1995 LAND ROVER DISCOVERY service

BRAKES
19
REPAIR SENSORS - REAR
Service repair no - 70.65.31
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush must be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor electrical connections,
located above rear axle.
3.Remove sensor from its locating clip.
4.Remove bolts securing mudshield.
5.Using a suitable lever, pry sensor from mounting
bush.
6.Release harness cable ties, remove sensor lead
from vehicle.
7.Remove sensor bush.
Refit
8.Fit new sensor bush.
9.Lightly grease new sensor using silicone grease.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
10.Push sensor through bush until it touches exciter
ring. Sensor will be 'knocked back' to correct
position when vehicle is driven.
11.Secure harness in position.
12.Reconnect sensor electrical connection.
13.Drive vehicle to ensure ABS warning light is
extinguished.STOP LIGHT SWITCH ABS
Service repair no - 86.65.51
Remove
1.Turn ignition off. Disconnect battery negative
lead.
2.Remove lower trim panel.
3.Disconnect multiplug to switch.
4.Depress brake pedal access front of switch.
5.Pull sleeve and plunger of switch FULLY
forward.
6.Remove switch rearwards
NOTE: If switch is difficult to release,
check sleeve is FULLY forward.
Refit
7.Pull sleeve and plunger of switch fully forward.
8.Depress brake pedal, fit switch. Ensure retaining
clips are FULLY located.
9.Hold switch firmly in place, pull brake pedal back
fully to set switch.
10.Reconnect battery and turn ignition on.
11.Check switch operation by slowly depressing
brake pedal and checking that the switch clicks
twice.
12.Check stop lamps go off when pedal is released.
13.Recheck switch is securely fitted.
14.Operation may be checked using Testbook.

70BRAKES
20
REPAIR STOP LIGHT SWITCH - NON ABS
Service repair no - 86.65.51
Remove
1.Disconnect battery negative lead.
2.Remove lower dash panel.
3.Depress foot brake.
4.Remove rubber protector from switch, if fitted.
5.Remove hexagon nut.
6.Withdraw switch.
7.Disconnect electrical leads.
Adjust
8.With switch still in position and multiplug
disconnected, connect an ohmmeter across
switch terminals.
9.Screw switch in until open circuit exists across
terminals with pedal released and continuity
exists as soon as pedal is depressed.
10.Tighten locknut.
CAUTION: Ensure switch does not prevent
brake pedal returning fully.
Refit
11.Reverse removal procedure.

70BRAKES
22
REPAIR MODULATOR UNIT
Service repair no - 70.65.45
WARNING: New modulator units are
supplied in a shock absorbing pack
marked with a use by date. The new
modulator will contain hydraulic brake fluid within
the valve block and all ports plugged.
Modulator units must be handled with care the
following must be avoided:- any impact, use of
compressed air on any of the hydraulic ports,
removing plugs to connection ports before fitting
unit.
Remove
1.Refer to the illustration of brake components
ABS. For details of modulator unit and hydraulic
pipe connections to it.
See Brake
Components ABS
2.Refer to general brake service practice.See
General Brake Service Practice
3.Check new modulator unit is packaged in
accordance with the WARNING above.
4.Disconnect battery negative lead.
5.Remove the two electrical plugs.
6.Identify 8 pipe to modulator connections for
correct reassembly.
7.Disconnect 8 pipe unions.
8.Remove nuts securing modulator to mounting
bracket.
9.Remove modulator unit.
10.Remove mounting bushes and cup.
Refit
11.Fit mounting bushes and cup to new modulator.
12.Fit modulator unit to mounting bracket.
13.Fit 8 pipes to modulator connections. Pipes
mustbe connected to correct port. Tighten to
15Nm.
14.Bleed the complete hydraulic system.See
Brake System Bleed
15.Check system function using the 'Testbook'
diagnostics
16.Test operation of brakes.ELECTRONIC CONTROL UNIT ABS
Service repair no - 70.65.01
Remove
For location of the ECU.
See Description and
operation, ABS Components
1.Disconnect battery negative lead.
2.Remove retaining bolt and lower alarm system
ECU and relay mounting bracket into passenger
footwell.
3.Remove two screws and detach ECU complete
with harness plug from mounting bracket.
4.Release ECU plug retaining clip.
5.Move plug in direction of arrow and release
hooked end of plug from retaining post.
Refit
6.Reconnect ECU harness plug ensuring that it is
firmly located and retaining clip secures plug.
7.Reverse removal procedure.

