Discovery 2. Manual — part 638

BRAKES

REPAIRS

70-43

Refit

1. Clean mating faces of alternator and vacuum

pump.

2. Fit vacuum pump to alternator and tighten

bolts to 8 Nm (6 lbf.ft).

3. Position alternator to engine and connect

multiplug.

4. Connect vacuum hose and oil drain hose to

vacuum pump and secure clips.

5. With assistance align alternator to mounting

bracket and fit but do not tighten bolt.

6. Fit bolt securing support stay to alternator and

tighten to 25 Nm (18 lbf.ft) .

7. Tighten bolt securing alternator to mounting

bracket to 45 Nm (33 lbf.ft).

8. Using new 'O' ring, connect oil supply pipe to

cylinder head and tighten to 10 Nm (7 lbf.ft).

9. Connect lead to alternator and tighten nut to 6

Nm (4.4 lbf.ft).

10. Fit auxiliary drive belt tensioner and tighten bolt

to 50 Nm (37 lbf.ft).

11. Fit auxiliary drive belt.

+

CHARGING AND STARTING,

REPAIRS, Belt - auxiliary drive.

Housing - caliper - front

$% 70.55.24

Remove

1. Raise front of vehicle, one side.

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(s).
3. Clamp brake hose to prevent fluid loss.

4. Remove brake hose banjo bolt and discard

sealing washers.

CAUTION: Always fit plugs to open
connections to prevent contamination.

5. Remove 2 guide pin bolts and remove caliper

housing from carrier.

6. Remove 2 brake pads from caliper carrier.

BRAKES

70-44

REPAIRS

Refit

1. Rotate disc by hand and scrape all scale and

rust from around edge of disc. Clean location
surfaces on caliper bracket.

2. Clean dust from brake parts using brake

cleaning fluid.

WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.

3. Fit brake pads to caliper carrier.
4. Position caliper housing to carrier, align flats on

guide pins with caliper housing.

5. Fit guide pin bolts and tighten to 30 Nm (22

lbf.ft).

6. Clean banjo bolt and fit new sealing washers.
7. Position hose to caliper and tighten banjo bolt

to 32 Nm (24 lbf.ft).

8. Remove clamp from brake hose.
9. Bleed brake system.

+

BRAKES, ADJUSTMENTS, Brake

system bleeding.

10. Fit road wheel(s) and tighten nuts to 140 Nm

(103 lbf.ft).

11. Remove stand(s) and lower vehicle.

Housing - caliper - rear

$% 70.55.25

Remove

1. Raise rear of vehicle, one side.

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(s).
3. Clamp brake hose to prevent fluid loss.

4. Remove brake hose banjo bolt and discard

sealing washers.

CAUTION: Always fit plugs to open
connections to prevent contamination.

5. Remove 2 guide pin bolts and remove caliper

housing from carrier.

6. Remove 2 brake pads from caliper carrier.

BRAKES

REPAIRS

70-45

Refit

1. Rotate disc by hand and scrape all scale and

rust from around edge of disc. Clean location
surfaces on caliper bracket.

2. Clean dust from brake parts using brake

cleaning fluid.

WARNING: Do not use compressed air to
clean brake components. Dust from friction
materials can be harmful if inhaled.

3. Fit brake pads to caliper carrier.
4. Position caliper housing to carrier, align flats on

guide pins with caliper housing.

5. Fit guide pin bolts and tighten to 30 Nm (22

lbf.ft).

6. Clean banjo bolt and fit new sealing washers.
7. Position hose to caliper and tighten banjo bolt

to 32 Nm (24 lbf.ft).

8. Remove clamp from brake hose.
9. Bleed brakes.

+

BRAKES, ADJUSTMENTS, Brake

system bleeding.

10. Fit road wheel(s) and tighten nuts to 140 Nm

(103 lbf.ft).

11. Remove stand(s) and lower vehicle.

ECU - Self levelling and anti locking
brakes (SLABS)

$% 70.65.01

Remove

1. Remove BCU.

+

BODY CONTROL UNIT, REPAIRS,

Body control unit (BCU).

2. Remove 5 multiplugs from SLABS ECU.
3. Remove multiplug from ACE ECU.
4. Remove lower nut and loosen upper nut

securing SLABS and ACE ECU bracket to
body.

5. Remove ECU's and bracket assembly.

BRAKES

70-46

REPAIRS

6. Remove 4 nuts securing SLABS ECU and

remove ECU.

Refit

1. Fit new SLABS ECU to bracket and secure with

nuts.

2. Fit ECU's and bracket assembly to body and

secure with nuts.

3. Connect multiplugs to ACE ECU and SLABS

ECU.

4. Fit BCU.

+

BODY CONTROL UNIT, REPAIRS,

Body control unit (BCU).

5. Programme the new SLABS ECU using

TestBook.

Sensor – ABS – front

$% 70.65.30

ABS sensor is supplied fitted to wheel hub and
must not be removed.

Remove

1. Remove wheel hub.

+

FRONT SUSPENSION, REPAIRS,

Wheel hub.

Refit

1. Fit wheel hub.

+

FRONT SUSPENSION, REPAIRS,

Wheel hub.