Land Rover Discovery: Brake Hydraulics
Always observe the following recommendations when working on the
braking system:
WARNING:
Do not intermix brake fluid of different specifications.
- Always use two spanners when loosening or tightening brake pipes or
hose connections.
- Make sure that hoses run in a natural curve and are not kinked or
twisted.
- Install brake pipes and hoses securely in their retaining clips and make
sure that they cannot contact a potential chafing point.
- Containers used for brake fluid must be kept absolutely clean.
- Do not store brake fluid in unsealed containers, the fluid will absorb
water
which will lower the boiling point of the fluid.
- Do not allow brake fluid to be contaminated with other fluids such as
mineral oil and do not put brake fluid in a container which has previously
been used for storing other fluids.
- Do not reuse brake fluid which has been bled from the system.
- Always use brake fluid or a suitable brake cleaning fluid to clean
hydraulic
components.
- Unless stated otherwise, use only clean brake fluid to lubricate
hydraulic
seals and components.
- Always install blanking plugs to hoses, pipes or components immediately
after disconnection.
- Check thread compatibility of original equipment with replacement
components.
- Observe absolute cleanliness when working with hydraulic components.
PIPES AND HOSES
When removing or installing flexible hydraulic pipes and hoses, make sure
that the following procedures are observed to make sure component
serviceability:
- Prior to removal, clean area around hose or pipe end which is to be
disconnected.
- Obtain appropriate blanking plugs or caps before disconnecting hose or
pipe end fittings in order that connections can be plugged immediately
following disconnection.
- Always install blanking plugs or caps to pipes and unions immediately
following disconnection.
- Clean hose or pipe and blow through with an air line.
WARNING:
Suitable eye protection must be worn.
- Check hoses externally for cracks, separation of plies, security of end
fittings and external damage; replace faulty hoses.
- Check pipes for signs of corrosion and chafing, replace as necessary.
CAUTION:
If pipes are found to be chafed, rectify clips, mounting points etc.,
to
prevent further problems in service.
- When installing hoses, make sure that no unnecessary bends are
introduced and that hoses are not kinked, twisted or positioned close to
potential chafing points.
- When installing pipes, make sure that pipes are positioned and clipped
clear of potential chafing points.
- Always replace sealing washers installed to banjo bolts, sealing plugs
etc,
unless stated otherwise in the procedure.
- Always use a backing spanner when tightening unions and do not
overtighten union nuts or banjo bolts.
- After any work on hydraulic systems, always check for fluid leaks whilst
a
second operator applies working pressure to the brake pedal or operates
the system that has been worked on.
Fuel system hoses
![Fuel system hoses](images/books/227/index.15.gif)
All fuel hoses are made up of two laminations, an armoured rubber outer
sleeve and an inner viton core. Whenever a hose is removed, make sure that
the inner bore is inspected to check that the viton lining has not become
separated from the outer sleeve.
WARNING:
Never attempt to repair fuel hoses or rectify leaking 'quick-fit'
connectors the fuel hose and connectors must be replaced as an
assembly.
Fuel system hose clips
![Fuel system hose clips](images/books/227/index.16.gif)
Certain fuel system hose clips are of the 'break-off head' type where a slot
in the screw head shears off when the clip is tightened to a specific torque.
These clips may be removed using a screwdriver and must be replaced with new
clips on reassembly. Clips must be tightened until the portion of the
slot shears off. Do not attempt to tighten clips by any other method, do not
install any other type of clip.
Cooling system hoses
CAUTION:
The following precautions must be observed to make sure that the
integrity of the cooling system hoses and their connection to the
system is maintained.
Hose orientation and connection
Correct orientation of cooling system hoses is important to make sure that
hoses do not become fatigued or damaged through contact with adjacent
components.
![Hose orientation and connection](images/books/227/index(1).17.jpg)
Where orientation marks are provided on the hose and corresponding
component, the marks must be aligned when the hose is installed. Hoses
must be installed fully on to their connection points, usually a moulded form
on a pipe provides a positive indicator.
Hose clips
![Hose clips](images/books/227/index(1).18.jpg)
Markings 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 pipe. Worm drive clips should be
orientated with the crimped side of the drive housing facing towards the
end of the hose or the hose may become pinched between the clip and the
stub pipe retaining lip. Unless otherwise stated, worm drive clips should be
tightened to 3 Nm (2 lb-ft). Make sure that hose clips do not foul adjacent
components.
![Hose clips](images/books/227/index(1).19.gif)
Oetiker clips may be removed by bending the tag (arrowed) and releasing
the free end of the clip. Clips must not be reused. When installing new clips,
make sure clip is positioned on hose before tightening and make sure that
when clip is tightened, the tag is located in the longitudinal slot in the free
end of the clip (arrowed in illustration).
Heat protection
Always make sure 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
manifolds and exhaust gas recirculation (EGR) pipes. Hoses will relax and
deflect slightly when hot, make sure this movement is taken into account
when routing and securing hoses.
READ NEXT:
GENERAL
The following guidelines are intended to make sure the safety of the
operator whilst preventing damage to the electrical and electronic
components of this vehicle.
EQUIPMENT
Prior to commencin
The following information lists basic precautions which must be observed if
fuel is to be handled safely. It also outlines other areas of risk which must
not be ignored. As this information is issued
Never use a seal which has been improperly stored or handled.
Take great care when removing old seals that the sealing surfaces and
seal
housing are not damaged.
Carefully examine seal before in
SEE MORE:
NOTES:
Some variation in the illustrations may occur, but the essential
information is always correct.
Left illustration shown, Right is similar.
NOTE:
The fog lamp beam should be set at 2% below the horizontal
and parallel.
Check the fog lamp beam alignment.
Align the beam setting equipment to
CHECK
WARNINGS:
Make sure that the steamer is in the OFF position before
connecting or disconnecting from the electrical outlet.
Do not use another high wattage device on the same electrical
circuit.
If the use of an extension cord is absolutely necessary, the
cord
must be rated at a minimu