1995 LAND ROVER DISCOVERY brake fluid

BRAKES
13
REPAIR FRONT BRAKE CALIPERS
Service repair no - 70.55.03
Service repair no - 70.55.16
Service tool:
LRT-70-500 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1.Loosen front wheel retaining nuts, raise front of
vehicle, lower onto axle stands, remove wheels.
2.Expose flexible brake hose by moving coiled
protective covering.
3.Using a recognised hose clamp, clamp hose to
prevent loss of brake fluid.
4.Disconnect rigid brake pipe from flexible hose,
seal exposed ends to prevent ingress of dirt.
5.Remove split [cotter] pin, retaining pins and
springs, withdraw pads. If refitting pads, identify
them for assembly to original locations.
6.Loosen bolts and remove caliper.
Repair
Do not separate caliper halves
7.Clean outer surfaces of caliper using aerosol
brake cleaner.
8.Using special tool LRT-70-500, clamp pistons in
inboard half of caliper. Gently, keeping fingers
clear, and withCAUTION,apply air pressure to
fluid inlet port to expel pistons. It is unlikely that
pistons will expel at same time, regulate rate
with a suitable piece of wood between
appropriate piston and caliper.
9.Finally remove pistons, identifying them with
their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal. Pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and seal grooves using
clean brake fluid only. If caliper or pistons are
corroded, or their condition is not perfect, new
parts must be fitted.

70BRAKES
14
REPAIR Assemble outboard pistons
13.Coat new fluid seal with brake fluid. Ease seal
into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat appropriate piston with brake fluid. Insert it
squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.
15.Coat new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.
Mounting inboard pistons
16.Clamp outboard pistons and carry out same
procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.
Fit calipers and pads
17.Fit caliper, tighten bolts evenly to
82 Nm.
18.Connect brake flexible hoses to caliper. Tighten
to
15 Nm.
19.Remove hose clamps.
20.Insert pads. Fit pins and springs, secure using
new split [cotter] pin.
21.Bleed brake system.
See Brake System Bleed
22.Press brake pedal firmly several times to locate
friction pads.
23.Fit road wheels, remove axle stands. Finally
tighten road wheel nuts to
130 Nm.
24.Road test vehicle. Note that new friction pads
require 'bedding-in', this may take several
hundred miles before brakes are at maximum
efficiency.

BRAKES
15
REPAIR REAR BRAKE CALIPERS
Service repair no - 70.55.06
Service repair no - 70.55.17
Service tool:
LRT-50-700 - Piston clamp
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
Remove caliper
1.Loosen rear road wheel nuts. Jack up vehicle,
lower onto axle stands, remove wheels.
2.Using a recognised hose clamp, clamp flexible
brake hose above rear axle.
3.Remove brake pipe(s) from rear brake caliper(s).
4.Seal pipe ends to prevent ingress of dirt.
5.Remove retaining pins and springs and withdraw
pads. If same pads are to be refitted, identify
them for assembly in original positions.
6.Remove two bolts, withdraw caliper from axle.
Repair
Do not separate caliper halves
7.Clean outer surfaces of caliper with aerosol
brake cleaner.
8. WITH CAUTIONexpel pistons from their bores
by applying air pressure to fluid inlet port. It is
unlikely both pistons will expel at same time,
regulate rate with a suitable piece of wood
inserted between two pistons.
9.Finally, remove pistons keeping them identified
with their respective bores.
10.Remove wiper seal retainer by inserting a blunt
screwdriver between retainer and seal and pry
retainer carefully from mouth of bore.
11.Taking care not to damage seal grooves, extract
wiper seal and fluid seal.
12.Clean bores, pistons and particularly seal
grooves using clean brake fluid only. If caliper or
pistons are corroded or their condition is not
perfect new parts must be fitted.

70BRAKES
16
REPAIR 13.Apply brake fluid to new seal. Fit seal into
groove in bore. When seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14.Coat piston with brake fluid. Insert it squarely
into bore. Do not tilt piston during insertion and
leave 8mm projecting from bore.
15.Coat a new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston into bore recess.
16.Using special tool LRT-70-500 - piston clamp,
press home seal retainer and piston.
Mounting inboard piston
17.Carry out same procedure as for removing and
fitting outboard piston and seals, instructions 8 to
16.
Fit calipers and pads to vehicle
18.Fit caliper to axle, tighten two bolts evenly to
82
Nm.
19.Connect brake pipe to caliper. Tighten to15Nm.
20.Remove clamp from flexible brake hose.
21.Insert pads and retaining springs, secure in
position with new retaining pins and spread
ends. Note correct position of retaining springs.
22.Bleed brake system.See Brake System Bleed
23.Press brake pedal firmly several times to locate
pads.
24.Fit road wheels, remove axle stands and finally
tighten road wheel nuts,
25.Road test vehicle. Note new brake pads require
'bedding-in', for several hundred miles before
brakes are at maximum efficiency.
PARKING BRAKE ADJUST
See SECTION 10,
Maintenance, Vehicle Interior

BRAKES
17
REPAIR REAR BRAKE CALIPER ASSEMBLY
LH Rear Caliper illustrated
Key to caliper
1. Caliper
2. Bleed screw
3. Pad retaining springs
4. Brake pads
5. Piston6. Wiper seal retainer
7. Wiper seal
8. Fluid seal
9. Retaining pins

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
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.

86ELECTRICAL
34
REPAIR PRINTED CIRCUIT AND WARNING LIGHTS
1. Panel illumination bulbs
2. Transmission oil temperature warning lamp bulb
3. Hazard warning lamp bulb
4. Check engine warning lamp bulb
5. Handbrake/brake fluid warning lamp bulb
6. ABS warning lamp bulb
7. Headlamp main beam warning lamp bulb
8. Trailer direction warning lamp bulb9. Direction indicator warning lamp bulb
10. Air suspension warning lamp bulb
11. Ignition/no charge warning lamp bulb
12. Seat belt warning lamp bulb
13. Not used
14. Traction control warning lamp bulb
15. Diesel heater plug warning lamp bulb (if fitted)
16. Main printed circuit