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Brake System - General Information Land Rover Range Rover L322

Anti-Lock/traction Control 17 illustrations ~2546 words

SPECIFICATIONS

ItemSpecification
* Recommended hydraulic fluidSHELL DONAX YB DOT4 ESL FLUID

BRAKE HYDRAULIC FLUID

CAUTION* If the above fluid is not available, use a low viscosity DOT 4 brake fluid meeting ISO 4925 Class 6 and Land Rover LRES22BF03 requirements.
ItemSpecification
Footbrake type
Vehicles without Brembo brakesHydraulic, servo assisted, self-adjusting with front/rear split hydraulic system, twin piston sliding calipers to the front and single piston sliding calipers to the rear
Vehicles with Brembo brakesHydraulic, servo assisted, self-adjusting with front/rear split hydraulic system, opposed four piston calipers to the front and single piston sliding calipers to the rear
Parking brake typeTwin shoe (leading/trailing) operating on rear wheels and controlled from park brake lever in floor console via twin cables

GENERAL SPECIFICATION

FRONT BRAKE DISC RUNOUT CHECK

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Dial indicator gauge holding fixture 100-053 (LRT-99-503)

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Scheme 14: FRONT BRAKE DISC RUNOUT CHECK
Scheme 14: FRONT BRAKE DISC RUNOUT CHECK
CAUTIONBrake discs must be renewed in pairs, unless one disc requires changing before 1000 miles (1500 kilometers) from new.

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  1. Release the brake hose bracket from the wheel knuckle. Remove the bolt.
  2. LH side only: Disconnect the brake pad wear indicator sensor.
  3. Remove the brake caliper lower bolt.
  4. Remove the brake caliper upper bolt.
  5. Tie the brake caliper housing aside.
  6. Remove the brake caliper anchor plate. Remove the 2 bolts.
  7. Measure the brake disc thickness at four points around the brake disc. Renew the brake disc if the thickness is less than the service limit, or if the maximum thickness variation is exceeded. Brake disc thickness, NEW = 30 mm, Service limit = 27 mm.
  8. Using the special tool, install a dial indicator gauge to the brake caliper lower mounting. Position the dial indicator gauge plunger 5 mm in from the outer edge of the brake disc.
  9. Install the wheel nuts. Install spacer washers under the wheel nuts. Tighten the wheel nuts to 140 Nm (103 lb.ft).
  10. Rotate the brake disc one revolution to measure the brake disc run-out. Brake disc run-out must not exceed 0.05 mm.
  11. If the brake disc run-out is outside the limit. Remove the brake disc.
  12. Make sure the brake disc and hub mating surfaces are clean.
  13. Install the brake disc. Tighten the Torx screw to 35 Nm (26 lb.ft).
  14. Install the wheel nuts. Install spacer washers under the wheel nuts. Tighten the wheel nuts to 140 Nm (103 lb.ft).
  15. Rotate the brake disc one revolution to measure the brake disc run-out. Brake disc run-out must not exceed 0.05 mm.
  16. If the brake disc run-out is still outside the limit, install a new brake disc and/or hub.
  17. Remove the dial indicator gauge and the special tool.
  18. Clean the caliper housing and anchor plate using brake cleaning fluid.
  19. Install the anchor plate. Tighten the bolts to 275 Nm (203 lb.ft).
  20. Install the brake caliper housing and fit the top bolt. Tighten the bolt to 32 Nm (24 lb.ft).
  21. Install the brake pads. Install the two clips.
  22. Rotate the brake caliper downwards. Tighten the bolt to 32 Nm (24 lb.ft).
  23. Connect the brake pad wear indicator sensor.
  24. Secure the brake hose retaining bracket to the wheel knuckle. Tighten the bolt to 22 Nm (16 lb.ft).
  25. Depress the brake pedal several times, check the fluid level in the brake fluid reservoir and top-up with brake fluid if necessary.

REAR BRAKE DISC RUNOUT CHECK

SPECIAL TOOLS Tool Illustration Tool Name Tool Number Dial indicator gauge holding fixture 100-053 (LRT-99-503)

Note. If the parking brake shoes or the brake discs have been removed for access to other components then DO NOT carry out the bedding in procedure.

