LAND ROVER DISCOVERY 1999 Workshop Manual

BRAKES
ADJUSTMENTS 70-29
ADJUST ME NTS
Handbrake
$% 70.45.09
Check
1.Apply the handbrake lever 3 notches on the
ratchet. The handbrake should be fully
operational.
2.If the handbrake is not fully operational, the
brake shoes and/or the handbrake cable need
adjusting.
Adjust
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Ensure handbrake lever is fully released.
3.Tighten brake shoe adjusting bolt until brake
drum is locked, then back off adjusting bolt 1.5
turns. Check that the brake drum is free to
rotate.
4.Recheck handbrake operation.If handbrake is
not fully applied with 3 notches on the
ratchet, the handbrake cable requires
adjustment.
5.Remove switch panel from centre console.

+ WINDOWS, REPAIRS, Switch -
console.
6.Release handbrake lever gaiter from centre
console.7.Rotate adjuster anti-clockwise to increase
cable tension (reduce notches) or clockwise to
decrease cable tension (increase notches).
8.Recheck handbrake operation.
9.Secure handbrake lever gaiter to centre
console.
10.Fit switch panel to centre console.

+ WINDOWS, REPAIRS, Switch -
console.
11.Remove stand(s) and lower vehicle.

BRAKES
70-30 ADJUSTMENTS
Brake system bleeding
$% 70.25.02
Bleeding of the brake system can be carried out
using the procedures given on TestBook, or by
following the manual procedure given below.
WARNING: If any components upstream of brake
modulator, including the modulator itself are
replaced, the brake system must be bled using
the procedure on TestBook/T4, to ensure that all
air is expelled from the new component(s).
WARNING: Do not allow brake fluid to come into
contact with eyes or skin.
Bleed
NOTE: This procedure covers bleeding the
complete system, but where only the primary or
secondary circuit have been disturbed in
isolation, it should only be necessary to bleed
that circuit. Partial bleeding of the hydraulic
system is only permissible if a brake pipe or
hose has been disconnected with only minor
loss of fluid.
1.Do not allow fluid level in master cylinder to fall
below 'MIN' mark during bleeding.
2.Do not fill reservoir above 'MAX' level.
3.Raise front and rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
4.Check all pipe and hose connections are tight
and there are no signs of leakage.
5.Top-up fluid level in brake reservoir to 'MAX'
mark.
WARNING: Do not allow dirt or foreign
liquids to enter the reservoir. Use only new
DOT 4 brake fluid from airtight containers.
Do not mix brands of brake fluid as they
may not be compatible.6.Attach bleed tube to the bleed screw on front
brake caliper on the passenger side, submerge
free end in a clear container containing brake
fluid.
7.Apply pressure to brake pedal several times,
then apply steady pressure.
8.Loosen bleed screw to release brake fluid and
air. Allow pedal to return unassisted.
9.Depress brake pedal steadily through its full
stroke and allow to return unassisted. Repeat
procedure until a flow of clean air-free fluid is
purged into container then, whilst holding
pedal at end of downward stroke, tighten brake
caliper bleed screw to 10 Nm (7 lbf.ft).
CAUTION: Ensure the fluid in the reservoir
is maintained between the minimum and
maximum levels throughout the bleed
procedure using new brake fluid.
10.Top-up brake fluid level to 'MAX' mark.

BRAKES
ADJUSTMENTS 70-31
Bleed sequence LHD
Bleed sequence RHD
11.Working in the sequence illustrated, repeat
steps 5 to 9 on remaining calipers.
WARNING: Braking efficiency may be
seriously impaired if the incorrect bleed
sequence is used.
12. Apply brakes and check for leakage.
13.Remove stand(s) and lower vehicle.
14.Road test vehicle. Check brake pedal for short
firm travel when brakes are applied.

