Rover 820 - Page 151

1380 Rover 800 Series Remake
9
General
System type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagonally-split, dual-circuit hydraulic with pressure-reducing valve in
rear hydraulic circuit and cable operated handbrake. Anti-lock braking
system (ABS) available as standard or optional equipment on later
models.
Front brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilated disc with single-piston sliding calipers
Disc diameter:
4-cylinder engine models without turbo . . . . . . . . . . . . . . . . . . . . . . . 262.0 mm
4-cylinder turbo engine models and V6 engine models . . . . . . . . . . . 285.0 mm
Disc thickness:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.0 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.0 mm
Maximum thickness variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm
Maximum disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 mm
Brake pad thickness (including backing but excluding shims):
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 mm
ABS wheel speed sensor-to-reluctor ring clearance . . . . . . . . . . . . . . . 0.30 to 1.02 mm
Rear brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid disc with single-sliding calipers
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260.0 mm
Disc thickness:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
Maximum thickness variation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 mm
Maximum disc run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.040 mm
Brake pad thickness (including backing):
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 mm
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 mm
ABS wheel speed sensor-to-reluctor ring clearance . . . . . . . . . . . . . . . 0.055 to 1.11 mm
Chapter 9 Braking system
Anti-lock braking system - component removal and refitting . . . . . . 25
Anti-lock braking system - general information . . . . . . . . . . . . . . . . 24
Brake check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front brake disc - inspection, removal and refitting . . . . . . . . . . . . . 6
Front brake caliper - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front brake caliper - removal and refitting . . . . . . . . . . . . . . . . . . . . 4
Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Handbrake cable (front) - removal and refitting . . . . . . . . . . . . . . . . 19
Handbrake cable (rear) - removal and refitting . . . . . . . . . . . . . . . . . 20
Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic pipes and hoses - inspection, removal and refitting . . . . . 15
Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 11
Master cylinder (ABS models) - overhaul . . . . . . . . . . . . . . . . . . . . . 13
Master cylinder (non-ABS models) - overhaul . . . . . . . . . . . . . . . . . 12
Pressure-reducing valve - general information,
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear brake caliper - overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear brake caliper - removal and refitting . . . . . . . . . . . . . . . . . . . . . 8
Rear brake disc - inspection, removal and refitting . . . . . . . . . . . . . 10
Rear brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Stop-light switch - removal, refitting and adjustment . . . . . . . . . . . . 21
Underbonnet check for fluid leaks and hose condition . .See Chapter 1
Vacuum servo unit - general information and testing . . . . . . . . . . . . 22
Vacuum servo unit - removal and refitting . . . . . . . . . . . . . . . . . . . . 23
9•1
Specifications
Contents
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult,
suitable for competent
DIY mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
5
4
3
2
1