2002 LAND ROVER DISCOVERY brake

GENERAL INFORMATION
03-1
GENERAL INFORMATION
General Precautions
Dangerous substances
Modern vehicles contain many materials and liquids
which if not handled with care can be hazardous to
both personal health and the environment.
WARNING: Many liquids and other substances
used in motor vehicles are poisonous and should
under no circumstances be consumed and
should, as far as possible, be kept from contact
with the skin. These liquids and substances
include acid, anti-freeze, asbestos, brake fluid,
fuel, windscreen washer additives, lubricants,
refrigerants and various adhesives.
Always read carefully the instructions printed on
labels or stamped on components and obey them
implicitly. Such instructions are included for
reasons of your health and personal safety.
Never disregard them.
Synthetic rubber
Many 'O' rings, seals, hoses, flexible pipes and other
similar items which appear to be natural rubber, are
in fact, made of synthetic materials called
Fluoroelastomers. Under normal operating
conditions this material is safe and does not present
a health hazard. However, if the material is damaged
by fire or excessive heating, it can break down and
produce highly corrosive Hydrofluoric acid.
Contact with Hydrofluoric acid can cause serious
burns on contact with skin. If skin contact does occur:
lRemove any contaminated clothing
immediately.
lIrrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
lObtain medical assistance immediately.
Should any material be in a burnt or overheated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.).
Decontaminate and dispose of gloves immediately
after use.Lubricating oils
Avoid excessive skin contact with used lubricating
oils and always adhere to the health protection
precautions.
WARNING: Avoid excessive skin contact with
used engine oil. Used engine oil contains
potentially harmful contaminants which may
cause skin cancer or other serious skin
disorders.
WARNING: Avoid excessive skin contact with
mineral oil. Mineral oils remove the natural fats
from the skin, leading to dryness, irritation and
dermatitis.
Health protection precautions
The following precautions should be observed at all
times.
lWear protective clothing, including impervious
gloves where practicable.
lAvoid prolonged and repeated contact with oils,
particularly used engine oils.
lDo not put oily rags in pockets.
lAvoid contaminating clothes (particularly those
next to the skin) with oil.
lOveralls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
lFirst aid treatment should be obtained
immediately for open cuts and wounds.
lApply barrier creams before each work period to
help prevent lubricating oil from contaminating
the skin.
lWash with soap and water to ensure all oil is
removed (proprietary skin cleansers and nail
brushes will help).
lUse moisturisers after cleaning; preparations
containing lanolin help replace the skin's natural
oils which have been removed.
lDo not use petrol/gasoline, kerosene, diesel
fuel, oil, thinners or solvents for cleaning skin.
lWhere practicable, degrease components prior
to handling.
lIf skin disorders develop, obtain medical advice
without delay.
lWear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in close
vicinity of the work area.

GENERAL INFORMATION
03-2
Safety Instructions
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
Always use the recommended jacking points.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
WARNING: Do not work on or under a vehicle
supported only by a jack. Always support the
vehicle on safety stands.
Do not leave tools, lifting equipment, spilt oil, etc.
around or on the work bench area. Always keep a
clean and tidy work area.
Brake shoes and pads
Always fit the correct grade and specification of
brake linings. When renewing brake pads and brake
shoes, always replace as complete axle sets.Brake hydraulics
Observe the following recommendations when
working on the brake system:
lAlways use two spanners when loosening or
tightening brake pipe or hose connections.
lEnsure that hoses run in a natural curve and are
not kinked or twisted.
lFit brake pipes securely in their retaining clips
and ensure that the pipe cannot contact a
potential chafing point.
lContainers used for brake fluid must be kept
absolutely clean.
lDo not store brake fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
lDo not allow brake fluid to be contaminated with
mineral oil, or put new brake fluid in a container
which has previously contained mineral oil.
lDo not re-use brake fluid removed from the
system.
lAlways use clean brake fluid or a recommended
alternative to clean hydraulic components.
lAfter disconnection of brake pipes and hoses,
immediately fit suitable blanking caps or plugs to
prevent the ingress of dirt.
lOnly use the correct brake fittings with
compatible threads.
lObserve absolute cleanliness when working
with hydraulic components.
Cooling system caps and plugs
Extreme care is necessary when removing
expansion tank caps and coolant drain or bleed
screws when the engine is hot, especially if it is
overheated. To avoid the possibility of scalding,
allow the engine to cool before attempting removal.

