LAND ROVER FRELANDER 2 2006 Repair Manual

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Brake Pads (206-04 Rear Di s c Brake, Removal and Ins t allat ion) /Brake Di sc (206-04 Rear Dis c Brake, Removal and Ins tal lati on).TEST the sys tem for normal operat ion.NoVehicle i s OK.
PINPOINT TEST B : VIBRATION WHEN BRAKES ARE APPLIED
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
B1: ROAD T EST VEHICLERoad tes t t he vehi cl e between 40-80 km/h (25-50 mph) wit hout applying brakes .
Is t he vibrati on pres ent ?YesTEST for nois e vibrat ion and hars hnes s (wheel /t ire balance, worn/damaged s us pensi onbus hings /component s , etc.). REPEAT road t es t i f neces sary.NoGO t o B2.B2: CHECK FOR BRAKE VIBRAT ION
Road tes t t he vehi cl e between 40-80 km/h (25-50 mph) wit h li ght and medium appli cat ion on thebrake pedal .Is a vibrat ion pres ent?YesCHECK the brake cal iper mounti ng bol ts and wheel hub nuts and TIGHTEN as necess ary. CHECK t hebal ance of al l road wheels and t ires and REPAIR as necess ary. CHECK t he brake di scs for excess i vewear, runout, t hicknes s vari ati on or cracks . INSTALL new brake di s cs and brake pads as required. GOto B3.NoVehi cl e i s OK.B3: IS VIBRAT IO N ST ILL PRESENT UNDER BRAKE APPLICAT ION?
Road tes t t he vehi cl e between 40-80 km/h (25-50 mph) wit h li ght and medium appli cat ion on thebrake pedal .Is a vibrat ion pres ent?YesCHECK for wear or fai lure of s t eering gear bushi ngs . CHECK for wear or fai lure of s teeri ng gear balljoi nt s . CHECK for wear or fail ure of front wheel bearings, s us pens ion bus hings and ball joints . CHECKfor wear or fail ure of rear wheel bearings , s us pensi on bushi ngs and bal l joint s . REFER t o relevants ect ion i n works hop manual and INSTALL new components as required.NoVehi cl e i s OK.
PINPOINT TEST C : THE BRAKES PULL OR DRIFT
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
C1: ROAD T EST VEHICLE
Road t es t t he vehi cle and apply t he brake pedal.
Does the vehicl e pull or drift ?YesGO to C2.NoVehicle is OK.C2: INSPECT T IRE CONDIT ION/PRESSURE
Check for exces s ive t ire wear or i ncorrect pres sures.
Are the t ires at t he correct pres sure and i n good condit ion?YesGO to C3.NoADJUST the ti re press ures or INSTALL new ti res i f exces si vel y worn. TEST t he s ys t em for normaloperat ion.
C3: CHECK CALIPERS
Check the di sc brake cal iper pis tons and pi ns for binding, leaking or s t icki ng.
Do t he dis c brake cali per pi st ons and pins bi nd, l eak or s t ick?YesRECTIFY s t icking pins and INSTALL new brake calipers as required.REFER to: Brake Cal iper (206-03 Front Dis c Brake, Removal and Inst all ati on) /Brake Cal iper (206-04 Rear Di sc Brake, Removal and Ins tal lati on).TEST t he sys t em for normal operat ion.NoGO to C4.
C4: INSPECT BRAKE DISCSCheck the brake di s cs for exces si ve damage, t hicknes s vari ati on or runout .
Does exces si ve damage or runout exi st ?YesINSTALL new brake dis cs and brake pads as required. TEST t he s ys t em for normal operati on.NoGO to C5.
C5: INSPECT T HE FRONT HUB AND WHEEL BEARING ASSEMBLYCheck the front hub and wheel bearing as s embl y.

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Are the wheel bearings OK?YesGO to C6.NoINSTALL new wheel bearings as requi red.REFER to: Front W heel Beari ng (204-01 Front Sus pensi on, Removal and Ins t al lat ion).TEST t he sys t em for normal operat ion.
