brakes LAND ROVER DISCOVERY 2002 Manual PDF
[x] Cancel search | Manufacturer: LAND ROVER, Model Year: 2002, Model line: DISCOVERY, Model: LAND ROVER DISCOVERY 2002Pages: 1672, PDF Size: 46.1 MB
Page 1089 of 1672
BRAKES
70-44 REPAIRS
Refit
1.Rotate disc by hand and scrape all scale and
rust from around edge of disc. Clean location
surfaces on caliper bracket.
2.Clean dust from brake parts using brake
cleaning fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
3.Fit brake pads to caliper carrier.
4.Position caliper housing to carrier, align flats on
guide pins with caliper housing.
5.Fit guide pin bolts and tighten to 30 Nm (22
lbf.ft).
6.Clean banjo bolt and fit new sealing washers.
7.Position hose to caliper and tighten banjo bolt
to 32 Nm (24 lbf.ft).
8.Remove clamp from brake hose.
9.Bleed brake system.
+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
10.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
11.Remove stand(s) and lower vehicle.
Housing - caliper - rear
$% 70.55.25
Remove
1.Raise rear of vehicle, one side.
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.Clamp brake hose to prevent fluid loss.
4.Remove brake hose banjo bolt and discard
sealing washers.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Remove 2 guide pin bolts and remove caliper
housing from carrier.
6.Remove 2 brake pads from caliper carrier.
Page 1090 of 1672
BRAKES
REPAIRS 70-45
Refit
1.Rotate disc by hand and scrape all scale and
rust from around edge of disc. Clean location
surfaces on caliper bracket.
2.Clean dust from brake parts using brake
cleaning fluid.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
3.Fit brake pads to caliper carrier.
4.Position caliper housing to carrier, align flats on
guide pins with caliper housing.
5.Fit guide pin bolts and tighten to 30 Nm (22
lbf.ft).
6.Clean banjo bolt and fit new sealing washers.
7.Position hose to caliper and tighten banjo bolt
to 32 Nm (24 lbf.ft).
8.Remove clamp from brake hose.
9.Bleed brakes.
+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
10.Fit road wheel(s) and tighten nuts to 140 Nm
(103 lbf.ft).
11.Remove stand(s) and lower vehicle.
ECU - Self levelling and anti locking
brakes (SLABS)
$% 70.65.01
Remove
1.Remove BCU.
+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
2.Remove 5 multiplugs from SLABS ECU.
3.Remove multiplug from ACE ECU.
4.Remove lower nut and loosen upper nut
securing SLABS and ACE ECU bracket to
body.
5.Remove ECU's and bracket assembly.
Page 1091 of 1672
BRAKES
70-46 REPAIRS
6.Remove 4 nuts securing SLABS ECU and
remove ECU.
Refit
1.Fit new SLABS ECU to bracket and secure with
nuts.
2.Fit ECU's and bracket assembly to body and
secure with nuts.
3.Connect multiplugs to ACE ECU and SLABS
ECU.
4.Fit BCU.
+ BODY CONTROL UNIT, REPAIRS,
Body control unit (BCU).
5.Programme the new SLABS ECU using
TestBook.
Sensor – ABS – front
$% 70.65.30
ABS sensor is supplied fitted to wheel hub and
must not be removed.
Remove
1.Remove wheel hub.
+ FRONT SUSPENSION, REPAIRS,
Wheel hub.
Refit
1.Fit wheel hub.
+ FRONT SUSPENSION, REPAIRS,
Wheel hub.
Page 1092 of 1672
BRAKES
REPAIRS 70-47
Sensor – ABS – rear
$% 70.65.31
ABS sensor is supplied fitted to wheel hub and
must not be removed.
Remove
1.Remove wheel hub.
+ REAR SUSPENSION, REPAIRS,
Wheel hub.
Refit
1.Fit wheel hub.
+ REAR SUSPENSION, REPAIRS,
Wheel hub.
Modulator unit - ABS
$% 70.65.49
Remove
1.Position cloth under modulator to absorb fluid
spillage.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
2.Disconnect 3 multiplugs from ABS modulator.
