ecu LAND ROVER DEFENDER 1999 Workshop Manual

57STEERING
2
REPAIR 15.Remove brake servo.See BRAKES, Repair.
16.Release ABS modulator multiplug from side of
brake pedal box.
17.Release mat from underside of fascia to gain
access to brake pedal box mounting bolts.
18.Remove 6 bolts securing brake pedal box to
bulkhead.
19.Disconnect 2 brake pedal switch Lucars.
20.Carefully remove brake pedal box assembly and
collect gasket.
21.Remove bolt securing column upper tie bar to
column.
22.Remove 2 bolts securing upper column to lower
mounting bracket.
23.Remove 2 bolts securing 2 halves of column
upper clamp.
24.Remove 2 bolts securing column upper clamp to
mounting bracket.
25.Remove column upper clamp and collect rubber
packing.
26.Remove 2 bolts securing column upper
mounting bracket to bulkhead.
27.Release upper column from lower column and
manouvre mounting bracket and upper column
assembly from vehicle.
28.Remove mounting bracket from column.
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STEERING
3
REPAIR Refit
NOTE: The steering column is a
non-servicable component and can only
be serviced as a complete assembly.
29.Fit mounting bracket to column and manouvre
assembly into position.
NOTE: Ensure marks on upper and lower
columns are aligned.
30.Loosely fit bolts securing mounting bracket to
bulkhead.
31.Fit upper clamp and rubber packing to column.
32.Loosely fit bolts securing upper clamp to
mounting bracket.
33.Loosely fit bolts securing 2 halves of upper
clamp.
34.Loosely fit bolts securing column lower mounting
bracket.
35.Fit bolt securing upper tie bar to steering column
and tighten to22 Nm (16 lbf.ft).
36.Tighten mounting bracket to bulkhead bolts,
clamp bolts, and lower mounting bolts.
M6 bolts =9 Nm (6 lbf.ft)
M8 bolts =22 Nm (16 lbf.ft)
37.Manouvre brake pedal box assembly and NEW
gasket into position in vehicle.
38.Tighten bolts securing brake pedal box to
bulkhead to25 Nm (18 lbf.ft)
39.Connect brake pedal switch Lucars.
40.Reposition mat to underside of fascia.
41.Secure ABS modulator multiplug to side of brake
pedal box.
42.Fit brake servo.See BRAKES, Repair.
43.Fit ignition switch to steering column, ensuring
inner shaft slot aligns with steering lock plunger.
44.Evenly tighten clamp bolts, but DO NOT shear at
this stage.
45.Temporarily fit steering wheel and check for
correct operation of switch and lock.
46.Remove steering wheel.
47.Fully tighten ignition switch bolts until heads
shear.48.Connect Lucars to rear of ignition switch.
49.Fit passive coil to ignition switch and connect
multiplug.
50.Fit switch assembly to steering column and
tighten clamping screw.
51.Connect column switch multiplugs.
52.Fit instrument pack.See INSTRUMENTS,
Repair.
53.Fit steering column nacelle.See this Section.
54.Fit bolt securing upper column to lower column
universal joint and tighten to25 Nm (18 lbf.ft).
55.Fit air inlet pipe between turbo and inlet air filter
and secure with clips.
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FRONT SUSPENSION
1
REPAIR PANHARD ROD - FROM 02MY
Service repair no - 60.10.07.
Remove
1.Remove fixings at mounting arm.
2.Remove fixings at axle bracket.
3.Remove panhard rod.
4.Using a suitable length of steel tubing, press out
flexible bushes. Ensure tubing locates on outer
edge of bush and not on rubber inner.
Refit
5.Fit replacement bushes.
CAUTION: Apply pressure to outer edge of
bush, and not rubber inner.
6.Fit panhard rod to axle bracket and mounting
arm. Tighten fixings to230 Nm (170 lbf/ft).BEARINGS - FRONT HUB
Service repair no - 60.25.14
Remove
1.Raise front of vehicle.
WARNING: Support on safety stands.
2.Remove front road wheel.
3.Pull back front brake caliper jump hose shield
and clamp brake hose.
4.Position container collect brake fluid.
5.Loosen brake pipe to jump hose union and
disconnect.
CAUTION: Use 2 spanners when loosening
or tightening unions.
6.Remove 2 bolts securing brake caliper to hub.
7.Remove brake caliper.
CAUTION: Plug the connections.
8.Remove dust cap.
9.Remove circlip and shim(s) from drive shaft.