C6: CHECK SUSPENSION BUSHINGS AND BALL JOINT S
Check al l s us pensi on bushi ngs and bal l joint s.
Are the s us pens ion bus hings and ball joints OK?YesCheck and adjust s t eering geomet ryREFER to: Four-W heel Alignment (204-00 Suspens ion Sys tem - General Informati on, GeneralProcedures ).NoINSTALL new sus pens i on bus hings and ball joints as required. REFER t o t he rel evant sect ion i n t heworks hop manual.
PINPOINT TEST D : THE PEDAL FEELS SPONG Y
T ESTCONDIT IO NSDET AILS/RESULT S/ACT IO NS
D1: CHECK FOR SPONGY PEDAL (ENGINE OFF)
Check for a fi rm brake pedal.
Is t he brake pedal effort and brake pedal t ravel normal?YesVehi cl e i s OK.NoGO t o D2.
D2: CHECK BR AKE PEDAL RESERVE (ENGINE OFF)Pump t he brake pedal 10 t imes and hol d on t he final appli cat ion.
Does t he brake pedal feel fi rm on final appl icat ion?YesGO t o D3.NoBLEED the brake sys tem.REFER t o: Brake Sys tem Bleeding (206-00 Brake Sys tem - General Informat ion, GeneralProcedures ) /Brake Syst em Press ure Bleeding (206-00 Brake Sys tem - General Informat ion, General Procedures ).D3: CHECK BR AKE PEDAL RESERVE (ENGINE ON)
Appl y Parking Brake and ens ure transmis s ion i s in park/neutral .
Start engine and al low to idle.
Appl y t he brake pedal l ightl y t hree or four t imes .
W ait 15 seconds for t he vacuum t o recover.
Pus h down on the brake pedal unti l it s tops movi ng downward or an increas ed res i st ance to t hebrake pedal t ravel occurs .Hold t he brake pedal in t he applied pos it ion whi le increasi ng t he engi ne s peed t o 2000 rpm.
Rel ease the accel erat or pedal.
Does t he brake pedal move downward as t he engine s peed ret urns t o idl e?YesGO t o D4.NoCHECK the vacuum t o brake boos ter.
D4: CHECK BR AKE FLUID LEVELCheck t he brake mas t er cyli nder reservoi r fl ui d l evel.
Is t he fluid level OK?YesBLEED the brake sys tem.REFER t o: Brake Sys tem Bleeding (206-00 Brake Sys tem - General Informat ion, GeneralProcedures ) /Brake Syst em Press ure Bleeding (206-00 Brake Sys tem - General Informat ion, General Procedures ).TEST the s ys tem for normal operat ion.NoCHECK for l eaking brake s ys t em and RECTIFY as necess ary. ADD fl ui d and BLEED t he brakesys t em.REFER t o: Brake Sys tem Bleeding (206-00 Brake Sys tem - General Informat ion, GeneralProcedures ) /Brake Syst em Press ure Bleeding (206-00 Brake Sys tem - General Informat ion, General Procedures ).TEST the s ys tem for normal operat ion. REPEAT road tes t i f required.
PINPOINT TEST E : THE PEDAL GOES DOWN FAST
T ESTCONDIT IO NSDET AILS/RESULT S/ACT IONS
E1: ROAD T EST VEHICLE
Road t es t the vehicle and appl y the brake pedal .
Is t he brake pedal effort and brake pedal t ravel normal?YesVehi cl e is OK.NoGO t o E2.E2: PRESSURIZE SYST EM AND CHECK BRAKE PEDAL T RAVEL

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W it h t he vehi cle s t at ionary pump t he brake pedal rapi dly (fi ve ti mes ).
Does t he brake pedal travel build up and t hen hol d?YesBLEED t he brake s ys tem.REFER t o: Brake Syst em Bleedi ng (206-00 Brake Sys tem - General Informati on, GeneralProcedures ) /Brake Sys t em Press ure Bleeding (206-00 Brake Sys tem - General Informat ion, General Procedures ).TEST t he s yst em for normal operati on.NoGO t o E3.