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  1. Enter the parking brake into the service mode. Turn the ignition key to position II. Apply, and hold, the footbrake. Apply, and hold, the parking brake switch to the RELEASE position. Turn the ignition key to position '0' and remove the key. Release the footbrake. Release the parking brake switch.
  2. RH side only: Disconnect the brake pad wear indicator sensor.
  3. Remove the brake caliper lower bolt.
  4. Remove the brake pads. Rotate the brake caliper upwards. Remove the two clips.
  5. Remove the brake caliper upper bolt.
  6. Tie the brake caliper housing aside.
  7. Remove the brake caliper anchor plate.
  8. Measure the brake disc thickness at four points around the brake disc. Renew the brake disc if the thickness is less than the service limit, or if the maximum thickness variation is exceeded. Brake disc thickness, NEW = 20 mm, Service limit = 17 mm.
  9. Using the special tool, install a dial indicator gauge to the brake caliper lower mounting. Position the dial indicator gauge plunger 5 mm in from the outer edge of the brake disc.
  10. Install the wheel nuts. Install spacer washers under the wheel nuts. Tighten the wheel nuts to 140 Nm (103 lb.ft).
  11. Rotate the brake disc one revolution to measure the brake disc run-out. Brake disc run-out must not exceed 0.09 mm.
  12. If the brake disc run-out is outside the limit. Remove the brake disc.
  13. Make sure the brake disc and hub mating surfaces are clean.
  14. Install the brake disc. Tighten the Torx screw to 35 Nm (26 lb.ft).
  15. Install the wheel nuts. Install spacer washers under the wheel nuts. Tighten the wheel nuts to 140 Nm (103 lb.ft).
  16. Rotate the brake disc one revolution to measure the brake disc run-out. Brake disc run-out must not exceed 0.09 mm.
  17. If the brake disc run-out is still outside the limit, install a new brake disc and/or hub.
  18. Remove the dial indicator gauge and the special tool.
  19. Install the anchor plate. Tighten the bolts to 115 Nm (85 lb.ft).
  20. Install the brake caliper housing and fit the top bolt. Tighten the bolt to 32 Nm (24 lb.ft).
  21. Install the brake pads. Install the 2 clips. Install the two clips.
  22. Rotate the brake caliper downwards. Tighten the bolt to 32 Nm (24 lb.ft).
  23. Connect the brake pad wear indicator sensor.
  24. Depress the brake pedal several times, check the fluid level in the brake fluid reservoir and top-up with brake fluid if necessary.

BRAKE SYSTEM BLEEDING (VEHICLES WITH: HIGH PERFORMANCE BRAKES)

WARNINGIf any components upstream of the Hydraulic Control Unit (HCU), including the HCU itself are replaced, the brake system must be bled using the procedure on T4. This will ensure that all air is expelled from the new component(s).

Note. Bleeding of the complete brake system must be carried out using the procedures given on T4. Where only the primary or secondary brake circuits have been disturbed in isolation, it should only be necessary to bleed that circuit. Partial bleeding of the hydraulic system is only permissible if a brake tube or hose has been disconnected with only minimal loss of fluid.

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  1. Raise and support the vehicle.
  2. Check that the brake fluid lines are secure and that there are no signs of a brake fluid leak. If a brake fluid leak is detected, investigate and rectify the cause of the leak before bleeding the brakes.
  3. Pump the brake pedal until the brake vacuum assistance is exhausted.
  4. Fill the brake fluid reservoir to the MAX mark. Disconnect the brake fluid reservoir electrical connector. Remove the brake fluid reservoir cap.
  5. Connect T4 to the vehicle, select diagnostic and proceed as directed for bleeding the brake system.
  6. Starting at the brake caliper furthest away from the brake master cylinder, loosen the bleed screw by one-half to three-quarters of a turn.
  7. Install the bleed tube to the brake caliper bleed screw and immerse the free end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
  8. With assistance, depress the brake pedal steadily through its full stroke and allow it to return to the rest position. Repeat the procedure until brake fluid, clean and air-free flows into the bleed jar.
  9. When brake fluid, clean and air-free flows into the bleed jar, depress and hold the brake pedal down.
  10. With the brake pedal fully depressed, tighten the bleed screw to 10 Nm (7 lb.ft).
  11. Fill the brake fluid reservoir to the MAX mark.
  12. Repeat the brake bleeding procedure for the remaining rear brake caliper. Tighten the bleed screw to 10 Nm (7 lb.ft).
  13. Repeat the brake bleeding procedure for each front brake caliper, following the above sequence. If access is restricted to the front caliper outer bleed screws, rotate the road wheels to gain access. Tighten the bleed screws to 19 Nm (14 lb.ft).
  14. Fill the brake fluid reservoir to the MAX mark.
  15. Apply the brakes and check for leaks.
  16. Install the brake fluid reservoir cap. Connect the brake fluid reservoir electrical connector.
  17. On completion, road test the vehicle and check the brake pedal operation. The pedal travel should be short with a firm feel.

