Page 565 of 1007
BRAKES
70-16 REPAIRS
6.Ease one brake shoe out of retaining groove in
abutment followed by the other shoe.
7.Manoeuvre brake shoe assembly around wheel
cylinder and rear hub and remove brake shoe
assembly.
CAUTION: Ensure edges of brake shoes do
not damage wheel cylinder dust covers.8.Fit an elastic band around wheel cylinder to
retain pistons.
9.Noting their fitted position, release and remove
return springs. Collect adjuster and expander.
10.Clean backplate and drum with brake cleaning
fluid.
WARNING: Do not use petroleum based
fluid as damage will occur to rubber
components
11.Use a wire brush to remove any corrosion, take
care not to damage wheel cylinder covers.
WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.
12.Inspect all parts for wear or damage.
13.Examine wheel cylinder dust seals for signs of
brake fluid leakage, a certain amount of
dampness is usual. However, if excessive fluid
is apparent, lift dust seals and check for
leakage. Renew wheel cylinders and brake
shoes if linings are contaminated.
Page 566 of 1007
BRAKES
REPAIRS 70-17
14.Check wheel cylinder pistons for freedom of
movement.
15.Check brake adjuster threads, nut and
handbrake linkage for wear. Renew if
necessary.
16.Check condition of return springs and renew if
necessary.
17.Ensure brake adjuster is fully off.
Refit
1.Position adjuster and expander to brake shoes
and fit return springs.
2.Smear brake shoe contact points with Molykote
111 grease.
3.Remove elastic band from wheel cylinder.
4.Manoeuvre brake shoes around rear hub and
locate to abutment and wheel cylinder.
5.Fit brake shoe retaining pins and secure with
clips.
6.Connect hand brake cable to brake shoe lever.
7.Fit brake drum.
+ BRAKES, REPAIRS, Drum - rear.
8.Apply brake pedal a min. of 30 times to ensure
full adjustment of rear brake shoes after
refitting.
9.Fit road wheel(s) and tighten nuts to 115 Nm
(85 lbf.ft).
10.Remove stands and lower vehicle.
Servo assembly - LHD
$% 70.50.01
Remove
1. Td4 models: Remove air cleaner element
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
2.Remove brake master cylinder.
+ BRAKES, REPAIRS, Cylinder -
master - tandem - LHD.
3. Td4 models: Remove bolt securing vacuum
reservoir and position reservoir aside.
4.Remove screw securing fuel filter housing to
bracket.
5.Release fuel filter housing from bracket.
6.Release and disconnect vacuum hose from
servo.
7.Remove and discard vacuum hose seal.
8.Release brake pipes from clips on bulkhead.
M70 1089
Page 567 of 1007
BRAKES
70-18 REPAIRS
9.Remove clip and clevis pin securing brake
servo push rod to brake pedal.
10.Remove 4 nuts securing servo to body and
remove servo.
11.Remove and discard gasket.Refit
1.Fit new gasket to servo.
2.Position servo to body, fit nuts and tighten in a
diagonal sequence to 22 Nm (16 lbf.ft).
3. Align push rod to brake pedal, fit clevis pin and
secure with new spring clip.
4.Position fuel filter to support bracket and secure
with screw.
5. Td4 models: Fit vacuum reservoir and washer
to mounting bracket, tighten bolt to 10 Nm (7.5
lbf.ft).
6.Fit new vacuum hose seal.
7.Connect vacuum hose to servo.
8.Fit brake master cylinder.
+ BRAKES, REPAIRS, Cylinder -
master - tandem - LHD.
9.Secure brake pipes in retaining clips.
10. Td4 models: Fit air cleaner element.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
Page 568 of 1007
BRAKES
REPAIRS 70-19
Servo assembly - RHD
$% 70.50.01
Remove
1. KV6 models: Remove engine acoustic cover.
2. Td4 models: Remove air cleaner element
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
3.Remove brake master cylinder.
+ BRAKES, REPAIRS, Cylinder -
master - tandem - RHD.
4.Release and disconnect vacuum hose from
servo.
5.Remove and discard vacuum hose seal.
6.Release brake pipes from clips on bulkhead.7.Remove clip and clevis pin securing brake
servo push rod to brake pedal.
8.Remove 4 nuts securing servo to body and
remove servo.
9.Remove and discard gasket.
Refit
1.Fit new gasket to servo.
2.Position servo to body, fit nuts and tighten to 22
Nm (16 lbf.ft).
3. Align push rod to brake pedal, fit clevis pin and
secure with new spring clip.
4.Fit new vacuum hose seal.
5.Connect vacuum hose to servo.