BRAKES
1
SERVICE TOOLS BRAKE SERVICE TOOLS
LRT-70-500 Brake piston compressor
18G 672

WHEELS AND TYRES
5
REPAIR Off vehicle balancing
Balance wheel assembly referring to equipment
manufacturer's instructions.
It is essential that the wheel is located by the centre
holeNOTthe stud holes. To ensure positive wheel
location the diameter of the locating collar on the
machine shaft must be 112.80 to 112.85 mm (4.441 to
4.443 in). This diameter will ensure that the collar fits
correctly within the centre hole of the wheel.
Where possible always use the vehicle wheel
retaining nuts to locate the wheel on the balancer, to
avoid damaging the wheel. If this is not possible, the
locating nuts must be of a similar pattern to the
original wheel nuts. The use of conical type wheel
nuts for this purpose may damage the aluminium
alloy.
Cleaning
Wash the aluminium wheels using a suitable wash
and wax concentrate correctly diluted and rinse with
cold clear water.DO NOTuse abrasives or aluminium
wheel cleaners containing acid, as they will destroy
the lacquer finish.
Tyre changing
Use only tyre changing equipment to mount or
demount tyres, following the equipment
manufacturer's instructions.DO NOTuse hand tools
or tyre levers, as they may damage tyre beads or the
aluminium wheel rim.
Puncture repair
Remove punctured tyre from wheel and repair using a
combination service plug and vulcanising patch.
Always follow manufacturer's instructions when using
a puncture repair kit.
Only punctures in tread area are repairable,DO NOT
attempt to repair punctures in tyre shoulders or
sidewalls.
Do not attempt to repair a tyre that has sustained the
following: bulges or blisters, ply separation, broken or
cracked beads, wear indicators visible and punctures
larger than 6 mm diameter.
CAUTION: Do not use tyre sealants that
are injected through valve stem to repair
punctured tyres, they may produce wheel
corrosion and tyre imbalance.
Aluminium wheel rim bead seats should be cleaned
using a non-abrasive cleaner to remove the mounting
lubricants and old rubber. Before mounting or
demounting a tyre, bead area should be well
lubricated with a suitable tyre lubricant.
TYRE FITTING
Alloy wheels
1.Install a new valve assembly.
2.Ensure wheel and tyre is adequately lubricated.
3.Mount tyre in normal manner. Inflate tyre and at
same time apply hand pressure to area around
valve to aid seating over valve first.
NOTE: Stop inflation immediately if tyre
seats opposite valve, as this will result in
valve being blocked by tyre beading,
making further inflation impossible, and carry out
following procedure.
4.Deflate tyre, unseat and rotate it around the rim
until valve is in line with that part of tyre which
seated initially. This part of beading having
seated over hump previously will automatically
seat first when tyre is re-inflated.
5.Inflate tyre to seat beads correctly, finally inflate
to correct pressure.

75SUPPLEMENTARY RESTRAINT SYSTEM
4
DESCRIPTION AND OPERATION GENERAL PRECAUTIONS
Impacts which do not deploy airbags
CAUTION: Check for structural damage in
the area of the impact, paying particular
attention to bumper armatures,
longitudinals, crash cans and bracketry.
1.Carefully inspect any airbag part before
installing. Do not install any part that shows
signs of being dropped or improperly handled,
such as dents, cracks or deformation.
2.Always remove the key from the starter switch
before beginning work.
3.Always disconnect both the negative '-' cable
and positive '+' cable at the battery before
removal of driver or passenger airbag modules.
Disconnect the negative cable first.
CAUTION: The airbag system has
sufficient stored energy to deploy airbags
for up to 20 minutes.
4.To continue work immediately, disconnect the
driver's airbag and passenger's airbag (where
fitted).
5.Do not try to dismantle the airbag module. There
are NO separately serviceable parts. Once an
airbag has been deployed, it cannot be repaired
or reused.
6.Do not install used airbag parts from another
vehicle. When repairing, use only new airbag
parts.

75SUPPLEMENTARY RESTRAINT SYSTEM
6
DESCRIPTION AND OPERATION AIRBAG STORAGE
Temporary storage
For temporary storage of the airbag module during
service, observe the following precautions:
Store the airbag module with the pad surface up.
Place the airbag module in designated storage area.
If no designated storage area is available, the module
may be stored in the boot of the vehicle from which it
was removed. Always lock the boot when module is
stored in it and inform workshop supervisor.
WARNING: If the airbag is improperly
stored face down, accidental deployment
could propel the unit with enough force to
cause serious injury.
Store the removed airbag module on a secure flat
surface away from heat, oil, grease, detergent or
water.
CAUTION: Improper handling or storage
can internally damage the airbag module,
making it inoperative. If you suspect the
airbag module has been damaged, install a new
unit.
Overnight storage
Airbag modules are classed as an explosive article
and as such they must be stored in a secure steel
cabinet which has been approved by the local
authority.

SUPPLEMENTARY RESTRAINT SYSTEM
1
REPAIR SYSTEM PRECAUTIONS
CAUTION: Before and during any removal
operations within the SRS section, note
routing and position of all harnesses to aid
correct refitting and to avoid accidentally trapping
cables.
CAUTION: During refitting of any item
within the SRS section, always ensure
connectors are fully engaged and latched
before proceeding to the next stage of the
operation.DRIVER'S AIRBAG MODULE
Service repair no - 76.74.01
WARNING: All the airbag system
components, including the wiring harness,
MUST be renewed after the airbags have
deployed.
Remove
1.Turn steering wheel 90Ê from horizontal.
2.Switch off ignition.
3.Disconnect battery negative '-' and then the
positive '+' lead.
CAUTION: Always disconnect both leads.
4.Release 2 turnbuckles and remove dash lower
panel.