10.Remove and discard 5 bolts securing driving
member to hub.
11.Remove driving member and discard gasket.
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60FRONT SUSPENSION
2
REPAIR 12.Knock back staking and using a suitable socket,
remove and discard hub nut.
13.Remove washer from hub.
14.Remove hub and brake disc assembly complete
with bearings.
15.Remove outer bearing and spacer from hub.
16.Remove grease seal and inner bearing from
hub.
17.Remove inner and outer bearing tracks from
hub.
Refit
18.Clean hub and bearing locations.
19.Fit inner and outer bearing tracks to hub.
20.Pack inner bearing with grease and fit to hub.
21.Fit new seal flush with rear face of hub using
LRT-54-003andLRT-99-003.
22.Clean stub axle.
23.Pack outer bearing with grease, fit spacer and
bearing to hub.
24.PositionLRT-54-019over hub nut threads on
axle casing.
25.Fit hub assembly to stub axle, remove
LRT-54-019.
26.Fit washer and new hub nut and tighten to30
Nm (22 lbf.ft).
27.Rotate and push/pull hub to setle bearings.
Tighten hub nut to210 Nm (150 lbf.ft).
28.To check drive shaft end float, mount a dial
gauge using bracketLRT-99-503to driving
member bolt hole.
29.Ensure dial gauge is contacting hub nut face.
30.Move drive shaft in and out noting dial gauge
reading.31.If end float is present refer to table for correct
spacer and change spacer as necessary.
32.When no end float is evident, remove the dial
gauge and mounting bracket.
33.Stake the hub nut.
34.Clean hub and axle shaft faces.
35.Fit new driving member gasket.
36.Position driving member to hub and tighten new
bolts to65 Nm (48 lbf.ft).
37.Fit original shim(s) to drive shaft and secure with
circlip.
38.Position brake caliper to hub, align fixings, fit
bolts and tighten to82 Nm (60 lbf.ft).
39.Remove plugs from brake pipe connections.
40.Connect brake pipe union to jump hose and
tighten union.
CAUTION: Use 2 spanners when
tightening or loosening unions.
41.Remove brake hose clamp from jump hose.
42.Bleed brake system.See BRAKES,
Adjustment.
43.Fit road wheel, remove axle stand and tighten
wheel nuts to130 Nm (95 lbf.ft).
44.Operate foot brake to locate brake pads before
taking vehicle on road.
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REAR SUSPENSION
1
REPAIR BEARING - REAR HUB
Service repair no - 64.15.14
Remove
1.Raise rear of vehicle.
WARNING: Support on safety stands.
2.Remove rear road wheel.
3.Remove 2 bolts securing brake caliper to hub.
4.Release caliper from disc and tie aside.
5.Remove 5 bolts securing axle shaft.
6.Remove axle shaft and discard gasket.
7.Knock back staking, and using a suitable socket,
remove and discard stake nut.
8.Remove hub nut washer.
9.Remove hub and brake disc assembly complete
with bearings.
10.Remove outer bearing and spacer from hub.
11.Remove grease seal and inner bearing from
hub.
12.Remove inner and outer bearing tracks from
hub.
Refit
13.Clean hub and bearing locations.
14.Fit inner and outer bearing tracks to hub.
15.Pack inner bearing with grease and fit to hub.
16.Fit new grease seal flush with rear face of hub
usingLRT-54-003andLRT-99-003.
17.Clean stub axle.
18.Pack outer bearing with grease, fit spacer and
bearing to hub.
19.Fit hub assembly to stub axle, remove
LRT-54-019.
20.Fit washer and new hub nut and tighten to30
Nm (22 lbf.ft).
21.Rotate and push/pull hub to settle bearings.
Tighten hub nut to210 Nm (150 lbf.ft).
22.To check drive shaft end float, mount a dial
gauge using bracketLRT-99-503to driving
member bolt hole.
23.Ensure dial gauge is contacting hub nut face.
24.Move drive shaft in and out noting dial gauge
reading.
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64REAR SUSPENSION
2
REPAIR 25.If end float is present refer to table for correct
spacer and change spacer as necessary.
26.When no end float is evident, remove the dial
gauge and mounting bracket.
27.Stake the hub nut.
28.Clean hub and axle shaft faces.
29.Fit new driving member gasket.
30.Position driving member to hub and tighten new
bolts to65 Nm (48 lbf.ft).
31.Fit original shim(s) to drive shaft and secure with
circlip.
