battery LAND ROVER DISCOVERY 1995 Workshop Manual

STEERING
15
REPAIR STEERING COLUMN LOCK ASSEMBLY
Service repair no - 57.40.31
Remove
CAUTION: Before removing any parts of
steering linkage, it is imperative that road
wheels are positioned straight ahead.
Then steering wheel removed to prevent rotary
coupler being wound up or damaged.
CAUTION: After refitting steering linkage
parts follow correct procedure to ensure
that road wheels, steering box and
steering wheel are correctly positioned relative to
each other when in straight ahead condition. If
steering wheel requires repositioning, ensure that
drive pegs on rotary coupler are correctly
positioned before steering wheel is replaced.
This ensures drive pegs locate in their holes in
rear of steering wheel.
After final alignment connect rotary coupler
multiplug, tighten steering wheel securing nut and
fit airbag module - if fitted.
1.Disconnect battery negative lead.
2.Remove steering column shroud.
See Steering
Column Shroud
3.Release turnbuckles, lower driver's access
panel.
4.If fitted, remove 4 screws securing knee pad,
remove bolster.
5.Disconnect ignition switch multiplug from fuse
box.
6.Disconnect ignition switch main feed multiplug.

57STEERING
16
REPAIR
7.Remove bulb holder from steering column lock
shroud.
8.Tap head of shear bolts anti-clockwise to release
them.
9.Remove and discard shear bolts.
10.Detach saddle.
11.Remove steering column lock assembly.
Refit
12.Position steering lock saddle on column, locating
spigot in hole provided.
13.Place lower lock assembly into column.
14.Fit but do not fully tighten new shear bolts.
15.Connect multiplugs.
16.Insert bulb holder into steering column lock
shroud.
17.Reconnect battery negative lead.
18.Check steering column lock for correct
operation, tighten shear bolts until heads shear
off.
19.Fit steering column shroud.
See Steering
Column Shroud
20.If fitted - fit knee bolster, fit and tighten screws.
21.Raise driver's access panel, secure turnbuckles.DROP ARM
Service repair no - 57.50.14
Remove
1.Place vehicle on a hoist, or support front axle on
axle stands.
2.Disconnect drag link ball joint from drop arm,
using extractor LRT-57-018.

BRAKES
1
FAULT DIAGNOSIS ABS FAULT DIAGNOSIS
If a fault has occurred, or has been identified by ECU
self diagnostic function and ABS warning light is
illuminated. The system and components must be
checked to locate and rectify fault, using Testbook
diagnostics.
NOTE: If warning lamp has indicated a
fault in system, and no fault code has been
stored in memory, cause of fault is:
a) Failure in electrical supply
b) Bad ECU ground
c) Faulty warning light relay
d) ECU not connected
Before commencing fault diagnosis procedure
following items must be checked:
1.Inspect all exposed cables for damage or
abrasion.
2.Check ground on ABS system.
3.Battery - state of charge.
4.Check hub end-float.
5.All ABS fuses and electrical connections.
Fault rectification
1.Complete harness should be replaced if faults
are found in wiring harness.
2.DO NOT use unspecified cables or connectors,
as this could jeopardise safe function of ABS.
3.DO NOT attempt to open sealed 35 way
connector to ECU.FAULT DIAGNOSIS PROCEDURE
NOTE: If ABS warning light illuminates due
to large sensor air gap, fault will be
retained by the ECU memory. Where wheel
sensors have been pushed fully home prior to
test, The ECU will indicate a fault that has been
rectified.
NOTE: After any steering adjustment,
bearing replacement/adjustment, brake
disc replacement: Check hub end-float and
sensor clearance.
RELAYS AND FUSES ABS
The location and identification of ABS electrical relays
are given in the Electrical Troubleshooting Manual
For location and identification of ABS electrical fuses.
See ELECTRICAL, Repair, Fuse Box - Interioror.
See ELECTRICAL, Repair, Fuse Box - Engine
Compartment