BRAKE SYSTEM BLEEDING (VEHICLES WITH: STANDARD BRAKES)

WARNINGIf any components upstream of the Hydraulic Control Unit (HCU), including the HCU itself are replaced, the brake system must be bled using the procedure on T4. This will ensure that all air is expelled from the new component(s).

Note. Bleeding of the complete brake system must be carried out using the procedures given on T4. Where only the primary or secondary brake circuits have been disturbed in isolation, it should only be necessary to bleed that circuit. Partial bleeding of the hydraulic system is only permissible if a brake tube or hose has been disconnected with only minimal loss of fluid.

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Scheme 29
  1. Raise and support the vehicle.
  2. Check that the brake fluid lines are secure and that there are no signs of a brake fluid leak. If a brake fluid leak is detected, investigate and rectify the cause of the leak before bleeding the brakes.
  3. Pump the brake pedal until the brake vacuum assistance is exhausted.
  4. Fill the brake fluid reservoir to the MAX mark. Disconnect the brake fluid reservoir electrical connector. Remove the brake fluid reservoir cap.
  5. Connect T4 to the vehicle, select diagnostic and proceed as directed for bleeding the brake system.
  6. Starting at the brake caliper furthest away from the brake master cylinder, loosen the bleed screw by one-half to three-quarters of a turn.
  7. Install the bleed tube to the brake caliper bleed screw and immerse the free end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
  8. With assistance, depress the brake pedal steadily through its full stroke and allow it to return to the rest position. Repeat the procedure until brake fluid, clean and air-free flows into the bleed jar.
  9. When brake fluid, clean and air-free flows into the bleed jar, depress and hold the brake pedal down.
  10. With the brake pedal fully depressed, tighten the bleed screw to 10 Nm (7 lb.ft).
  11. Fill the brake fluid reservoir to the MAX mark.
  12. Repeat the brake bleeding procedure for each brake caliper, following the above sequence.
  13. Fill the brake fluid reservoir to the MAX mark.
  14. Apply the brakes and check for leaks.
  15. Install the brake fluid reservoir cap. Connect the brake fluid reservoir electrical connector.
  16. On completion, road test the vehicle and check the brake pedal operation. The pedal travel should be short with a firm feel.

BRAKE SYSTEM PRESSURE BLEEDING

WARNINGIf any components upstream of the Hydraulic Control Unit (HCU), including the HCU itself are replaced, the brake system must be bled using the procedure on T4, to ensure that all the air is expelled from the new component(s).

Note. The following procedure covers bleeding the complete system. Where only the primary or secondary brake circuits have been disturbed in isolation, it should only be necessary to bleed that circuit. Partial bleeding of the hydraulic system is only permissible if a brake tube or hose has been disconnected with only minimal loss of fluid.

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Scheme 30
  1. Raise and support the vehicle.
  2. Check that all the brake line connections are tight and that there are no signs of leaks. If any leak of brake fluid is observed, investigate and rectify the cause of the leak before bleeding the brakes. See «Specifications»(/land-rover/range-rover/l322-2005-2009/remont/anti-locktraction-control/#brake-system-general-information) . .
  3. Release the 3 clips and remove the cover.
  4. Fill the brake fluid reservoir to the MAX mark.
  5. Install the bleed tube to the brake caliper bleed screw and immerse the free end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
  6. Starting at the brake caliper furthest away from the brake master cylinder, loosen the bleed screw by one-half to three-quarters of a turn.
  7. Depress the brake pedal steadily through its full stroke and allow to return to the rest position. Repeat the procedure until a flow of clean, air-free fluid is being pumped into the bleed jar.
  8. With the brake pedal fully depressed, tighten the bleed screw to 10 Nm (7 lb.ft).
  9. Fill the brake fluid reservoir to the MAX mark.
  10. Repeat the brake bleeding procedure for each brake caliper.
  11. Using T4, bleed the braking system.
  12. Apply the brakes and check for leaks.
  13. Install the cover.