E3: CHECK FOR BRAKE SYST EM LEAKS
Check for ext ernal brake sys t em l eaks . For addit ional informati on, refer t o brake mas t er cyli ndercomponent tes t in this secti on.
Are l eaks found?YesREPAIR as neces s ary, ADD fluid and BLEED brake s ys t em.REFER t o: Brake Syst em Bleedi ng (206-00 Brake Sys tem - General Informati on, GeneralProcedures ) /Brake Sys t em Press ure Bleeding (206-00 Brake Sys tem - General Informat ion, General Procedures ).TEST t he s yst em for normal operati on.NoSys tem is OK.
PINPOINT TEST F : THE PEDAL GOES DOWN SLOWLY
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
F1: CHECK FOR BRAKE SYST EM LEAKS
Check for ext ernal brake s yst em leaks . For addi ti onal i nformat ion, refer to brake mas ter cyl indercomponent t es t i n t hi s s ect ion.
Are there any ext ernal brake s ys t em l eaks ?YesREPAIR as neces sary. ADD fl uid and BLEED t he brake s yst em.REFER to: Brake Sys t em Bleeding (206-00 Brake Sys t em - General Informat ion, GeneralProcedures) /Brake Sys tem Pres s ure Bl eeding (206-00 Brake Sys t em - General Informat ion, General Procedures).TEST the sys tem for normal operat ion.NoCheck for brake mas t er cyli nder i nt ernal leaks, refer t o brake mas t er cyli nder component t est int hi s s ect ion, and repair as necess ary.
PINPOINT TEST G : EXCESSIVE BRAKE PEDAL EFFORT
T ESTCO NDIT IONSDET AILS/RESULT S/ACT IONS
G1: CHECK BR AKE PADSCheck t he brake pads for wear, contaminati on, correct i nst all at ion, damage and t ype.
Are any concerns found?YesINSTALL brake pads correctl y or INSTALL new brake pads as requi red.REFER t o: Brake Pads (206-03 Front Dis c Brake, Removal and Ins tall ati on) /Brake Pads (206-04 Rear Di sc Brake, Removal and Ins tal lat ion).TEST the s ys tem for normal operat ion. REPEAT road tes t .NoGO t o G2.G2: CHECK VACUUM
Dis connect the vacuum hose from t he brake boos ter.
Connect a vacuum/pres sure t est er to the vacuum hose.
Run the engine at normal operati ng temperat ure.
Record the vacuum readi ng.
Is t he readi ng 90 kPa (26.5 in-Hg) or greaterYesGO t o G3.NoLO CATE and REPAIR t he s ource of low vacuum. TEST t he s yst em for normal operati on.
G3: INSPECT SYST EM
Swit ch the engine off.
Reconnect t he vacuum hos e.
Ins pect t he brake boos ter, rubber grommet, and al l vacuum plumbi ng for cracks, hol es, damagedconnect ions , or mis s ing clamps .
Pump t he brake pedal s everal ti mes t o exhaus t the vacuum. Pus h down on the brake pedal andhol d.
Does the brake pedal move down when t he engi ne is st art ed?YesVacuum sys tem is OK.NoGO t o G4.G4: CHECK PO WER BRAKE BOOST ER VALVE
Check t he brake boost er val ve. For addit ional i nformati on, refer to Brake Boost er component tes t i nthi s s ect ion.

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Is t he power brake boost er val ve OK?YesCHECK the brake boos t er. For addit ional informat ion, refer t o Brake Boos t er component t es t in t hissect ion. INSTALL a new brake boos ter as requi red.REFER t o: Brake Boos ter (206-07 Power Brake Act uati on, Removal and Ins tal lati on).TEST the s ys tem for normal operat ion.NoINSTALL a new brake boos t er valve. TEST the sys tem for normal operat ion.
