300Tdi Discovery
BRAKES
7
REPAIR
19. Coat new seals in unused brake fluid. Fit ’L’ seal
to plunger.
20. Fit washer followed by recuperating seal. Fit seal
retainer and springs, ensure springs are
correctly seated.
Assembling master cylinder
CAUTION: It is important that following
instructions are carried out precisely,
otherwise damage could be caused to new
seals when inserting plungers into cylinder bore.
Generous amounts of new brake fluid should be
used to lubricate parts during assembly.
21. Fit new swirl tube to bottom of cylinder bore.
22. Lubricate secondary plunger and cylinder bore.
Offer plunger assembly to cylinder until
recuperation seal is resting centrally in mouth of
bore. Gently introduce plunger with a circular
rocking motion, as illustrated. Ensuring that seal
does not become trapped, ease seal into bore
and slowly push plunger down bore in one
continuous movement.
23. Fit new primary plunger assembly using same
method as for secondary plunger.
24. Fit original guide ring to support primary plunger.
25. Coat a new ’O’ ring with brake fluid and fit to its
respective groove on outer location surface of
master cylinder.
CAUTION: Do not roll ’O’ ring down outer
location surface of master cylinder. It
should be slightly stretched and eased
down cylinder and into its groove. Do not over
stretch seal.
26. Fit new retaining ring on outer surface of master
cylinder ensuring that serrations of ring are
facing mounting flange.
27. Fit two new reservoir seals in respective ports.
28. Fit a new vacuum seal to either primary plunger
or to bottom of transfer housing bore, open face
of seal towards primary plunger.
29. Lubricate vacuum seal with brake fluid. Fit
transfer housing to master cylinder, push
housing fully up to cylinder mounting flange, Do
not adjust transfer housing after fitting.
30. Lubricate new water ingress seal with brake
fluid, Slightly stretch seal and ease down
housing until it is in position between housing
and flange.
31. Roll reservoir into top of master cylinder,
reversing procedure described in instruction 10.
Refit
NOTE: Ensure O ring seal between master
cylinder and servo unit is fitted correctly.
32. Fit master cylinder to servo. Secure in position
with two nuts, plain and spring washers. Tighten
to
26 Nm.
33. Fit brake pipes to master cylinder. Tighten to
15Nm.
34. Top-up master cylinder with correct grade of
brake fluid.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
35. Bleed system.
See Brake System Bleed
36. Fit cap, reconnect electrical lead to fluid level
switch. Reconnect battery negative lead.