BRAKES
REPAIRS 70-33
REPAIRS
Brake disc - front
$% 70.12.10
Brake discs must be renewed in pairs, unless
one disc requires changing before 1000 miles
(1500 km) from new.
Remove
1.Raise front of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Remove 2 bolts securing brake caliper to
swivel hub.
4.Release caliper and tie aside clear of brake
disc.
CAUTION: Do not allow caliper to hang on
brake hose.
5.Remove screw securing disc to drive flange.
6.Remove brake disc from drive flange Refit
1.Clean mating faces of drive flange and new
disc.
2.Fit brake disc to drive flange, fit screw and
tighten to 13 Nm (10 lbf.ft).
3.Clean mating faces of caliper and hub.
4.Fit caliper, and tighten bolts to 175 Nm (129
lbf.ft).
5.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
6.Remove stand(s) and lower vehicle.

BRAKES
70-34 REPAIRS
Brake disc - rear
$% 70.12.33
Brake discs must be renewed in pairs, unless
one disc requires changing before 1000 miles
(1500 km) from new.
Remove
1.Raise rear of vehicle.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
2.Remove road wheel(s).
3.Remove 2 bolts securing brake caliper to rear
hub.
4.Release caliper and tie aside clear of brake
disc.
CAUTION: Do not allow caliper to hang on
brake hose.
5.Remove screw securing disc to drive flange.
6.Remove brake disc from drive flange. Refit
1.Clean mating faces of drive flange and new
disc.
2.Fit brake disc to drive flange, fit screw and
tighten to 13 Nm (10 lbf.ft).
3.Clean mating faces of caliper and hub.
4.Fit caliper and tighten bolts to 95 Nm (70 lbf.ft).
5.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
6.Remove stand(s) and lower vehicle.

BRAKES
REPAIRS 70-35
Master cylinder - brake
$% 70.30.08
Remove
1.Disconnect multiplug from fluid level switch.
2.Position cloth under master cylinder to absorb
spilled fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
3.Disconnect secondary system pipe union from
master cylinder.
4.Disconnect primary system pipe union from
master cylinder.
5. Manual gearbox only: Release clip and
disconnect clutch fluid supply hose from
reservoir.
CAUTION: Always fit plugs to open
connections to prevent contamination.
6.Remove 2 nuts and washers securing master
cylinder to servo.
7.Remove master cylinder. Refit
1.Clean master cylinder and servo mating
surfaces.
2.Align push rod and position master cylinder to
servo.
3.Fit nuts and washers securing master cylinder
to servo and tighten to 25 Nm (18 lbf.ft).
4.Connect primary and secondary brake pipes,
and tighten unions to 25 Nm (18 lbf.ft).
5. Manual gearbox only: Connect clutch fluid
hose to reservoir, secure with clip.
6.Connect fluid level switch multiplug.
7.Bleed brake system using TestBook/T4.

+ BRAKES, ADJUSTMENTS, Brake
system bleeding.

BRAKES
70-36 REPAIRS
Cable - handbrake
$% 70.35.25
Remove
1.Remove centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
2.Remove clip and clevis pin securing cable to
hand brake lever.
3.Remove brake shoes from hand brake
assembly.

+ BRAKES, REPAIRS, Brake shoes -
handbrake.
4.From below the vehicle, pull handbrake cable
through transmission tunnel.
5.Release handbrake cable from backplate. Refit
1.Fit and secure handbrake cable to backplate.
2.Position hand brake cable through
transmission tunnel.
3.Fit brake shoes to hand brake assembly.

+ BRAKES, REPAIRS, Brake shoes -
handbrake.
4.Align cable to hand brake lever and secure with
clip and clevis pin.
5.Fit centre console.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.

+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
6.Adjust handbrake.

+ BRAKES, ADJUSTMENTS,
Handbrake.

BRAKES
REPAIRS 70-37
Switch - brake light
$% 70.35.42
The brake switch is set automatically during fitment.
If the setting is disturbed, the switch can be reset by
depressing the brake pedal and pulling the plunger
out of the switch body, until it contacts the pedal.
Remove
1.Remove 3 fasteners and move drivers side
lower closing panel aside.
2.Disconnect multiplug from brake light switch.
3.Remove brake light switch from pedal bracket.
Refit
1.Engage switch fully into pedal bracket location
and connect multiplug.
2.Position lower closing panel and secure with
fasteners.