6.Fit brake master cylinder.
+ BRAKES, REPAIRS, Cylinder -
master - tandem - RHD.
7.Secure brake pipes in retaining clips.
8. Td4 models: Fit air cleaner element.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
9. KV6 models: Fit engine acoustic cover.
Page 569 of 1007
BRAKES
70-20 REPAIRS
Vacuum pump - Td4 - manual
$% 70.50.19
Remove
1.Disconnect battery earth lead.
2.Remove air cleaner element.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
3.Move injector harness clear of vacuum pump.
4.Release clip and disconnect hose from vacuum
pump.
5.Remove and discard 2 bolts securing vacuum
pump.
6.Remove vacuum pump and discard 'O' ring.Refit
1.Clean vacuum pump and mating face.
2.Fit new 'O' ring to vacuum pump.
3.Rotate vacuum pump drive to align with
camshaft, fit vacuum pump and tighten new
bolts to 22 Nm (16 lbf.ft).
4.Connect hose to vacuum pump and secure with
clip.
5.Reposition injector harness.
6.Fit air cleaner element.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Element - air cleaner.
7.Connect battery earth lead.
M70 1031
Page 570 of 1007
BRAKES
REPAIRS 70-21
Vacuum pump - Td4 - automatic
$% 70.50.19
Remove
1.Disconnect battery earth lead.
2.Remove camshaft cover.
+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
3.Mark EGR pipe and cooler to aid refit.
4.Loosen clamps EGR pipes to cooler and move
clamps aside.
5.Remove pipe, EGR cooler to EGR valve.
6.Remove bolt securing fuel rails to support
bracket.
7.Remove bolt securing intercooler pipe to
support bracket.
8.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.9.Remove bolt securing turbo outlet pipe to upper
coolant rail.
10.Remove 2 bolts securing pipe support bracket
to engine lifting bracket, remove support
bracket.
11.Release clip and remove vacuum hose.
12.Remove and discard 2 bolts securing vacuum
pump.
M17 0283
Page 571 of 1007
BRAKES
70-22 REPAIRS
13.Remove 3 bolts securing EGR cooler to
cylinder head and lifting bracket.
14.Move EGR cooler aside for access to vacuum
pump.
15.Remove vacuum pump and discard 'O' ring.
Refit
1.Clean vacuum pump and mating face.
2.Fit new seal to vacuum pump, fit vacuum pump
and tighten new bolts to 22 Nm (16 lbf.ft).
3.Position EGR cooler to mounting, fit bolts and
tighten to 25 Nm (18 lbf.ft).
4.Position pipe support bracket to engine lifting
bracket, fit and tighten bolts to 25 Nm (18 lbf.ft).
5.Fit vacuum hose and tighten clip.
6.Fit bolt securing turbocharger pipe to coolant
rail and tighten to 25 Nm (18 lbf.ft).
7.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
8.Fit bolt securing turbocharger intercooler pipe
to support bracket and tighten to 10 Nm (7.5
lbf.ft).
9.Fit bolt securing fuel rails to support bracket
and tighten to 10 Nm (7.5 lbf.ft).
10.Align EGR pipe to cooler, fit clamp but do not
fully tighten until camshaft cover is refitted.
11.Fit EGR pipe clamp and tighten screw.
12.Fit camshaft cover.
+ ENGINE - Td4, REPAIRS, Gasket -
camshaft cover.
13.Connect battery earth lead.
Vacuum - enhancer - KV6
$% 70.50.20
Remove
1.Disconnect battery earth lead.
2.Remove engine accoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
3.Release enhancer from support clips.
4.Disconnect multiplug from solenoid valve if
fitted.
5.Release and disconnect servo pipe.
6.Release clip and disconnect from intake hose.
7.Release and remove enhancer assembly from
inlet manifold.
Refit
1.Fit enhancer to inlet manifold.
2.Connect to intake hose and secure with clip.
3.Connect servo hose.
4.Connect multiplug to solenoid valve if fitted.
5.Fit enhancer into clips.
6.Fit engine acoustic cover.
+ ENGINE - K SERIES KV6, REPAIRS,
Cover - engine acoustic.
7.Connect battery earth lead.
Page 572 of 1007
BRAKES
REPAIRS 70-23
Carrier assembly - calliper - front
$% 70.55.28
Remove
1.Raise front of vehicle.
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.
3.Remove 2 guide pins from calliper housing.
4.Release calliper housing from calliper carrier
and tie aside.
5.Remove 2 brake pads and retainers from
calliper carrier.6.Remove 2 bolts securing calliper carrier and
remove carrier.
7.Remove guide pins and seals from carrier.
