre, inline 4, turbocharged and intercooled diesel engine, twin overhead
camshaft, 4 valves per cylinder
Cylinder arrangement
Inline 4
Cylinder numbering
No.1 from gearbox end
Bore - nominal
85.0 mm (3.346 in)
Stroke
96.0 mm (3.779 in)
Capacity
2179 cm³ (132.9 in³)
Firing order
1 - 3 - 4 - 2
Compression ratio
16.6:1
Direction of rotation
Clockwise viewed at FEAD
Maximum permissable cylinder head
warp
0.03mm (0.00118 in)
Maximum power
All markets except Belgium
118 kW (160 ps) @ 4000rpm
Belgium specification
110 kW (150 ps) @ 4000rpm
Maximum torque
400 Nm (295 lb-ft) @ 2000rpm
Engine oil pressure*:
At 1750 rev/min
1.6 bar/160 kPa/23 lb/in²
At 4000 rev/min
3.1 bar/310 kPa/45 lb/in²
Balance shaft to crankshaft
clearance**:
Minimum
0.01mm
Maximum
0.07mm
* Prior to checking the engine oil pressure, a road test of 6 miles (10 kilometres) must be carried out. Do not
attempt to attain normal engine operating temperature by allowing the engine to idle.
**If the backlash between the balance shaft and crankshaft is less than 0.01 mm or greater than 0.07 mm then the
balance shaft assembly must be replaced.
Torque Specifications
Description
Nm
lb-ft
Accessory drive belt idler bolt
48
35
Accessory drive belt tensioner bolt
48
35
Camshaft pulley bolt
Stage 1
20
15
Stage 2
60°
60°
Camshaft timing belt cover bolts
6
5
Camshaft timing chain tensioner bolts
7
5
Crankshaft pulley bolt:
Stage 1
70
52
Stage 2
60°
60°
Crankshaft rear seal retainer plate
9
7
Coolant outlet elbow
9
7
Cylinder head bolts
A
A
Dipstick tube bolt
10
7
Engine insulator lower
110
81
Engine insulator lower heat shield
10
7
Engine insulator lower link brackets
110
81
Engine insulator upper
110
81
Description
Nm
lb-ft
Engine mount bracket LH:
M8*
25
18
M12*
80
59
Engine mount bracket RH:
M12*
80
59
M14*
175
129
Engine mount LH bolt
175
129
Engine mount RH bolts
80
59
Flywheel bolts
A
A
Fuel injector wiring harness bolt
10
7
Fuel filter bracket bolts
25
18
Intake manifold runner control (IMRC) actuator bolt
10
7
Intake manifold adaptor and throttle housing bolt
6
5
Intake manifold bolts
9
7
Lifting brackets
10
7
Oil cooler brackets
10
7
Oil cooler to cylinder block bolts
20
15
Oil filler tube
9
7
Oil pan drain plug
20
15
Oil pan bolts
9
7
Oil pan extension panel:
Stage 1
10
7
Stage 2
16
12
Oil pump bolts:
9
7
Stage 1
7
5
Stage 2
9
7
Oil separator bolts
7
5
Oil level sensor
8
6
Piston cooling jet bolt
10
7
Timing belt tensioner bolt
25
18
Timing belt idler pulley bolt
60
44
Timing belt rear cover
6
4
Valve cover bolts
10
7
Vacuum pump bolts
9
7
* New nuts/bolts must be fitted
A = refer to procedure for correct torque sequence
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