70BRAKES
2
REPAIR BRAKE SYSTEM BLEED
Service repair no - 70.25.02
The following method for bleeding the hydraulic brake
system applies to both ABS and NON ABS vehicles.
Preparation
WARNING: Before bleeding the brake
system refer to general brake service
practice.
See General Brake Service
Practice
·During bleed procedure, brake fluid level
must not be allowed to fall below the MIN
level. Keep reservoir topped to the MAX level.
·To bleed the hydraulic circuits four bleed
nipples are provided, one at each caliper.
·There are two methods by which air can be
removed from the braking system:-
1. MANUAL BLEED PROCEDURE.
2. PRESSURE BLEED PROCEDURE.
Pressure bleed procedure
Purpose designed equipment for pressure filling and
bleeding of hydraulic systems may be used on Land
Rover vehicles. The equipment manufacturer's
instructions must be followed and the pressure must
not exceed 4.5 bar.
Manual bleed procedure
Equipment required
·Clean glass receptacle
·Bleed hose
·Wrench
·Approx 2 litres brake fluid.
See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information, Recommended Lubricants and
Fluids
Master cylinder bleed
1.Disconnect battery negative lead.
2.Depress brake pedal fully and slowly 5 times.
3.Release the pedal and wait for ten seconds.
4.Air bubbles will rise into the reservoir during
these instructions.
5.Repeat instructions until a firm resistance is felt
at the pedal.
Complete circuit bleed
1.Disconnect battery negative lead.
2.Fit bleed hose to any caliper bleed screw.
3.Dip free end of bleed hose into brake fluid in
bleed bottle.
4.Open bleed screw of caliper.
5.Depress brake pedal fully several times until fluid
is clear of air bubbles.
6.Keeping pedal fully depressed, tighten bleed
screw, then release pedal.
7.Repeat the above procedure on remaining three
calipers.
8.Fit all bleed screw protection caps.
9.Check/top-up fluid level when bleeding is
complete.
See Fluid Level Check / Top-Up

BRAKES
3
REPAIR MASTER CYLINDER ABS
Service repair no - 70.30.08
- Lucas Girling - Type 25.4mm CV/CV
NOTE: This master cylinder is identified by
a 3rd plugged outlet port protruding down
from the master cylinder body.
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove
1.Disconnect battery negative lead.
2.Place a suitable container under master cylinder
to catch brake fluid from cylinder when brake
pipes are disconnected.
3.Thoroughly clean immediate area around all
outlet ports. Remove each brake pipe, sealing
each pipe and outlet port with suitable plugs to
prevent ingress of foreign matter.
4.Disconnect electrical plug from low fluid switch
on reservoir cap.
5.Remove two nuts securing master cylinder to
servo unit remove also spring and plain washers.
6.Detach master cylinder from servo, remove
reservoir cap and drain brake fluid into a
container.Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
7.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
8.Fit brake pipes to master cylinder. Tighten to
15Nm.
9.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
10.Bleed system.See Brake System Bleed
11.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.

70BRAKES
4
REPAIR MASTER CYLINDER NON ABS
Service repair no - 70.30.08 - Remove
Service repair no - 70.30.09 - Repair
- Lucas Girling - Type 25.4mm AS/AS
WARNING: This master cylinder is not
suitable to be fitted on vehicles with
antilock brake systems.
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove
1.Disconnect battery negative lead.
2.Place a suitable container under master cylinder
to catch brake fluid from cylinder when brake
pipes are disconnected.
3.Thoroughly clean immediate area around all
outlet ports. Remove each brake pipe, sealing
each pipe and outlet port with suitable plugs to
prevent ingress of foreign matter.
4.Disconnect electrical plug from low fluid switch
on reservoir cap.
5.Remove two nuts securing master cylinder to
servo unit remove also spring and plain washers.
6.Detach master cylinder from servo, remove
reservoir cap and drain brake fluid into a suitable
container.Repair
7.Thoroughly clean master cylinder and inspect
outer surfaces for damage and condition, renew
complete assembly if necessary.
8.Using two soft jaws, clamp master cylinder
flange in a suitable vice. Remove water ingress
'O' ring seal from master cylinder to servo flange
and discard.
9.Grip outside of transfer housing with a suitable
pair of pliers, carefully pull, working pliers in a
backwards and forwards rocking motion to ease
housing off master cylinder. Discard housing and
vacuum seal.

