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Land Rover Defender 1999 2002my Workshop Supplement Body Repair 3rd Edition Rover Manual

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    							70 - BRAKES
    CONTENTS
    Page
    DESCRIPTION AND OPERATION
    REAR BRAKE CALIPERS - FROM 02MY 2...........................................................
    ADJUSTMENT
    BRAKE SYSTEM BLEED 1.....................................................................................
    PARK BRAKE - ADJUST 2.....................................................................................
    REPAIR
    ECU - ABS 1...........................................................................................................
    SENSOR - ABS - FRONT WHEEL 2......................................................................
    SENSORS - ABS - REAR WHEELS 3....................................................................
    MASTER CYLINDER 4...........................................................................................
    SERVO ASSEMBLY 5............................................................................................
    MODULATOR UNIT - ABS 6...................................................................................
    BRAKE CALIPER - FRONT 7.................................................................................
    BRAKE CALIPER - REAR 8....................................................................................
    SWITCH - STOP LIGHT 9.......................................................................................
    FRONT BRAKE PADS - FROM 02MY 10...............................................................
    REAR BRAKE PADS - FROM 02MY 11................................................................. 
    						
    							BRAKES
    1
    DESCRIPTION AND OPERATION This page is intentionally left blank 
    						
    							70BRAKES
    2
    DESCRIPTION AND OPERATION REAR BRAKE CALIPERS - FROM 02MY
    1.Deflector
    2.Rear brake caliper
    3.Rear brake pads 
    						
    							BRAKES
    3
    DESCRIPTION AND OPERATION Modifications to the rear brakes have been introduced on 110 and 130 models. This is to increase the service life
    of the rear brake pads in harsh environments.
    New rear brake calipers are introduced which allow the fitment of brake pads with a thicker friction material. The
    brake pads have increased leading and trailing edge chamfers which improve efficiency.
    Aerodynamic deflectors are located forward of the rear wheels to protect the rear calipers from the ingress of dirt,
    which can cause excessive pad wear. The deflectors are manufactured from moulded rubber and are flexible to
    prevent damage from impact. These deflectors are fitted to 90, 110 and 130 models in markets where
    environmental conditions cause excessive brake pad wear. 
    						
    							70BRAKES
    4
    DESCRIPTION AND OPERATION 
    						
    							BRAKES
    1
    ADJUSTMENT BRAKE SYSTEM BLEED
    Service repair no - 70.25.02
    Preparation
    WARNING: Before bleeding the brake
    system refer to general brake service
    practice.See this Section. general brake
    service practice
    During bleed procedure, brake fluid level must
    not be allowed to fall below the MIN mark. Keep
    reservoir topped up to the MAX mark.
    To bleed the hydraulic circuits, four bleed
    nipples are provided, one at each caliper.
    There are two methods by which air can be removed
    from the braking system:-
    1.MANUAL BLEED PROCEDURE
    2.PRESSURE BLEED PROCEDURE
    Pressure bleed procedure
    Purpose designed equipment for pressure filling and
    bleeding of hydraulic systems may be used on Land
    Rover vehicles. The equipment manufacturers
    instructions must be followed and the pressure must
    not exceed 4.5 bar, 65 lb/in.
    Manual bleed procedure
    Equipment required
    Clean glass receptacle
    Bleed hose
    Wrench
    Approx. 2 litres (3 pts) brake fluid
    Master cylinder bleed
    1.Disconnect battery negative lead.
    2.Depress brake pedal fully and slowly 5 times.
    3.Release pedal and wait 10 seconds.
    4.Repeat until firm resistance is felt at the pedal.Complete circuit bleed
    1.Disconnect battery negative lead.
    2.Fit bleed hose to caliper bleed screw.
    3.Dip free end of bleed hose into brake fluid in
    bleed bottle.
    4.Open bleed nipple.
    5.Depress brake pedal fully several times until fluid
    is clear of air bubbles.
    6.Keeping pedal fully depresses, tighten bleed
    nipple then release pedal.
    7.Repeat procedure for remaining calipers.
    8.Fit bleed screw protection caps.
    9.Check/top-up fluid level when bleeding is
    complete. 
    						
    							70BRAKES
    2
    ADJUSTMENT PARK BRAKE - ADJUST
    Service repair no - 70.45.09
    Check
    NOTE: The park brake should be fully
    operational on third notch of ratchet.
    1.Raise one rear wheel clear of ground and
    support on axle stand.
    2.Release park brake lever.
    3.Tighten brake adjuster to25 Nm (18 lbf.ft)to
    fully expand shoes to drum.
    4.Back off adjuster 1
    1/2turns, check that drum is
    free to rotate.
    5.Check operation of park brake lever to give pawl
    2 notches free movement on ratchet before
    being fully operational on third notch of ratchet.
    Adjust park brake accordingly if lever travel
    exceeds the above tolerance.
    CAUTION: Cable adjustment must ONLY
    be used for initial setting and to
    compensate for cable stretch. It MUST
    NOT be used to take up brake shoe wear, which
    MUST be adjusted at brake drum.
    6.Remove axle stand and wheel chock. 
    						
    							BRAKES
    1
    REPAIR ECU - ABS
    Service repair no - 70.65.01
    Remove
    1.Disconnect battery negative lead.
    2.Release and remove passenger seat base.
    3.Release clip securing ECU cover plate.
    4.Remove ECU cover plate.
    5.Disconnect 3 multiplugs from ABS ECU.
    6.Disconnect 2 multiplugs from engine
    management ECU.
    7.Release seat base carpet to gain access to ECU
    mounting plate Torx screws.
    8.Remove 2 Torx screws securing front edge of
    ECU mounting plate.
    9.Remove nut securing rear edge of ECU
    mounting plate.
    10.Remove mounting plate and ECU assembly from
    seat base.
    11.Remove 3 bolts securing ABS ECU to mounting
    plate.
    12.Remove ABS ECU.
    Refit
    13.Position ABS ECU to mounting plate and secure
    with bolts.
    14.Fit mounting plate and ECU assembly to seat
    base.
    15.Fit Torx screws and nut securing mounting plate
    to seat base.
    16.Re-position carpet.
    17.Connect multiplugs to ABS and engine
    management ECU’s.
    18.Fit ECU cover plate to seat base and secure in
    position with clip.
    19.Fit passenger seat base.
    20.Reconnect battery negative lead. 
    						
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