1999 LAND ROVER DISCOVERY brakes

BRAKES
70-42 REPAIRS
Servo - brake
$% 70.50.01
Remove
1.Remove brake master cylinder.

+ BRAKES, REPAIRS, Master cylinder
- brake.
2.Disconnect vacuum pipe from servo.
3.Release spring clip securing servo push-rod to
brake pedal and release pedal.
4.Remove 2 flanged nuts securing servo to
bulkhead.
5.Remove brake servo. Refit
1.Clean servo and mating faces,
2.Position servo and tighten nuts to 25 Nm (18
lbf. ft).
3.Position brake pedal to servo push-rod and
secure with spring clip.
4.Connect vacuum pipe to servo.
5.Fit brake master cylinder.
+ BRAKES, REPAIRS, Master cylinder
- brake.

BRAKES
REPAIRS 70-43
Vacuum pump - servo
$% 70.50.19
Remove
1.Remove auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.
2.Release cover and remove nut securing lead
to alternator.
3.Disconnect alternator multiplug.
4.Remove bolt (LH thread) and remove auxiliary
drive belt tensioner. 5.Remove bolt securing support stay to
alternator.
6.Release clip and disconnect oil drain hose from
vacuum pump.
7.Disconnect vacuum pump oil supply pipe from
cylinder head and discard 'O' ring.
8.Remove bolt securing alternator and release
from mounting bracket.
9.Disconnect vacuum hose from vacuum pump.
10.Remove alternator. Take care not to damage
radiator cooling fins.
11.Remove 4 bolts, and remove vacuum pump
from alternator.
CAUTION: Always fit plugs to open
connections to prevent contamination.

BRAKES
70-44 REPAIRS
Refit
1.Clean mating faces of alternator and vacuum
pump.
2.Fit vacuum pump to alternator and tighten
bolts to 8 Nm (6 lbf.ft).
3.Position alternator to engine and connect
multiplug.
4.Connect vacuum hose and oil drain hose to
vacuum pump and secure clips.
5.With assistance align alternator to mounting
bracket and fit but do not tighten bolt.
6.Fit bolt securing support stay to alternator and
tighten to 25 Nm (18 lbf.ft) .
7.Tighten bolt securing alternator to mounting
bracket to 45 Nm (33 lbf.ft).
8.Using new 'O' ring, connect oil supply pipe to
cylinder head and tighten to 10 Nm (7 lbf.ft).
9.Connect lead to alternator and tighten nut to 6
Nm (4.4 lbf.ft).
10.Fit auxiliary drive belt tensioner and tighten bolt
to 50 Nm (37 lbf.ft).
11.Fit auxiliary drive belt.

+ CHARGING AND STARTING,
REPAIRS, Belt - auxiliary drive.

BRAKES
REPAIRS 70-45
Housing - caliper - front
$% 70.55.24
Remove
1.Raise front 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. 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.

BRAKES
70-46 REPAIRS
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. 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.

BRAKES
REPAIRS 70-47
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. 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.

BRAKES
70-48 REPAIRS
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.
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.

BRAKES
REPAIRS 70-49
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. 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.