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Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
Land Rover Range Rover 2002my On Workshop Procedures Lm 6th Edition Nas Rover Manual
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BRAKES 70-4 ADJUSTMENTS Brake system bleeding $% 70.25.02 Bleeding of the brake system can be carried out using the procedures given on TestBook/T4, or by following the manual procedure given below. Check 1.The following procedure covers bleeding the complete system but where only the primary or secondary circuit have been disturbed in isolation, it should only be necessary to bleed that system. Partial bleeding of the hydraulic system is only permissible if a brake pipe or hose has been disconnected with only minor loss of fluid. WARNING: If any components upstream of brake modulator, including the modulator itself are replaced, the brake system must be bled using the procedure on TestBook/ T4, to ensure that all air is expelled from the new component(s). Adjust 1.Raise front and rear of vehicle. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. 2.Check all pipe and hose connections are tight and there are no signs of leakage.3.Top-up fluid level in brake reservoir to MAX mark. + MAINTENANCE, PROCEDURES, Fluid reservoirs. WARNING: Do not allow dirt or foreign liquids to enter the reservoir. Use only new Shell DOT 4 ESL brake fluid from airtight containers. Do not mix brands of brake fluid as they may not be compatible. 4.Attach bleed tube to front brake caliper bleed screw on passenger side, submerge free end in a clear container containing brake fluid. 5.Apply pressure to brake pedal several times, then apply steady pressure. 6.Loosen bleed screw to release brake fluid and air. Allow pedal to return unassisted.
BRAKES ADJUSTMENTS 70-5 7.Depress brake pedal steadily through its full stroke and allow to return unassisted. Repeat procedure until a flow of clean, air-free fluid is purged into container, then whilst holding pedal at end of its downward stroke, tighten bleed screw to 14 Nm (10 lbf.ft) CAUTION: Ensure the fluid in the reservoir is maintained between the minimum and maximum levels throughout the bleed procedure using new brake fluid. 8.Top up brake system reservoir. 9.Repeat procedure at each wheel in the sequence shown. WARNING: Braking efficiency may be seriously impaired if the incorrect bleed sequence is used. 10.Remove tube from bleed screw and fit bleed screw dust cap. 11.Apply brakes and check for leakage. 12.Remove stands and lower vehicle. 13.Road test vehicle. Check brake pedal for short firm travel when brakes are applied. Handbrake adjustment $% 70.35.10 Check 1. Rear brake shoe bedding-in WARNING: Where possible, a road test should be on well surfaced and dry roads. Always comply with speed limits and local traffic regulations. 2.Ensure handbrake is correctly adjusted as detailed below. 3. On a dynamometer: Apply hand brake for approximately 40 seconds, a braking force reading of 800 Nm must be obtained. 4. On road test: At approximately 24 mph (40 km/ h), apply handbrake until braking force can be felt. Apply handbrake one further notch and drive on for 440 yards (400 metres). Adjust 1.Raise rear 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 rear road wheels. 3.On each rear brake:
BRAKES 70-6 ADJUSTMENTS 4.Remove adjuster access plug from brake disc. 5.Rotate brake disc until access hole is in the 6 oclock position. 6.Using a screwdriver or similar tool, turn brake shoe adjuster until resistance is felt. Apply handbrake several times to centre shoes, re- adjust if required and repeat. 7.Ensure handbrake is released and check disc will not rotate. 8.Back the adjuster off 8 notches, check disc is free to rotate. 9.Fit adjuster access plug. 10.Fit rear road wheels and tighten nuts to 140 Nm (103 lbf.ft). 11.Handbrake lever assembly is self adjusting and will correctly tension cables. However after adjustment apply handbrake several times, release handbrake and ensure road wheels are free to rotate. 12.Lower vehicle.
BRAKES REPAIRS 70-7 REPAIRS Brake disc - front $% 70.12.10 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 bolts securing brake caliper to hub. Release caliper from hub and tie aside. CAUTION: Do not allow caliper to hang on brake hose. 4.Remove Allen screw securing brake disc to drive flange. 5.Remove brake disc.Refit 1.Ensure mating surfaces of disc and drive flange are clean. 2.Fit disc to flange, fit Allen screw and tighten to 16 Nm (12 lbf.ft). 3.Position caliper to hub, fit bolts and tighten to 110 Nm (81 lbf.ft). 4.Fit road wheel and tighten nuts to 140 Nm (103 lbf.ft). M70 1133
BRAKES 70-8 REPAIRS Brake disc - rear $% 70.12.33 Remove 1.Raise rear 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 bolts securing brake caliper to hub. Release caliper from hub and tie aside. CAUTION: Do not allow caliper to hang on brake hose. 4.Remove Allen screw securing brake disc to drive flange. 5.Remove brake disc.Refit 1.Ensure mating surfaces of disc and drive flange are clean. 2.Fit disc to flange, fit Allen screw and tighten to 16 Nm (12 lbf.ft). 3.Position caliper to rear hub, fit bolts and tighten to 65 Nm (48 lbf.ft). 4.Fit road wheel and tighten nuts to 140 Nm (103 lbf.ft). 5.Adjust handbrake. + BRAKES, ADJUSTMENTS, Handbrake adjustment. 6.Remove stands and lower vehicle. M70 1146