PINPOINT TEST H : BRAKE LOCKUP DU RING LIG HT BRAKE PEDAL FORCE
T EST CONDIT IONSDET AILS/RESULT S/ACT IONS
H1: T EST BRAKE LOCKUPRoad t est t he vehicle and apply the brake pedal li ght ly.
Do t he brakes l ockup?YesGO to H2.NoVehicle is OK.
H2: INSPECT BRAKE PADS
Inspect brake pads for contami nat ion, correct ins t al lat ion, damage and type.
Are any concerns found?YesINSTALL t he brake pads correct ly or INSTALL new brake pads as required.REFER t o: Brake Pads (206-03 Front Di s c Brake, Removal and Ins t allat ion) /Brake Pads (206-04 Rear Dis c Brake, Removal and Inst all ati on).TEST t he s ys t em for correct operati on.NoGO to H3.
H3: INSPECT BRAKE CALIPERSInspect brake calipers for bindi ng, l eaking or s t icking.
Are any concerns found?YesINSTALL t he brake cali pers correct ly or INSTALL new brake cal ipers as required.REFER t o: Brake Caliper (206-03 Front Dis c Brake, Removal and Ins tall ati on) /Brake Cal iper (206-04 Rear Di sc Brake, Removal and Ins t al lat ion).TEST t he s ys t em for normal operati on.NoVehicle is OK.
PINPOINT TEST I : BRAKES DRAG
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
I1: ROAD T EST VEHICLE
Road t es t t he vehi cl e and apply t he brakes .
Are the brakes funct ioning correct ly?YesVehicle i s OK.NoGO to I2.
I2: CHECK BRAKE CALIPERS AND PARKING BRAKE CABLES
Check the front and rear cali per pis t ons and pins for bi ndi ng, l eaki ng or st icking and parki ng brakecabl es for s t icki ng/binding.
Do t he dis c brake cali per pi st ons and pins bind, l eak or s t ick, or t he parking brake cabl es st ick/bi nd?YesREPAIR or INSTALL new components as required. Tes t the s ys tem for normal operat ion. Road tes tvehi cle i f neces sary.NoGO to I3.
I3: CHECK BRAKE BO OST ER
Check the brake boos ter connecti ng rod alignment and t ravel.
Is the connect ing rod OK?YesVehicle i s OK.NoINSTALL a new brake boost er.REFER to: Brake Boos t er (206-07 Power Brake Actuat ion, Removal and Ins t allat ion).TEST the sys tem for normal operat ion.
PINPOINT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
T ESTCONDIT IONSDET AILS/RESULT S/ACT IONS
J1: T EST ON ROUGH ROAD
Road t es t the vehicle on rough road condit ions .
Apply the brakes s l owly.
Is t he brake pedal effort and brake pedal t ravel normal?YesVehicl e is OK.NoGO t o J2.
J2: CHECK BRAKE FLUID LEVEL

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Check t he brake mas ter cylinder res ervoir flui d level.
Is t he fl uid l evel OK?YesGO t o J3.NoCHECK brake mas ter cyl inder res ervoir s ealing poi nts . For addit ional informat ion, refer t o Brakemast er cyl inder component t es t in t his secti on. ADD brake fluid and BLEED t he brake s ys tem.REFER t o: Brake Syst em Bl eedi ng (206-00 Brake Syst em - General Informati on, General Procedures )/Brake Sys t em Pres s ure Bleedi ng (206-00 Brake Sys tem - General Informati on, General Procedures ).TEST t he s yst em for normal operati on. REPEAT road tes t if neces s ary.J3: CHECK BRAKE PEDAL RESERVE
Run engine at idle speed.
Apply the brake pedal li ght ly three or four ti mes .
W ait 15 s econds for the vacuum t o repl eni sh.
Pus h down on t he brake pedal unt il i t s tops moving downward or an increas ed res is t ance t o t hebrake pedal t ravel occurs .
Hol d t he brake pedal i n t he appl ied pos it ion whi le i ncreas i ng the engine speed t o 2000 rpm.
Rel eas e t he accel erator pedal .
