brake LAND ROVER DISCOVERY 2002 User Guide

GENERAL INFORMATION
03-6
General Fitting Instructions
Component removal
Whenever possible, clean components and
surrounding area before removal.
lBlank off openings exposed by component
removal.
lImmediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.
lClose the open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.
lImmediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.
lClean bench and provide marking materials,
labels and containers before dismantling a
component.
Dismantling
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.
lBlow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
'O' rings used for sealing are correctly replaced
or renewed, if disturbed during the process.
lUse marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.
lWire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
lWire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
lDo not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.
General inspection
All components should be inspected for wear or
damage before being reassembled.
lNever inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.
lWhen a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.
lReject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.
lA part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition. Use 'Plastigauge' 12
Type PG-1 for checking bearing surface
clearances.

GENERAL INFORMATION
03-9
Joints and Joint Faces
General
Fit joints dry unless specified otherwise.
lAlways use the correct gaskets as specified.
lWhen jointing compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent jointing compound from entering
oilways, pipes or blind tapped holes.
lIf gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or jointing material to
enter any tapped holes or enclosed parts.
lPrior to reassembly, blow through any pipes,
channels or crevices with compressed air.
Locking Devices
General
Always replace locking devices with one of the same
design.
Tab washers
Always release locking tabs and fit new locking
washers. Do not re-use locking tabs.
Locking nuts
Always use a backing spanner when loosening or
tightening locking nuts, brake and fuel pipe unions.
Roll pins
Always fit new roll pins of an interference fit in the
hole.
Circlips
Always fit new circlips of the correct size for the
groove.
Keys and keyways
Remove burrs from edges of keyways with a fine file
and clean thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.

GENERAL INFORMATION
03-13
Self-locking nuts
Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the same
type.
Flexible Pipes and Hoses
General
When removing and installing flexible hydraulic pipes
and hoses, ensure that the following practices are
observed to ensure component serviceability.
lBefore removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
lObtain appropriate plugs or caps before
detaching hose end fittings, so that the ports can
be immediately covered to prevent the ingress
of dirt.
lClean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
lWhen refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.
lFit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of
dirt.
lAbsolute cleanliness must be observed with
hydraulic components at all times.
lAfter any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.

GENERAL INFORMATION
03-15
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2 lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold and the Exhaust Gas
Recirculation (EGR) pipe. Hoses will relax and
deflect slightly when hot; ensure this movement is
taken into account when routing and securing hoses.
Rolling Road Testing
General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.
WARNING: Do not attempt to test ABS function
on a rolling road.
Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheel rolling road
Up to 03MY
ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.
If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:
lPropeller shaft to the rear axle is removed.
lNeutral selected in gearbox.
When checking brakes, run engine at idle speed to
maintain servo vacuum.
From 03MY
The differential lock must be engaged for two wheel
rolling road testing. It will also be necessary to
disconnect the propeller shaft from the transfer box
output shaft driving the axle whose wheels are NOT
on the rolling road. Additionally, the ETC system
must be deactivated by either removing the 10 amp
fuse (Number 28, labelled ABS in the main fuse box)
or disconnecting the ABS modulator pump. This
must be done with the ignition OFF ; a fault in the
ABS system may still be recorded.
WARNING; VEHICLES NOT FITTED WITH A
DIFFERENTIAL LOCK MUST NOT BE TESTED
ON A ROLLING ROAD WHERE THE ROLLERS
ARE DRIVEN BY THE VEHICLE.

GENERAL DATA
04-16
Brakes
Wheels and tyres
CAUTION: When towing, the additional load imposed may cause the tyre maximum load rating to be
exceeded. This is permissible provided the load rating is not exceeded by more than 15% and that road
speeds are limited to 62 mph (100 km/h) and tyres pressures are increased by at least 3 lbf/in
2 (0.2 bar).
NOTE: The tyre size is displayed on the outer wall of each tyre.
Normal operating conditions: carrying up to 4 passengers and luggage.
Type Servo assisted, diagonally split hydraulic on outboard discs, with
four channel electronic control ABS
Disc diameter:

Front 297.0 - 297.4 mm (11.693 - 11.709 in)

Rear 303.8 - 304.2 mm (11.961 - 11.976 in)
Front disc minimum thickness:

New 24.9 - 25.1 mm (0.980 – 0.988 in)

Service limit 22.0 mm (0.866 in)
Rear disc minimum thickness:

New 12.5 – 12.7 mm (0.492 – 0.500 in)