3.Disconnect 2 inlet brake pipe unions from pump
side of modulator.
CAUTION: Always fit plugs to open
connections to prevent contamination.
4.Disconnect 4 outlet brake pipe unions from top
of modulator.
CAUTION: Always fit plugs to open
connections to prevent contamination.
5.Loosen 3 nuts securing modulator to mounting
bracket.
6.Release and remove modulator from mounting
bracket.
7.Remove 3 mounting rubbers from modulator.
Page 1093 of 1672
BRAKES
70-48 REPAIRS
Refit
1.Position mounting rubbers to modulator.
2.Position modulator to mounting bracket,
tighten nuts to 9 Nm (7 lbf.ft).
3.Clean brake pipe unions.
4.Connect brake pipe unions to modulator
ensuring pipes are connected to their correct
ports.
5.Tighten 13 mm unions to 22 Nm (16 lbf.ft) and
11 mm unions to 14 Nm (10 lbf.ft).
6.Connect multiplugs to modulator.
7.Bleed brakes.
+ BRAKES, ADJUSTMENTS, Brake
system bleeding.
8.To ensure correct operation, the ABS system
MUST be tested using TestBook.
Switch - Hill descent control
$% 70.70.11
Remove
1.Carefully remove switch.
2.Disconnect multiplug from switch.
3.Remove switch.
Refit
1.Connect multiplug switch.
2.Position switch and push to secure.
Page 1094 of 1672
BRAKES
REPAIRS 70-49
Switch - handbrake
$% 86.65.45
Remove
1.Remove centre console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
2.Disconnect Lucar from handbrake warning
switch.
3.Remove clip and clevis pin securing cable to
handbrake lever.
4.Remove 2 bolts and remove handbrake lever.
5.Remove 2 screws securing switch to
handbrake lever and remove switch.
Refit
1.Fit switch to handbrake lever and tighten
screws.
2.Position handbrake lever to floor and tighten
bolts to 22 Nm (16 lbf.ft).
3.Align cable to handbrake lever and fit clevis pin
and clip.
4.Connect Lucar to handbrake switch.
5.Fit centre console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - automatic
models.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - centre - manual
models.
Page 1095 of 1672
BRAKES
70-50 REPAIRS
Page 1276 of 1672
PANEL REPAIRS
REPAIRS 77-2-27
11.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
14.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Valance upper assembly - LH
In this procedure, the front wing, the valance outer
reinforcement and the bonnet alarm switch mounting
bracket are replaced in conjunction with the LH
valance upper assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Remove brake pipes from valance.
8.Release harness from valance and position
aside.
9. Models with A/C: Depressurise A/C system
and remove pipes from valance.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
Page 1277 of 1672
PANEL REPAIRS
77-2-28 REPAIRS
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit brake pipes to valance.
4.Fit ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
5.Fit PAS/ACE reservoir, refill fluids to correct
levelsand bleed ACE system.
+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.6.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
7.Fit front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
8.Connect leads/multiplug to alternator.
9.Connect battery leads, negative lead last.
M77 1743
M77 1690A
Page 1279 of 1672
PANEL REPAIRS
77-2-30 REPAIRS
Valance upper assembly (front section) -
LH
In this procedure, the front wing, the valance outer
reinforcement (front section) and the bonnet alarm
switch mounting bracket are replaced in conjunction
with the LH valance upper assembly (front section).
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
5.Remove PAS/ACE reservoir.
6.Remove ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
7.Release harness from valance and position
aside.
8. Models with A/C: Depressurise A/C system
and remove pipes from valance.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. Models with A/C: Fit A/C pipes and recharge
A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
2.Fit harness to valance.
3.Fit ABS modulator.
+ BRAKES, REPAIRS, Modulator unit
- ABS.
4.Fit PAS/ACE reservoir and refill fluids to correct
levels.
+ FRONT SUSPENSION,
ADJUSTMENTS, ACE hydraulic system
bleeding.
+ CAPACITIES, FLUIDS AND
LUBRICANTS, Fluids.
M77 1744
M77 1689A