Does t he brake pedal move downward as t he engi ne s peed returns to idle?YesGO t o J4.NoCHECK the vacuum t o the brake boos t er.
J4: CHECK T HE FRO NT WHEEL BEARING ASSEMBLY
Check t he front wheel bearing as s embly.
Are t he front wheel beari ngs l oose?YesINSTALL a new front wheel beari ng if damaged.REFER t o: Front W heel Bearing (204-01 Front Suspens ion, Removal and Inst all at ion).TEST t he s yst em for normal operati on.NoCHECK the front brake di scs for thicknes s variances .
PINPOINT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETU RN
T ESTCONDIT IO NSDET AILS/RESULT S/ACT IO NS
K1: CHECK FOR BRAKE PEDAL RET URN
Run the engine at i dle whi le maki ng s everal brake appli cat ions .
Pul l the brake pedal rearward wi th approxi matel y 44.5 N (10lb) force.
Rel eas e t he brake pedal and measure t he dis tance t o t he toe board.
Make a hard brake appl icat ion.
Rel eas e t he brake pedal and measure t he brake pedal t o t oe board di st ance. The brake pedalshould return t o it s original posi ti on.
Does t he brake pedal return t o it s original posi ti on?YesVehi cl e is OK.NoGO t o K2.
K2: CHECK FOR BRAKE PEDAL BINDINGDis connect t he brake boos ter from the brake pedal. Check t he brake pedal t o ens ure freeoperat ion.
Is t he brake pedal operat ing freel y?YesINSTALL a new brake boos ter.REFER t o: Brake Boost er (206-07 Power Brake Act uat ion, Removal and Ins tall ati on).TEST t he s yst em for normal operati on.NoREPAIR or INSTALL new brake pedal. TEST t he s ys t em for normal operati on.
Component Tests
Brake Booster
1. Check al l hos es and connecti ons . All unus ed vacuum connect ors s houl d be capped. Hos es and thei r connect ionss hould be correctl y s ecured and in good condi ti on wit h no hol es and no col laps ed areas. Ins pect t he val ve on t hebrake boos ter for damage.
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2. Check t he hydraulic brake s ys t em for leaks or low flui d.2.
3. W i th the aut omat ic trans mi s si on in PARK, s t op the engine and apply the parki ng brake. Pump t he brake pedals everal ti mes t o exhaus t all vacuum in the s ys tem. W it h t he engi ne s wit ched off and al l vacuum i n t he s ys t emexhaus t ed, apply the brake pedal and hold i t down. St art t he engi ne. If t he vacuum sys tem is operat ing, t hebrake pedal wil l tend t o move downward under cons t ant foot pres sure. If no mot ion is felt , the vacuum boos t ers ys tem is not funct ioning.
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4. Remove the vacuum hos e from t he brake boos ter. Mani fol d vacuum should be avai lable at t he brake boos ter endof t he hose wit h t he engi ne at idl e s peed and t he automat ic trans mi ss i on in PARK. Make s ure that all unusedvacuum outl ets are correct ly capped, hos e connectors are correct ly secured and vacuum hoses are i n goodcondit ion. W hen it is es tabli s hed that manifold vacuum is avai lable t o t he brake boos ter, connect t he vacuumhos e t o t he brake boost er and repeat St ep 3. If no downward movement of the brake pedal is felt , ins tal l a new
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brake boos ter.
5. Operate the engine for a minimum of 10 s econds at a fast i dle. Stop the engine and al low t he vehicle t o s t andfor 10 mi nut es. Then, appl y the brake pedal wi th approxi mately 89 N (20lb) of force. The pedal feel (brakeappli cat ion) s houl d be t he s ame as t hat not ed wit h t he engine runni ng. If the brake pedal feel s hard (no poweras s is t), ins t al l a new valve and t hen repeat t he tes t. If t he brake pedal s t ill feels hard, i ns t all a new brakeboos ter. If t he brake pedal movement feel s s pongy, bleed t he brake s ys t em.REFER t o: Brake Syst em Bl eedi ng (206-00 Brake Syst em - General Informati on, General Procedures ) /Brake Sys t em Pres s ure Bl eedi ng (206-00 Brake Syst em - General Informati on, General Procedures ).