Service limit 11.7 mm (0.461 in)
Maximum disc runout 0.15 mm (0.006 in)
Minimum pad material thickness 2.0 mm (0.079 in)
Handbrake Cable operated drum on transfer box rear output shaft
Wheel size:

Steel 7J x 16

Alloy 7J x 16
8J x 16
8J x 18
Tyre size

With 7J x 16 wheels 235/70 R16 Wrangler HP 105H
235/70 R16 Michelin XPC * 105H

With 8J x 16 wheels 255/65 R16 Wrangler HP 109H
255/65 R16 Michelin XPC * 109H

With 8J x 18 wheels 255/55 R18 Wrangler HP 109H
Tyre Pressures
All tyres - normal operating conditions Front Up to 03MY - 1.9 Bar (28 lbf.in
2)
From 03MY - 2.1 Bar (30 lbf.in2)
Rear 2.6 Bar (38 lbf.in
2)
All tyres - vehicle at GVW Front Up to 03MY - 1.9 Bar (28 lbf.in
2)
From 03MY - 2.1 Bar (30 lbf.in2)
Rear 3.2 Bar (46 lbf.in
2)

TORQUE WRENCH SETTINGS
06-12
Rear suspension
Brakes
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts140 Nm (103 lbf.ft)
Wheel hub to axle 100 Nm (74 lbf.ft)
Damper to axle125 Nm (92 lbf.ft)
SLS height sensor link to radius arm 25 Nm (18 lbf.ft)
Radius arm230 Nm (170 lbf.ft)
Transverse links to pivot housing 155 Nm (114 lbf.ft)
Pivot housing to axle bolts 230 Nm (170 lbf.ft)
Transverse link to chassis 140 Nm (103 lbf.ft)
SLS height sensor 6 Nm (4.4 lbf.ft)
SLS compressor25 Nm (18 lbf.ft)
ACE actuator to short arm 185 Nm (136 lbf.ft)
ACE actuator to long arm 48 Nm (35 lbf.ft)
ACE actuator pipe cap nuts 29 Nm (21 lbf.ft)
Anti-roll bar link - upper 50 Nm (37 lbf.ft)
Anti-roll bar link - lower 100 Nm (74 lbf.ft)
ACE long arm to torsion bar 180 Nm (133 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Brake caliper bleed screw 10 Nm (7 lbf.ft)
Brake disc to drive flange 13 Nm (10 lbf.ft)
Caliper bolts - Front 175 Nm (129 lbf.ft)
Caliper bolts - Rear 95 Nm (70 lbf.ft)
Master cylinder to servo 25 Nm (18 lbf.ft)
Master cylinder brake pipe, unions 25 Nm (18 lbf.ft)
Brake caliper pivot bolt 30 Nm (22 lbf.ft)
Vacuum pump8 Nm (6 lbf.ft)
Vacuum pump lubrication pipe union 10 Nm (7 lbf.ft)
Brake caliper guide pin bolts 30 Nm (22 lbf.ft)
Brake caliper banjo bolt 32 Nm (24 lbf.ft)
ABS modulator to mounting bracket nuts 9 Nm (7 lbf.ft)
ABS modulator - 13 mm unions 22 Nm (16 lbf.ft)
ABS modulator - 11 mm union 14 Nm (10 lbf.ft)
Handbrake lever to floor bolts 22 Nm (16 lbf.ft)

LIFTING AND TOWING
08-1
LIFTING AND TOWING
LIFTING
The following instructions must be carried out before
raising the vehicle off the ground.
lUse a solid level ground surface.
lApply hand brake.
lSelect 'P' (Automatic gearbox) or 1st gear
(Manual gearbox) in main gearbox.
lSelect Low range in transfer gearbox.
To avoid damage occurring to the under body
components of the vehicle the following jacking
procedures must be adhered to.
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
lBody structure
lBumpers
lFuel lines
lBrake lines
lFront radius arms
lPanhard rod
lSteering linkage
lRear trailing arms
lFuel tank
lEngine sump
lGearbox bell housing
Vehicle jack
The jack provided with the vehicle is only intended for
use in an emergency, for changing a tyre. DO NOT
use the jack for any other purpose. Refer to Owner's
Handbook for vehicle jack location points and
procedure. Never work under a vehicle supported
solely by the vehicle jack.
Hydraulic jack
A hydraulic jack with a minimum 1500 kg, 3,300 lbs
load capacity must be used. Do not commence
work on the underside of the vehicle until
suitable axle stands have been positioned under
the axle.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.Raising and supporting the vehicle
Position cup of hydraulic arm under differential
casing (1).The differential casing is not central to
the axle. Care should be taken when raising the
front road wheels off the ground as the rear axle
has less sway stiffness.
Raise vehicle to enable an axle stand to be installed
under left hand axle tube (2).
Position an axle stand under right hand axle tube (4).
Carefully lower jack until vehicle sits securely on both
axle stands, remove jack.
Alternatively, the axle stands can be positioned
under the chassis longitudinals at the front and/or
rear of the vehicle.
Before commencing work on underside of vehicle re-
check security of vehicle on stands.
WARNING: Always chock the wheels when
jacking. The hand brake acts on the the
transmission, not the rear wheels, and may be
ineffective when the wheels are off the ground.