BRAKES
7
REPAIR 19.Coat new seals in unused brake fluid. Fit 'L' seal
to plunger.
20.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
Assembling master cylinder
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
21.Fit new swirl tube to bottom of cylinder bore.
22.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23.Fit new primary plunger assembly using same
method as for secondary plunger.
24.Fit original guide ring to support primary plunger.
25.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: Do not roll 'O' ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. Do not over
stretch seal.
26.Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27.Fit two new reservoir seals in respective ports.
28.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29.Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, Do
not adjust transfer housing after fitting.
30.Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
32.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33.Fit brake pipes to master cylinder. Tighten to
15Nm.
34.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35.Bleed system.See Brake System Bleed
36.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.

BRAKES
9
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
NOTE: The filter, non-return valve and
grommet, are the only serviceable
components, in event of failure or damage
fit a new unit.
1.Disconnect battery negative lead.
2.Disconnect electrical plug to low fluid level
switch.
3.Thoroughly clean immediate area around all
master cylinder outlet ports. Remove each brake
pipe, sealing each pipe and outlet port to prevent
ingress of foreign matter.
4.Disconnect vacuum supply hose to servo.
5.Remove lower dash panel to gain access to
servo push rod to brake pedal.
6.Remove clevis pin securing servo push rod to
brake pedal.
7.Remove two nuts and plain washers securing
servo.
8.Remove servo and master cylinder assembly.
9.Drain brake fluid into a suitable container. (If
master cylinder is kept horizontal it is not
necessary to drain fluid).10.Detach spacer from pedal box mounting face of
servo.
NOTE: Retain spacer for reassembly. The
spacer ensures stringent pedal to servo
operating dimensions are maintained.
11.Remove master cylinder from existing servo and
refit to new servo, if fitting new unit.
Refit
12.Fit spacer to servo.
13.Fit servo to pedal box.
14.Lightly grease brake pedal around area servo
push rod pivots.
15.Fit push rod to lower hole of brake pedal. Fit
clevis pin and clip.
16.Secure servo with two nuts and plain washers.
Tighten nuts to
26 Nm.
17.Refit lower dash panel.
18.Fit master cylinder to servo, refit nuts, plain and
spring washers. Tighten nuts to
26 Nm.
19.Remove all sealing plugs. Refit brake pipes to
respective ports. Tighten brake pipes to
15 Nm.
20.Refit vacuum supply hose.
21.Fill master cylinder to correct level using correct
grade of brake fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
22.Bleed brake system.See Brake System Bleed

BRAKES
11
REPAIR REAR BRAKE PADS
Service repair no - 70.40.03
Service tool:
LRT-70-500 - Piston clamp
Remove
1.Remove rear road wheels.
See WHEELS AND
TYRES, Repair, Wheels
2.Disconnect battery negative lead.
3.Clean exterior of calipers.
4.Remove pad retaining pins and springs.
5.Remove brake pads.
6.Clean exposed parts of pistons, using new brake
fluid. Wipe away excess with a lint free cloth.
7.Using piston clamp LRT-70-500 press each
piston back into its bore. Ensure that displaced
brake fluid does not overflow from reservoir.Refit
8.Insert brake pads.
9.Position pad retaining springs, fit new pins and
spread ends.
10.Apply service brake pedal several times to locate
pads.
11.Check fluid reservoir, top up if necessary, using
correct grade of fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids

70BRAKES
18
REPAIR SENSORS - FRONT
Service repair no - 70.65.32
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush and seal must
be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect required sensor electrical
connection, located on inner wing [fender] panel.
3.Remove sensor lead from clips.
4.Clean area surrounding sensor to prevent
ingress of dirt. Using a suitable lever pry sensor
from mounting bush.
5.Release harness cable ties, remove sensor lead
from vehicle.
6.Remove top swivel retaining bolts complete with
brake jump hose and sensor seal. Remove
sensor bush.
Refit
7.Insert new sensor bush and seal.
8.Refit brake jump hose bracket, coat bolts with
Loctite 270.
9.Lightly coat new sensor using EP 90 oil. Push
sensor through bush until it contacts exciter ring.
Sensor will be 'knocked back' to correct position
when vehicle is driven.
10.Secure sensor lead in original position.
11.Reconnect sensor electrical connection.
12.Drive vehicle to ensure ABS warning light is
extinguished.
SENSOR RINGS
The rear sensor ring is assembled to the rear brake
disc to form part of the rear hub assembly.
See
REAR AXLE AND FINAL DRIVE, Repair, Rear Hub
Assembly
The front sensor ring is a toothed ring on the axle
shaft which forms part of the front stub axle assembly.
See FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS