2006 LAND ROVER FRELANDER 2 brake fluid

Publi s hed: 11-May-2011
Front Disc Brake - Brake Disc
Removal and Inst all ati on
Removal
1. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he front wheel .
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
2. 3. CAUTION: Make s ure that no load i s placed on
t he brake hos e.
Releas e t he brake caliper and t ie as ide.
3. Remove t he brake dis c.
4.
Installation Make s ure the brake di s c and hub mati ng s urfaces are cl ean.
1.
Inst all t he brake dis c and t ighten the Torx s crew.
T orque: 35 Nm 2.
3. W ARNING: Do not use compress ed air t o clean brake
component s. Dus t from fricti on mat erial s can be harmful i f inhaled.
Clean t he brake cali per hous ing and anchor pl at e us ing brake
cleaning fluid.
3.

Remove t he brake pad cli ps .
5.
Installation 1. W ARNING: Do not use compress ed air t o clean brake
component s. Dus t from fricti on mat erial s can be harmful i f inhaled.
Clean t he brake cali per hous ing and anchor pl at e us ing brake
cleaning fluid.
1.
Inspect the cali per pi st on and s li de pin seals for damage.
2. Pos it ion a bl eed jar cont aining a s mall quant it y of
approved brake fluid. Connect t he bleed t ube to the
bleed s crew and loos en the s crew.
3.
Pres s t he pis t on int o t he cal iper hous ing and ti ght en t he bleed
s crew.
T orque: 10 Nm 4.
Di sconnect t he bleed t ube and remove t he jar.
5.
6. CAUTIONS: If new brake pads are ins tal led, a new gold col oured brake pad
cli p mus t be fit ted i n t he lower posi ti on. The cl ip wi th one hol e mus t
be fit ted to pet rol vehi cl es. The cl ip wi th two hol es mus t be fi tt ed t o
dies el vehi cl es . Fail ure t o follow thi s ins truct ion may res ult i n
damage t o t he vehi cl e. If new brake pads are ins tal led, a new bl ack coloured brake
6.

6. CAUTION: Make s ure that all openi ngs are
s ealed. Use new blanking caps.
6.
Remove t he brake caliper housi ng.
7.
Installation
1. W ARNING: Do not use compress ed air t o clean brake
component s. Dus t from fricti on mat erial s can be harmful i f inhaled.
Clean t he brake cali per hous ing and anchor pl at e us ing brake
cleaning fluid.
1.
Inst all t he brake caliper.
2.
Connect t he brake t ube to the brake cal iper.
T orque: 30 Nm 3.
Inst all t he brake caliper upper bolt .
T orque: 30 Nm 4.
Inst all t he two cl ips . Inst all t he brake pads.5.
6. CAUTION: Make s ure that the brake hose is not t wis ted and
i s correctl y located.
Inst all t he brake caliper lower bolt .
T orque: 30 Nm 6.
Inst all t he wheel and t ire.
Refer t o: W heel and Ti re (204-04 W heel s and Tires, Removal and
Inst all at ion).
7.
Bleed t he brake s ys tem.
Refer t o: Brake Syst em Bl eedi ng (206-00 Brake Syst em - General
Informat ion, General Procedures).
8.

brake hos e.
Tie the brake cal iper hous ing as i de. 7.
8.
Installation 1. W ARNING: Do not use compress ed air t o clean brake
component s. Dus t from fricti on mat erial s can be harmful i f inhaled.
Clean t he brake cali per hous ing and anchor pl at e us ing brake
cleaning fluid.
1.
Clean and l ubricat e the gui de pins .
2.
Inst all t he gui de pins .
3.
4. CAUTION: Make s ure that new bolt s are ins tal led.
Inst all t he brake caliper anchor plat e.
T orque: 110 Nm 4.
5. CAUTION: Make s ure that new bolt s are ins tal led.
Inst all t he brake caliper housi ng and ins tal l the t op bolt .
T orque: 35 Nm 5.
Inst all t he cl ips and brake pads .
6.
7. CAUTIONS:
7.