32.Position caliper to hub, fit bolts and tighten to82
Nm (61 lbf.ft).
33.Fit road wheel, remove axle stands and tighten
road wheel nuts to130 Nm (96 lbf.ft).
34.Operate brake pedal to locate brake pads before
driving vehicle.
35.Check and top up brake fluid.
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70 - BRAKES
CONTENTS
Page
DESCRIPTION AND OPERATION
REAR BRAKE CALIPERS - FROM 02MY 2...........................................................
ADJUSTMENT
BRAKE SYSTEM BLEED 1.....................................................................................
PARK BRAKE - ADJUST 2.....................................................................................
REPAIR
ECU - ABS 1...........................................................................................................
SENSOR - ABS - FRONT WHEEL 2......................................................................
SENSORS - ABS - REAR WHEELS 3....................................................................
MASTER CYLINDER 4...........................................................................................
SERVO ASSEMBLY 5............................................................................................
MODULATOR UNIT - ABS 6...................................................................................
BRAKE CALIPER - FRONT 7.................................................................................
BRAKE CALIPER - REAR 8....................................................................................
SWITCH - STOP LIGHT 9.......................................................................................
FRONT BRAKE PADS - FROM 02MY 10...............................................................
REAR BRAKE PADS - FROM 02MY 11.................................................................
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BRAKES
1
REPAIR ECU - ABS
Service repair no - 70.65.01
Remove
1.Disconnect battery negative lead.
2.Release and remove passenger seat base.
3.Release clip securing ECU cover plate.
4.Remove ECU cover plate.
5.Disconnect 3 multiplugs from ABS ECU.
6.Disconnect 2 multiplugs from engine
management ECU.
7.Release seat base carpet to gain access to ECU
mounting plate Torx screws.
8.Remove 2 Torx screws securing front edge of
ECU mounting plate.
9.Remove nut securing rear edge of ECU
mounting plate.
10.Remove mounting plate and ECU assembly from
seat base.
11.Remove 3 bolts securing ABS ECU to mounting
plate.
12.Remove ABS ECU.
Refit
13.Position ABS ECU to mounting plate and secure
with bolts.
14.Fit mounting plate and ECU assembly to seat
base.
15.Fit Torx screws and nut securing mounting plate
to seat base.
16.Re-position carpet.
17.Connect multiplugs to ABS and engine
management ECU’s.
18.Fit ECU cover plate to seat base and secure in
position with clip.
19.Fit passenger seat base.
20.Reconnect battery negative lead.
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70BRAKES
2
REPAIR SENSOR - ABS - FRONT WHEEL
Service repair no - 70.65.30
Remove
1.Raise vehicle on a 2 post ramp.
2.Carefully prize ABS sensor from front hub.
3.Release clip securing ABS sensor harness to
brake pipe.
4.Release clip securing ABS sensor harness to
inner wing.
5.Lower vehicle.
6.Release second clip securing ABS harness to
inner wing.
7.Disconnect sensor harness multiplug.
8.Remove sensor and harness.
Refit
9.Connect sensor harness multiplug.
10.Position sensor harness and secure to inner
wing with clip.
11.Raise vehicle.
12.Secure harness to inner wing and brake pipe
with clips.
13.Apply grease to sensor.
14.Carefully fit sensor to hub assembly.
15.Lower vehicle.
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BRAKES
3
REPAIR SENSORS - ABS - REAR WHEELS
Service repair no - 70.65.31
Remove
1.Raise vehicle on a 2 post ramp.
2.Remove both rear wheels.
3.Remove 3 bolts securing each brake disc
backplate to hub assemblies.
4.Remove both back plates.
5.Remove 2 cable ties securing sensor harness to
outer ends of axle.
6.Carefully prise both sensors from hub
assemblies.
7.Release 4 clips securing sensor harness to axle.
8.Release cable tie securing harness to
differential.
9.Release 3 cable ties securing harness to chassis
longitudinal.
10.Disconnect sensor multiplug.
11.Remove harness and sensor assembly.
Refit
12.Position harness and sensor assembly to vehicle
and connect multiplug.
13.Apply grease to both sensors.
14.Carefully fit both sensors to hub assemblies.
15.Secure harness to axle and differential with
cable ties.
16.Secure harness to axle with clips.
17.Secure harness to chassis with cable ties.
18.Fit both back plates to hub assemblies and
secure with bolts.
19.Fit rear wheels and tighten to130 Nm (95 lbf.ft)
.
20.Lower vehicle.
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