GENERAL INFORMATION
03-6
General Fitting Instructions
Component removal
Whenever possible, clean components and
surrounding area before removal.
lBlank off openings exposed by component
removal.
lImmediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or
plugs to prevent loss of fluid and ingress of dirt.
lClose the open ends of oilways exposed by
component removal with tapered hardwood
plugs or conspicuous plastic plugs.
lImmediately a component is removed, place it in
a suitable container; use a separate container
for each component and its associated parts.
lClean bench and provide marking materials,
labels and containers before dismantling a
component.
Dismantling
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on. A
particle of dirt or a cloth fragment could cause a
serious malfunction if trapped in these systems.
lBlow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
'O' rings used for sealing are correctly replaced
or renewed, if disturbed during the process.
lUse marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could
initiate cracks or distortion in marked
components.
lWire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
lWire labels on to all parts which are to be
renewed, and to parts requiring further
inspection before being passed for reassembly;
place these parts in separate containers from
those containing parts for rebuild.
lDo not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.Cleaning components
Always use the recommended cleaning agent or
equivalent. Ensure that adequate ventilation is
provided when volatile degreasing agents are being
used. Do not use degreasing equipment for
components containing items which could be
damaged by the use of this process.
General inspection
All components should be inspected for wear or
damage before being reassembled.
lNever inspect a component for wear or
dimensional check unless it is absolutely clean;
a slight smear of grease can conceal an
incipient failure.
lWhen a component is to be checked
dimensionally against recommended values,
use the appropriate measuring equipment
(surface plates, micrometers, dial gauges etc.).
Ensure the measuring equipment is calibrated
and in good serviceable condition.
lReject a component if its dimensions are
outside the specified tolerances, or if it appears
to be damaged.
lA part may be refitted if its critical dimension is
exactly to its tolerance limit and it appears to be
in satisfactory condition. Use 'Plastigauge' 12
Type PG-1 for checking bearing surface
clearances.

GENERAL INFORMATION
03-9
Joints and Joint Faces
General
Fit joints dry unless specified otherwise.
lAlways use the correct gaskets as specified.
lWhen jointing compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent jointing compound from entering
oilways, pipes or blind tapped holes.
lIf gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or jointing material to
enter any tapped holes or enclosed parts.
lPrior to reassembly, blow through any pipes,
channels or crevices with compressed air.
Locking Devices
General
Always replace locking devices with one of the same
design.
Tab washers
Always release locking tabs and fit new locking
washers. Do not re-use locking tabs.
Locking nuts
Always use a backing spanner when loosening or
tightening locking nuts, brake and fuel pipe unions.
Roll pins
Always fit new roll pins of an interference fit in the
hole.
Circlips
Always fit new circlips of the correct size for the
groove.
Keys and keyways
Remove burrs from edges of keyways with a fine file
and clean thoroughly before attempting to refit key.
Clean and inspect key closely; keys are suitable for
refitting only if indistinguishable from new, as any
indentation may indicate the onset of wear.

GENERAL INFORMATION
03-13
Self-locking nuts
Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the same
type.
Flexible Pipes and Hoses
General
When removing and installing flexible hydraulic pipes
and hoses, ensure that the following practices are
observed to ensure component serviceability.
lBefore removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
lObtain appropriate plugs or caps before
detaching hose end fittings, so that the ports can
be immediately covered to prevent the ingress
of dirt.
lClean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
lWhen refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.
lFit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of
dirt.
lAbsolute cleanliness must be observed with
hydraulic components at all times.
lAfter any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.

GENERAL INFORMATION
03-15
Hose clips
Markings (4) are usually provided on the hose to
indicate the correct clip position. If no markings are
provided, position the clip directly behind the
retaining lip at the end of the stub as shown. Worm
drive clips should be oriented with the crimped side
of the drive housing (5) facing towards the end of the
hose, or the hose may become pinched between the
clip and the stub pipe retaining lip. Worm drive clips
should be tightened to 3 Nm (2 lbf.ft) unless
otherwise stated. Ensure that hose clips do not foul
adjacent components.
Heat protection
Always ensure that heatshields and protective
sheathing are in good condition. Replace if damage
is evident. Particular care must be taken when
routing hoses close to hot engine components, such
as the exhaust manifold and the Exhaust Gas
Recirculation (EGR) pipe. Hoses will relax and
deflect slightly when hot; ensure this movement is
taken into account when routing and securing hoses.
Rolling Road Testing
General
IMPORTANT: Use a four wheel rolling road for
brake testing if possible.
WARNING: Do not attempt to test ABS function
on a rolling road.
Four wheel rolling road
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the tyres.
Before testing a vehicle with anti-lock brakes on a
four wheel rolling road, disconnect the ABS
modulator. The ABS function will not work, the ABS
warning light will illuminate. Normal braking will be
available.
Two wheel rolling road
Up to 03MY
ABS will not function on a two wheel rolling road. The
ABS light will illuminate during testing. Normal
braking will be available.
If brake testing on a two wheel rolling road is
necessary, the following precautions should be
taken:
lPropeller shaft to the rear axle is removed.
lNeutral selected in gearbox.
When checking brakes, run engine at idle speed to
maintain servo vacuum.
From 03MY
The differential lock must be engaged for two wheel
rolling road testing. It will also be necessary to
disconnect the propeller shaft from the transfer box
output shaft driving the axle whose wheels are NOT
on the rolling road. Additionally, the ETC system
must be deactivated by either removing the 10 amp
fuse (Number 28, labelled ABS in the main fuse box)
or disconnecting the ABS modulator pump. This
must be done with the ignition OFF ; a fault in the
ABS system may still be recorded.
WARNING; VEHICLES NOT FITTED WITH A
DIFFERENTIAL LOCK MUST NOT BE TESTED
ON A ROLLING ROAD WHERE THE ROLLERS
ARE DRIVEN BY THE VEHICLE.