3-St opl amp s wit ch
4-Hydrauli c pipes
5-Integrat ed Hydrauli c Cont rol Unit (HCU) and Anti -l ock Brake Sys t em (ABS) modul e6-Brake mast er cyl inder and flui d res ervoir
OVERVIEW
The hydraulic brake s ys t em i s a diagonally spl it dual ci rcuit s yst em and cons is ts of the brake pedal, brake mast er cyl inder,HCU and t he hydrauli c pipes and hoses . The s ys t em al so features a non-acti ve brake boost er.For addit ional informat ion, refer t o: Brake Boos ter (206-07 Power Brake Act uati on, Des cript ion and Operat ion).
The preformed rigi d brake pipes di st ri but e press ure from t he mas ter cyli nder t o t he 4 brake cali pers , vi a t he int egratedHCU and ABS modul e. Fl exi ble hos es connect the rigid brake pipes t o t he front and rear cal ipers .
BRAKE PEDAL
ItemPart NumberDescription
1-St oplamp swi tchThe brake pedal i s mounted in a bracket t hat is at tached to the rear si de of the engine bul khead. The pedal as sembl y isdifferent for LHD and RHD vehicles , and is connect ed to the brake boos t er pus h rod wit h a cl evi s pin.
The s toplamp s wit ch is mount ed on t he brake pedal bracket and wil l ill uminat e the vehicl e s toplamps when the brakepedal i s pres s ed. The s t opl amp s wit ch is al s o used as an input to the speed cont rol s ys tem, and wi ll cancel the currents peed set ti ng when t he brake pedal i s pres s ed. For addi ti onal i nformat ion, refer to:
Speed Cont rol - 3.2L (310-03 Speed Cont rol - 3.2L, Des cript ion and Operat ion),Speed Cont rol - 2.2L Di esel (310-03 Speed Cont rol - 2.2L Di esel , Descri pti on and Operat ion).
BRAKE MASTER CYLINDER AND FLUID RESERVOIR

ItemPart NumberDescription
1-Brake fluid res ervoir cap2-Brake fluid level s wi tch
3-Brake fluid res ervoir
4-Secondary circui t inlet port5-Primary circui t inl et port
6-Brake mas ter cyli nder
7-Screw8-Primary circui t outl et port
9-Secondary circui t out let port
The brake mas t er cyli nder i s att ached t o t he front of the brake boos ter, on t he driver's s ide of t he engine compart ment.The brake mas t er cyli nder i s a t andem desi gn that s uppl ies press ure to 2 independent (primary and s econdary) hydrauliccircuit s . Each ci rcuit is connect ed between t he cali pers of diagonal ly opposi ng front and rear wheel s t o provide a fai l safebrake s yst em.
A reservoi r is mount ed on t op of the mast er cyl inder and retai ns suffi ci ent vol ume of hydraul ic flui d to allow for normals ys t em us e, and to compens ate for the replenis hment of the s ys tem as the brake li nings wear. The res ervoi r is i nt ernall ydivided t o provi de an independent s uppl y of fl ui d t o each brake circui t, and prevents a s ingle flui d leak from dis abling bot hpri mary and secondary brake circui ts . If a fai lure occurs i n one brake hydrauli c circui t the remaining ci rcuit wi ll s ti ll operat eeffect ively, alt hough brake pedal t ravel and vehicle braking dis t ances wi ll increas e.
On vehicles wi th manual t rans mis s ion, t he brake fluid res ervoir als o s upplies hydrauli c fluid for operati on of the cl ut chas sembl y.
Brake Fluid Level Switch

ItemPart NumberDescription
1-Contact carri er2-Contact
3-Float
The res ervoir i ncorporates a brake fl uid l evel s wit ch t hat i s hardwired t o t he Cent ral Junct ion Box (CJB). W hen t he res ervoirfl uid fall s to a predet ermi ned low l evel , the s wi tch contacts cl os e and provi de a s ignal feed back t o the CJB. The CJB t henbroadcas t s a mes s age on t he medium speed Controll er Area Network (CAN) bus t o t he i ns t rument clus ter t hat i n t urnil lumi nat es t he brake fluid warning i ndi cat or lamp.For addit ional informat ion, refer t o: Ins t rument Clus ter (413-01 Inst rument Cl us t er, Des cript ion and Operat ion).
HYDRAULIC CONTROL UNIT

pis t ons and will flow unrest ri cted t hrough t he inlet ports , between t he chambers and t he res ervoir.
Pres s urized fluid ent ers the HCU that i s mounted on t he front of the ABS modul e. The HCU t hen modul ates t he s uppl y ofpres s urized fluid to the brakes under cont rol of the ABS modul e.For addit ional informat ion, refer t o: Anti -Lock Cont rol - St abi li ty As s is t (206-09 Anti -Lock Cont rol - St abi li ty As s is t ,Des cript ion and Operat ion).