Vacuum brake booster (Discovery 3)

Removal

All cars

1. Remove the driver's side trim panel. Release the clip.

• Remove 2 screws.
• Disconnect the electrical connector.

2. Remove the instrument panel access panel. Remove 2 screws.



3. Remove the brake pedal buffer.

• Remove 4 Torx screws.
• Disconnect the wiring harness clamp.

4. Remove the brake booster rod fork pin. Remove the clamp.





5. Remove the base of the inner chamber. For more information, refer to Additional Battery Shelf (76.10.31)

6.

CAUTION: Brake fluid may damage paintwork if it comes into contact with it. If any fluid is spilled, remove it immediately and rinse the area with water.

Place an absorbent cloth to collect any spilled liquid.

7.

CAUTION: Before disconnecting or removing any parts, ensure that the area around mating surfaces and connections is clean. To avoid contamination of the system, cover all open connections.

Disconnect the 2 brake lines from the ABS module.



Cars with manual transmission

8. Disconnect the clutch master cylinder line.



All cars



9. Disconnect the 2 brake lines from the master cylinder.



10. Disconnect the low brake fluid level indicator switch electrical connector.

11. Disconnect the brake booster vacuum hose from the brake booster.

12. Remove the master brake cylinder. Unscrew the 2 nuts.

13. Remove the brake booster. Unscrew the 4 nuts.

Installation

All cars

1. Install the brake booster. Tighten the nuts. (tightening torque 23 Nm).

2. Install the brake master cylinder. Tighten the nuts. (tightening torque 26 Nm).

3. Connect the brake booster vacuum hose.

Cars with manual transmission

4. Connect the clutch master cylinder line.

All cars

5. Connect the low brake fluid level indicator switch electrical connector.

6. Install the brake lines.

• Tighten the brake pipe fittings M12 (tightening torque 16 Nm).
• Tighten the brake pipe fittings M14 (tightening torque 18 Nm).

7. Install the base of the inner chamber. For more information, refer to Additional Battery Shelf (76.10.31)

8. Install the brake booster rod fork pin. Install a new clamp.

9. Install the brake pedal buffer.

• Tighten the bolts to 10 Nm.
• Secure the wire harness clamp.

10. Install the instrument panel access panel. Tighten the 2 screws.

11. Bleed the brake system using T4. For more information, refer to Bleeding the Brake System Under Pressure (70.25.02)

12. Install the decorative panel.

• Connect the electrical connector.
• Secure the clamp.
• Tighten the screws.

Cars with manual transmission

13. Bleed the clutch system. For more information, refer to Bleeding the Clutch System