300Tdi Discovery
70
BRAKES
14
REPAIR
Assemble outboard pistons
13. Coat new fluid seal with brake fluid. Ease seal
into groove in bore using only fingers, ensuring it
is properly seated. Fluid seal and groove are not
same in section, so when seal is seated it feels
raised to touch at edge furthest away from
mouth of bore.
14. Coat appropriate piston with brake fluid. Insert it
squarely into bore by hand only. Do not tilt piston
during insertion, leave approximately 8mm
projecting from bore.
15. Coat new wiper seal with brake fluid and fit to
new seal retainer. Slide assembly, seal first, over
protruding piston and into bore recess. Use
piston clamp to press home seal retainer and
piston.
Mounting inboard pistons
16. Clamp outboard pistons and carry out same
procedure for removing and fitting outboard
pistons and seals, instructions 8 to 15.
Fit calipers and pads
17. Fit caliper, tighten bolts evenly to
82 Nm.
18. Connect brake flexible hoses to caliper. Tighten
to
15 Nm.
19. Remove hose clamps.
20. Insert pads. Fit pins and springs, secure using
new split [cotter] pin.
21. Bleed brake system.
See Brake System Bleed
22. Press brake pedal firmly several times to locate
friction pads.
23. Fit road wheels, remove axle stands. Finally
tighten road wheel nuts to
130 Nm.
24. Road test vehicle. Note that new friction pads
require ’bedding-in’, this may take several
hundred miles before brakes are at maximum
efficiency.