GENERAL DATA
04-16
Brakes
Wheels and tyres
CAUTION: When towing, the additional load imposed may cause the tyre maximum load rating to be
exceeded. This is permissible provided the load rating is not exceeded by more than 15% and that road
speeds are limited to 62 mph (100 km/h) and tyres pressures are increased by at least 3 lbf/in
2 (0.2 bar).
NOTE: The tyre size is displayed on the outer wall of each tyre.
Normal operating conditions: carrying up to 4 passengers and luggage.
Type Servo assisted, diagonally split hydraulic on outboard discs, with
four channel electronic control ABS
Disc diameter:

Front 297.0 - 297.4 mm (11.693 - 11.709 in)

Rear 303.8 - 304.2 mm (11.961 - 11.976 in)
Front disc minimum thickness:

New 24.9 - 25.1 mm (0.980 – 0.988 in)

Service limit 22.0 mm (0.866 in)
Rear disc minimum thickness:

New 12.5 – 12.7 mm (0.492 – 0.500 in)

Service limit 11.7 mm (0.461 in)
Maximum disc runout 0.15 mm (0.006 in)
Minimum pad material thickness 2.0 mm (0.079 in)
Handbrake Cable operated drum on transfer box rear output shaft
Wheel size:

Steel 7J x 16

Alloy 7J x 16
8J x 16
8J x 18
Tyre size

With 7J x 16 wheels 235/70 R16 Wrangler HP 105H
235/70 R16 Michelin XPC * 105H

With 8J x 16 wheels 255/65 R16 Wrangler HP 109H
255/65 R16 Michelin XPC * 109H

With 8J x 18 wheels 255/55 R18 Wrangler HP 109H
Tyre Pressures
All tyres - normal operating conditions Front Up to 03MY - 1.9 Bar (28 lbf.in
2)
From 03MY - 2.1 Bar (30 lbf.in2)
Rear 2.6 Bar (38 lbf.in
2)
All tyres - vehicle at GVW Front Up to 03MY - 1.9 Bar (28 lbf.in
2)
From 03MY - 2.1 Bar (30 lbf.in2)
Rear 3.2 Bar (46 lbf.in
2)

TORQUE WRENCH SETTINGS
06-12
Rear suspension
Brakes
TORQUE DESCRIPTION METRIC IMPERIAL
Wheel nuts140 Nm (103 lbf.ft)
Wheel hub to axle 100 Nm (74 lbf.ft)
Damper to axle125 Nm (92 lbf.ft)
SLS height sensor link to radius arm 25 Nm (18 lbf.ft)
Radius arm230 Nm (170 lbf.ft)
Transverse links to pivot housing 155 Nm (114 lbf.ft)
Pivot housing to axle bolts 230 Nm (170 lbf.ft)
Transverse link to chassis 140 Nm (103 lbf.ft)
SLS height sensor 6 Nm (4.4 lbf.ft)
SLS compressor25 Nm (18 lbf.ft)
ACE actuator to short arm 185 Nm (136 lbf.ft)
ACE actuator to long arm 48 Nm (35 lbf.ft)
ACE actuator pipe cap nuts 29 Nm (21 lbf.ft)
Anti-roll bar link - upper 50 Nm (37 lbf.ft)
Anti-roll bar link - lower 100 Nm (74 lbf.ft)
ACE long arm to torsion bar 180 Nm (133 lbf.ft)
TORQUE DESCRIPTION METRIC IMPERIAL
Brake caliper bleed screw 10 Nm (7 lbf.ft)
Brake disc to drive flange 13 Nm (10 lbf.ft)
Caliper bolts - Front 175 Nm (129 lbf.ft)
Caliper bolts - Rear 95 Nm (70 lbf.ft)
Master cylinder to servo 25 Nm (18 lbf.ft)
Master cylinder brake pipe, unions 25 Nm (18 lbf.ft)
Brake caliper pivot bolt 30 Nm (22 lbf.ft)
Vacuum pump8 Nm (6 lbf.ft)
Vacuum pump lubrication pipe union 10 Nm (7 lbf.ft)
Brake caliper guide pin bolts 30 Nm (22 lbf.ft)
Brake caliper banjo bolt 32 Nm (24 lbf.ft)
ABS modulator to mounting bracket nuts 9 Nm (7 lbf.ft)
ABS modulator - 13 mm unions 22 Nm (16 lbf.ft)
ABS modulator - 11 mm union 14 Nm (10 lbf.ft)
Handbrake lever to floor bolts 22 Nm (16 lbf.ft)