LIFTING AND TOWING
08-2
Reverse procedure when removing vehicle from
stands.
Hydraulic ramps
Use only a 'drive on' type ramp which supports a
vehicle by it's own road wheels. If a 'wheel free'
condition is required, use a 'drive on' ramp
incorporating a 'wheel free' system that supports
under axle casings. Alternatively, place vehicle on a
firm, flat floor and support on axle stands.
TOWING
Towing
The vehicle has permanent four wheel drive. The
following towing instructions must be adhered
to:
Towing on 4 wheels with driver
Turn ignition key to position '1' to release steering
lock.
Select neutral in main gearbox and transfer gearbox.
Secure tow rope, chain or cable to towing eye.
Release the handbrake.
The brake servo and power assisted steering
system will not be functional without the engine
running. Greater pedal pressure will be required
to apply the brakes, the steering system will
require greater effort to turn the front road
wheels. The vehicle tow connection should be
used only in normal road conditions, 'snatch'
recovery should be avoided.Suspended tow
To prevent vehicle damage, front or rear
propeller shaft MUST BE removed, dependent
upon which axle is being trailed.
Mark propeller shaft drive flanges at transfer box and
axles with identification lines to enable the propeller
shaft to be refitted in its original position.
Remove the propeller shaft fixings, remove the shaft
from the vehicle.
If the front axle is to be trailed turn ignition key to
position '1' to release steering lock.
The steering wheel and/or linkage must be
secured in a straight ahead position. DO NOT use
the steering lock mechanism for this purpose.
Towing eyes
The towing eyes at the front and rear of the vehicle
are designed for vehicle recovery purposes only and
must NOT be used to tow a trailer or caravan.
Front:A single towing eye, set behind a removable
panel in the front spoiler. DO NOT use the front
lashing rings for towing.

LIFTING AND TOWING
08-4
DO NOT secure lashing hooks or trailer fixings to
any other part of the vehicle.
Position the vehicle on the trailer and apply the
handbrake. Select neutral in the manual gearbox ('N'
on automatic gearbox). Selecting 'N' will prevent
damage to the parking pawl in the automatic
gearbox.

CAPACITIES, FLUIDS AND LUBRICANTS
09-2
Refrigerant - A/C system
Fluids
Anti-freeze
Use Havoline Extended Life Coolant (XLC), or any
ethylene glycol based anti-freeze (containing no
methanol) with only Organic Acid Technology
corrosion inhibitors, to protect the cooling system
CAUTION: No other anti-freeze should be used
with Havoline Extended Life Coolant.
The cooling system should be drained, flushed and
refilled with the correct amount of anti-freeze solution
at the intervals given on the Service Maintenance
Check Sheet.
After filling with anti-freeze solution, attach a warning
label to a prominent position on the vehicle stating
the type of anti-freeze contained in the cooling
system to ensure that the correct type is used for
topping-up.
Brake/Clutch fluid
Use only DOT 4 brake fluid.
PAS/ACE fluid
Use Texaco cold climate power assisted steering
fluid 14315.
Air conditioning
Use only refrigerant R134a.
Refrigerant oil
Use only NipponDenso ND-oil 8 or Unipart ND-oil 8.
Refrigerant oil absorbs water and must not be stored
for long periods. Do not pour unused oil back into the
container.
NOTE: The total quantity of refrigerant oil in the
system is 180 ml.
CAUTION: Do not use any other type of
refrigerant oil.

Refill3.4 pt

Fill from dry 3.6 pt
Cooling system - V8 Engine:

Refill24.2 pt

Fill from dry 26.2 ptComponent US Units

Front A/C 700 ± 25 g

Front/rear A/C 900 ± 25 g