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Brake Master Cylinder
Us ual ly, t he fi rs t and s tronges t indicat or of anything wrong i n t he brake s ys t em i s a feeling through t he brake pedal. Indiagnosi ng the condit ion of t he brake mas t er cyli nder, check pedal feel as evidence of a brake concern. Check for brakewarni ng lamp ill uminat ion and t he brake fluid level i n t he brake mas t er cyli nder reservoi r.
Normal Condit ions
The fol lowing condit ions are cons idered normal and are not i ndi cat ions t hat t he brake mast er cyl inder i s i n need of repair.
Modern brake sys tems are des igned t o produce a pedal effort that is not as hard as in the pas t . Compl aint s of lightpedal effort s s houl d be compared t o t he pedal efforts of another vehi cl e of t he s ame model and year.The fl uid l evel wi ll fal l wit h brake pad wear.
Abnormal Condi ti ons
Changes i n t he brake pedal feel or brake pedal travel are indicators t hat s omet hi ng coul d be wrong in the brake sys tem.The diagnost ic procedure and techni ques us e brake pedal feel , warning i ndi cat or il lumi nat ion and l ow brake flui d level asindicat ors t o diagnosi ng brake s yst em concerns . The foll owing condi ti ons are consi dered abnormal and indi cat e t hat t hebrake mas t er cyli nder i s in need of repai r:
• NOTE: Pri or to carrying out any diagnosi s , ens ure the brake sys tem warni ng indicator i s functi onal .
Brake pedal goes down fast . This could be caus ed by an external or int ernal leak.Brake pedal goes down s l owl y. Thi s coul d be caused by an int ernal or external l eak.Brake pedal is l ow or feels spongy. Thi s condit ion may be caus ed by no fl ui d i n the brake mas ter cylinder, reservoi rcap vent holes cl ogged or air i n t he hydraul ic s ys tem.Brake pedal effort is excess ive. This may be caus ed by a bi nd or obs t ructi on in the pedal/li nkage, a faul tynon-ret urn val ve, boost er or ins ufficient boos t er vacuum.Rear brakes lock up during light pedal force. Thi s may be caus ed by damaged brake pads , a parti ally appl ied parkingbrake, a damaged ABS s ens or or bearing fail ure.Brake pedal effort errat ic. This condit ion could be caus ed by the brake boos t er or incorrectl y ins tal led brake pads .Brake warning i ndi cat or is on. This may be caus ed by low fl uid l evel or fl oat as s embly damaged.
Non Pressure Leaks
Any reduced fl uid volume in t he brake mast er cyl inder res ervoi r may be caused by two types of none pres sure externalleaks .
Type 1: An ext ernal leak may occur at the brake mast er cyl inder res ervoir cap because of incorrect posi ti oning of t hegasket and cap. Repos it ion cap and gasket .
Type 2: An ext ernal leak may occur at the brake mast er cyl inder res ervoir mounti ng seal s. Repair s uch a l eak by ins tall ingnew s eals and make s ure that t he brake mas t er cyli nder reservoi r ret ai ning bolt i s correct ly i nst all ed.

Publi s hed: 11-May-2011
Brake System - General Information - Brake System Bleeding
General Procedures
W ARNING: If any component s upst ream of the Hydraul ic Control Uni t (HCU), including the HCU it sel f are replaced,t he brake s ys t em mus t be bl ed usi ng Land Rover approved diagnos t ic equipment . Thi s wil l ens ure that all ai r is expelledfrom the new component (s).
• NOTE: The fol lowi ng procedure covers bleedi ng t he brake s yst em i f components down st ream of the HCU have beenrepl aced. W here onl y t he primary or s econdary brake ci rcuit s have been di s turbed in i sol ati on, i t should onl y be neces s aryt o bleed t hat ci rcuit . Parti al bl eedi ng of the hydrauli c s ys t em i s only permis s ible if a brake tube or hos e has beendis connected wi th onl y mi nimal los s of fluid.
