1995 LAND ROVER DISCOVERY light

70BRAKES
2
FAULT DIAGNOSIS ABS FAULT AND REMEDY CHART
SYMPTOM POSSIBLE CAUSE CHECK REMEDY
ABS warning light on ABS electrical fault Check ABS electrical
circuit with Testbook
diagnostic equipmentChange component if
necessary
High sensor air gaps Push in sensors
Brake fluid warning light
ONFluid loss Check reservoir fluid level
and inspect system for
leaksRectify leakage, refill
reservoir
Reservoir fluid level
switch malfunctionCheck fluid level switch Change reservoir
cap/switch
Pedal travel increased,
foot pressure normalAir in system Rebleed brake system
Master cylinder
malfunctionChange master cylinder
Pedal can be moved
downwards under
constant pressureSeal leaking in master
cylinderInspect system for leaks Change master cylinder
Seal leaking in servo unit Change servo unit

BRAKES
7
REPAIR 19.Coat new seals in unused brake fluid. Fit 'L' seal
to plunger.
20.Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
Assembling master cylinder
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
21.Fit new swirl tube to bottom of cylinder bore.
22.Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23.Fit new primary plunger assembly using same
method as for secondary plunger.
24.Fit original guide ring to support primary plunger.
25.Coat a new 'O' ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: Do not roll 'O' ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. Do not over
stretch seal.
26.Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27.Fit two new reservoir seals in respective ports.
28.Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29.Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, Do
not adjust transfer housing after fitting.
30.Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31.Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
32.Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33.Fit brake pipes to master cylinder. Tighten to
15Nm.
34.Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35.Bleed system.See Brake System Bleed
36.Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.

BRAKES
9
REPAIR SERVO ASSEMBLY
Service repair no - 70.50.01
Remove
Before starting repair refer to general brake service
practice.
See General Brake Service Practice
NOTE: The filter, non-return valve and
grommet, are the only serviceable
components, in event of failure or damage
fit a new unit.
1.Disconnect battery negative lead.
2.Disconnect electrical plug to low fluid level
switch.
3.Thoroughly clean immediate area around all
master cylinder outlet ports. Remove each brake
pipe, sealing each pipe and outlet port to prevent
ingress of foreign matter.
4.Disconnect vacuum supply hose to servo.
5.Remove lower dash panel to gain access to
servo push rod to brake pedal.
6.Remove clevis pin securing servo push rod to
brake pedal.
7.Remove two nuts and plain washers securing
servo.
8.Remove servo and master cylinder assembly.
9.Drain brake fluid into a suitable container. (If
master cylinder is kept horizontal it is not
necessary to drain fluid).10.Detach spacer from pedal box mounting face of
servo.
NOTE: Retain spacer for reassembly. The
spacer ensures stringent pedal to servo
operating dimensions are maintained.
11.Remove master cylinder from existing servo and
refit to new servo, if fitting new unit.
Refit
12.Fit spacer to servo.
13.Fit servo to pedal box.
14.Lightly grease brake pedal around area servo
push rod pivots.
15.Fit push rod to lower hole of brake pedal. Fit
clevis pin and clip.
16.Secure servo with two nuts and plain washers.
Tighten nuts to
26 Nm.
17.Refit lower dash panel.
18.Fit master cylinder to servo, refit nuts, plain and
spring washers. Tighten nuts to
26 Nm.
19.Remove all sealing plugs. Refit brake pipes to
respective ports. Tighten brake pipes to
15 Nm.
20.Refit vacuum supply hose.
21.Fill master cylinder to correct level using correct
grade of brake fluid.
See LUBRICANTS,
FLUIDS AND CAPACITIES, Information,
Recommended Lubricants and Fluids
22.Bleed brake system.See Brake System Bleed

70BRAKES
18
REPAIR SENSORS - FRONT
Service repair no - 70.65.32
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush and seal must
be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect required sensor electrical
connection, located on inner wing [fender] panel.
3.Remove sensor lead from clips.
4.Clean area surrounding sensor to prevent
ingress of dirt. Using a suitable lever pry sensor
from mounting bush.
5.Release harness cable ties, remove sensor lead
from vehicle.
6.Remove top swivel retaining bolts complete with
brake jump hose and sensor seal. Remove
sensor bush.
Refit
7.Insert new sensor bush and seal.
8.Refit brake jump hose bracket, coat bolts with
Loctite 270.
9.Lightly coat new sensor using EP 90 oil. Push
sensor through bush until it contacts exciter ring.
Sensor will be 'knocked back' to correct position
when vehicle is driven.
10.Secure sensor lead in original position.
11.Reconnect sensor electrical connection.
12.Drive vehicle to ensure ABS warning light is
extinguished.
SENSOR RINGS
The rear sensor ring is assembled to the rear brake
disc to form part of the rear hub assembly.
See
REAR AXLE AND FINAL DRIVE, Repair, Rear Hub
Assembly
The front sensor ring is a toothed ring on the axle
shaft which forms part of the front stub axle assembly.
See FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS

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.

74WHEELS AND TYRES
6
REPAIR WHEELS
Remove
WARNING: The parking brake acts on
transmission, not rear wheels, and may
not hold vehicle when jacking unless
following procedure is used. If one front wheel
and one rear wheel is raised no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select 'P' or a gear in main
gearbox and engage low gear in transfer box.
1.Loosen five wheel nuts.
2.Using a suitable trolley jack raise vehicle and
place on axle stands.
See INTRODUCTION,
Information, Jacking
3.Remove wheel nuts and carefully withdraw
wheel over studs.Refit
4.Ensure that retaining studs and nuts are clean.
5.Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6.Refit wheel taking care not to damage stud
threads. (Do not apply oil)
7.Fit wheel nuts and turn by hand for at least three
full threads before using any form of wheel
wrench.
8.Tighten nuts as much as possible using a
suitable wrench.
9.Lower vehicle and finally tighten nuts to correct
torque sequence shown. Alloy wheels and steel
wheels:
130Nm.

SUPPLEMENTARY RESTRAINT SYSTEM
1
DESCRIPTION AND OPERATION SYSTEM COMPONENTS
1. Airbag crash sensors (distributed SRS)
2. SRS warning light (airbag)
3. Rotary coupler
4. Driver's airbag module
5. Passenger's airbag module6. Airbag diagnostic socket
7. Airbag diagnostic control unit
8. Airbag harness (distributed SRS)
9. Knee bolsters (where fitted)
10. Airbag harness