BRAKES REPAIRS 70-9 Pump - pre-charge $% 70.25.17 Remove 1.Remove front wheel arch liner. + EXTERIOR FITTINGS, REPAIRS, Liner - front wheel arch. 2.Remove nut securing alarm sounder to mounting bracket and move aside. 3.Position container to collect fluid spillage. CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove fluid and clean area with water. 4.Disconnect brake pipe from master cylinder. CAUTION: Always fit plugs to open connections to prevent contamination.5.Disconnect feed hose. 6.Remove bolt securing pre-charge pump bracket to body. 7.Release pump from rubber mounting. 8.Disconnect multiplug. 9.Remove pump. NOTE: Do not carry out further dismantling if component is removed for access only. M70 1158 M70 1159
BRAKES 70-10 REPAIRS 10.Noting its fitted position, remove brake pipe. 11.Release multiplug, remove 3 bolts and remove mounting bracket and cover. Refit 1.Fit mounting bracket and cover to pre-charge pump, fit bolts and tighten to 8 Nm (6 lbf.ft). 2.Secure multiplug. 3.Clean brake pipe unions. 4.Fit brake pipe to pump and lightly tighten union. 5.Connect multiplug. 6.Locate pre-charge pump to mounting rubbers. 7.Fit bolt securing pre-charge pump and tighten to 8 Nm (6 lbf.ft). 8.Connect pre-charge pump pipe to master cylinder, tighten both unions to 14 Nm (10 lbf.ft). 9.Connect master cylinder feed to pre-charge pump and tighten union to 14 Nm (10 lbf.ft). 10.Position alarm sounder to bracket, fit nut and tighten to 8 Nm (6 lbf.ft). 11.Fit front wheel arch liner. + EXTERIOR FITTINGS, REPAIRS, Liner - front wheel arch. 12.Bleed brakes using TestBook/T4. Reservoir - brake fluid $% 70.25.31 Remove 1.Position container to collect fluid spillage. CAUTION: Brake fluid will damage paint finished surfaces. If spilled, immediately remove fluid and clean area with water. 2.Disconnect multiplug from low fluid level sensor. 3.Release harness from clip. 4.Release clip and disconnect pre-charge pump feed hose. CAUTION: Plug hose immediately to prevent fluid loss from pre-charge pump. 5.Release 2 clips and remove reservoir. 6.Remove and discard 2 reservoir seals. CAUTION: Always fit plugs to open connections to prevent contamination. M70 1150
BRAKES REPAIRS 70-11 Refit 1.Clean reservoir and master cylinder mating faces. 2.Fit seals. 3.Fit brake master cylinder. 4.Connect pre-charge pump feed hose and secure with clip. 5.Secure harness to clip. 6.Connect multiplug to low fluid level sensor. 7.Bleed brakes using TestBook/T4. Cylinder - master - tandem $% 70.30.08 Remove 1.Remove fluid reservoir. + BRAKES, REPAIRS, Reservoir - brake fluid. 2.Disconnect brake pipes. CAUTION: Always fit plugs to open connections to prevent contamination. 3.Remove and discard 2 nuts securing master cylinder to servo, remove master cylinder. 4.Remove and discard sealing ring. Refit 1.Clean master cylinder and servo mating surfaces. 2.Fit new sealing ring to master cylinder. 3.Align push rod and position master cylinder to servo. 4.Fit new nuts securing brake master cylinder and tighten to 26 Nm (19 lbf.ft). 5.Clean brake pipe unions. 6.Connect brake pipes to master cylinder and tighten unions to 14 Nm (10 lbf.ft). 7.Fit fluid reservoir. + BRAKES, REPAIRS, Reservoir - brake fluid.
BRAKES 70-12 REPAIRS Pedal box $% 70.35.03 Remove 1.Remove closing panel. + INTERIOR FITTINGS, REPAIRS, Closing panel - passenger side. 2.Remove shroud. + INTERIOR FITTINGS, REPAIRS, Shroud - lower - fascia. 3.Disconnect brake sensor multiplug from pedal box. 4.Remove clip and clevis pin securing brake servo push rod to brake pedal. 5.Remove and discard 3 nuts securing pedal box to bulkhead. 6.Release and withdraw pedal box. NOTE: Do not carry out further dismantling if component is removed for access only. 7.Release and remove brake sensor from holder. 8.Remove holder from pedal bracket. 9.Remove pedal return spring. 10.Remove 2 nuts and bolts securing return spring bracket to pedal box. Remove bracket. Refit 1.Position return spring bracket to pedal box, fit nuts, bolts and tighten to 10 Nm (7 lbf.ft). 2.Fit return spring and sensor holder to pedal bracket. 3.Position pedal box to bulkhead, fit new nuts and tighten to 26 Nm (19 lbf.ft). CAUTION: Nuts securing brake servo to pedal bracket must be re-torqued after 30 minutes have elapsed.4.Position sensor, connect multiplug and secure to holder. 5.Align push rod, fit clevis pin and secure with clip. 6.With brake pedal released, ensure sensor is in contact with operating tang on brake pedal. 7.Fit shroud. + INTERIOR FITTINGS, REPAIRS, Shroud - lower - fascia. 8.Fit closing panel. + INTERIOR FITTINGS, REPAIRS, Closing panel - passenger side.
BRAKES REPAIRS 70-13 Lever assembly - handbrake $% 70.35.08 Remove 1.Remove centre console. + INTERIOR FITTINGS, REPAIRS, Centre console. 2.Release and remove air duct. 3.Release clip and disconnect handbrake cables from compensator.4.Release lead from switch. 5.Remove 2 nuts securing handbrake lever. 6.Remove handbrake lever. Refit 1.Fit handbrake lever to bracket, fit nuts and tighten to 21 Nm (15 lbf.ft). 2.Connect lead to switch. 3.Connect cables to compensator. 4.Fit air duct. 5.Fit centre console. + INTERIOR FITTINGS, REPAIRS, Centre console. 6.Check handbrake operation, adjust if necessary. + BRAKES, ADJUSTMENTS, Handbrake adjustment. M70 1168 M70 1162