1. W ARNING: Do not work on or under a vehi cle s upported onl yby a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
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Check that t he brake fl uid l ines are s ecure and that t here are nos igns of a brake fl ui d l eak. If a brake fluid leak is det ect ed,i nves ti gat e and rect ify t he caus e of t he leak before bleeding t hebrakes .
Refer t o: Brake Syst em (206-00 Brake Sys t em - General Informat ion,Di agnos is and Tes ti ng).
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Pump t he brake pedal unt il t he brake vacuum ass i st ance isexhaus t ed.3.
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5. W ARNING: Do not allow dirt or forei gn li qui ds to ent er theres ervoi r. Us e only new brake fl uid of t he correct s peci fi cat ion fromairti ght cont ai ners . Do not mix brands of brake fl uid as t hey may notbe compati ble.
CAUTION: Brake fl ui d wi ll damage paint fi nis hed s urfaces. Ifs pil led, immedi at ely remove t he fl uid and clean t he area wit h wat er.
Remove t he brake fluid res ervoir cap.
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Fil l the brake fl ui d res ervoi r to t he MAX mark.6.
Inst all t he bleed t ube to the brake cali per bl eed s crew and i mmers et he free end of the bl eed tube i n a bl eed jar cont aini ng a s mallquant it y of approved brake fluid.
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St arti ng at t he brake cal iper furthes t away fromt he brake mas t er cyli nder, loosen the bl eeds crew by one-hal f to three-quarters of a t urn.
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9. CAUTION: The brake flui d res ervoir mus t remain full wi th
new, clean brake fluid at al l ti mes duri ng bleeding.
W it h ass i st ance, depres s t he brake pedal s t eadil y t hrough it s ful l
s troke and all ow it t o return t o the res t pos i ti on. Repeat the
procedure unt il brake fluid, clean and air-free fl ows int o t he bleed
jar.
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W hen brake fl uid, cl ean and air-free flows i nto the bl eed jar, depres s
and hold the brake pedal down.
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11. CAUTION: Make s ure t he bleed s crew cap is i nst all ed aft er
bleeding. This wi ll prevent corros ion t o t he bleed s crew.
W it h the brake pedal ful ly depres s ed, ti ght en t he bleed s crew.
T orque: 10 Nm 11.
Fil l the brake fl ui d res ervoi r to t he MAX mark.
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13. W ARNING: Braking efficiency may be seriousl y i mpai red if
an i ncorrect bl eed s equence is us ed.
Repeat t he brake bl eedi ng procedure for each brake cali per,
fol lowi ng the above s equence.
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Fil l the brake fl ui d res ervoi r to t he MAX mark.
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Apply t he brakes and check for leaks.
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Inst all t he brake fluid res ervoir cap.
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Inst all t he fl uid reservoi r access panel.
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Publi s hed: 11-May-2011
Front Disc Brake -
General SpecificationItemSpecification
Front dis cVenti lated
Front disc diameter:3.2 Pet rol316 mm (12.4 i n)
2.2 Dies el300 mm (11.8 i n)
Front dis c t hicknes s new (All engines )28 mm (1.10 i n)Service l imit (All engi nes )26 mm (1.024 i n)
Maximum dis c run-out - dis c ins t al led0.080 mm (0.003 i n)
Pad mi nimum thi cknes s2 mm (0.078 i n)Pis t on diamet er60 mm (2.362 i n)
Torque SpecificationsDescriptionNmlb-ft
Brake cali per bl eed screw86
Brake cali per mount ing pl at e t o wheel knuckle bolt s *200148Brake cali per gui de pin bolt s2821
Brake di sc dus t s hield bol ts107
Brake di sc Torx s crew3526Brake flexi hose uni on to cal iper3224
Brake hos e retaini ng bracket t o damper bol t2216
* New nuts/bolts must be fitted