COMPONENT BLEEDING (VEHICLES WITH: HIGH PERFORMANCE BRAKES)

WARNINGIf any components upstream of the Hydraulic Control Unit (HCU), including the HCU itself are replaced, the brake system must be bled using the procedure on T4. This will ensure that all air is expelled from the new component(s).

Note. The following manual procedure covers bleeding the brake system for components down stream of the HCU, where only the primary or secondary brake circuits have been disturbed in isolation. Partial bleeding of the hydraulic system is only permissible if a brake tube or hose has been disconnected with only minimal loss of fluid.

  1. Raise and support the vehicle.
  2. Check that the brake fluid lines are secure and that there are no signs of a brake fluid leak. If a brake fluid leak is detected, investigate and rectify the cause of the leak before bleeding the brakes.
  3. Pump the brake pedal until the brake vacuum assistance is exhausted.
  4. Fill the brake fluid reservoir to the MAX mark. Disconnect the brake fluid reservoir electrical connector. Remove the brake fluid reservoir cap.
  5. Install the bleed tube to the brake caliper bleed screw and immerse the free end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
  6. Loosen the bleed screw by one-half turn to three-quarters of a turn. If access is restricted to the front caliper outer bleed screws, rotate the road wheels to gain access.
  7. With assistance, depress the brake pedal steadily through its full stroke and allow it to return to the rest position. Repeat the procedure until brake fluid, clean and air-free flows into the bleed jar.
  8. When brake fluid, clean and air-free flows into the bleed jar, depress and hold the brake pedal down.
  9. With the brake pedal fully depressed, tighten the bleed screw.
  10. Rear brakes: Tighten the bleed screw to 10 Nm (7 lb.ft).
  11. Front brakes: Tighten the bleed screw to 19 Nm (14 lb.ft).
  12. Fill the brake fluid reservoir to the MAX mark.
  13. Apply the brakes and check for leaks.
  14. Install the brake fluid reservoir cap. Connect the brake fluid reservoir electrical connector.
  15. On completion, road test the vehicle and check the brake pedal operation. The pedal travel should be short with a firm feel.

COMPONENT BLEEDING (VEHICLES WITH: STANDARD BRAKES)

WARNINGIf any components upstream of the Hydraulic Control Unit (HCU), including the HCU itself are replaced, the brake system must be bled using the procedure on T4. This will ensure that all air is expelled from the new component(s).

Note. The following manual procedure covers bleeding the brake system for components down stream of the HCU, where only the primary or secondary brake circuits have been disturbed in isolation. Partial bleeding of the hydraulic system is only permissible if a brake tube or hose has been disconnected with only minimal loss of fluid.

  1. Raise and support the vehicle.
  2. Check that the brake fluid lines are secure and that there are no signs of a brake fluid leak. If a brake fluid leak is detected, investigate and rectify the cause of the leak before bleeding the brakes.
  3. Pump the brake pedal until the brake vacuum assistance is exhausted.
  4. Fill the brake fluid reservoir to the MAX mark. Disconnect the brake fluid reservoir electrical connector. Remove the brake fluid reservoir cap.
  5. Install the bleed tube to the brake caliper bleed screw and immerse the free end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
  6. Loosen the bleed screw by one-half turn to three-quarters of a turn.
  7. With assistance, depress the brake pedal steadily through its full stroke and allow it to return to the rest position. Repeat the procedure until brake fluid, clean and air-free flows into the bleed jar.
  8. When brake fluid, clean and air-free flows into the bleed jar, depress and hold the brake pedal down.
  9. With the brake pedal fully depressed, tighten the bleed screw to 10 Nm (7 lb.ft).
  10. Fill the brake fluid reservoir to the MAX mark.
  11. Apply the brakes and check for leaks.
  12. Install the brake fluid reservoir cap. Connect the brake fluid reservoir electrical connector.
  13. On completion, road test the vehicle and check the brake pedal operation. The pedal travel should be short with a firm feel.

See also:
• Specifications

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