Handbrake
Handbrake linkage lever-to-stop pin clearance . . . . . . . . . . . . . . . . . . . 0.5 to 2.0 mm
Torque wrench settings Nm lbf ft
Caliper guide pin bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 24
Front caliper carrier bracket to steering knuckle . . . . . . . . . . . . . . . . . . 75 55
Rear caliper carrier bracket to hub carrier . . . . . . . . . . . . . . . . . . . . . . . 45 33
Caliper bleed screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Brake hose banjo union bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 26
Brake pipe union nuts:
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 11
M12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 16
Brake disc retaining screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 9
Handbrake linkage cover to rear caliper . . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Handbrake lever to floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Handbrake front cable guide plate bolts . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Handbrake rear cable support clip bolts . . . . . . . . . . . . . . . . . . . . . . . . 10 7
Master cylinder to servo unit nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Servo unit to bulkhead nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Brake pedal pivot bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Pressure reducing valve mounting bracket bolts . . . . . . . . . . . . . . . . . . 10 7
Hydraulic modulator mounting nuts (ABS) . . . . . . . . . . . . . . . . . . . . . . . 10 7
Wheel speed sensor to sensor bracket bolt (ABS) . . . . . . . . . . . . . . . . . 10 7
Wheel speed sensor bracket bolts (ABS) . . . . . . . . . . . . . . . . . . . . . . . . 25 18
Wheel speed sensor wiring clips and bracket bolts (ABS) . . . . . . . . . . . 10 7
Copy valve mounting bracket bolts (ABS) . . . . . . . . . . . . . . . . . . . . . . . 10 7
Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 81
9•2 Braking system
1380 Rover 800 Series Remake
1 General information
The braking system is of the servo-
assisted, dual-circuit hydraulic type,
incorporating disc brakes at the front and
rear. A diagonally-split dual circuit hydraulic
system is employed, in which each circuit
operates one front and one diagonally
opposite rear brake from a tandem master
cylinder. Under normal conditions, both
circuits operate in unison; however, in the
event of hydraulic failure in one circuit, full
braking force will still be available at two
wheels. A pressure-reducing valve is
incorporated in the rear brake hydraulic
circuit. This valve regulates the hydraulic
pressure applied to each rear brake, and
reduces the possibility of the rear wheels
locking under heavy braking.
Self-adjusting single-piston sliding type
calipers are used in conjunction with
ventilated and solid discs at the front and rear
respectively. A cable-operated handbrake
provides an independent mechanical means
of rear brake application.
An anti-lock braking system (ABS) is
available on some models and features many
of the components in common with the
conventional braking system. Further details
on the ABS can be found later in this Chapter.
Note: When servicing any part of the system,
work carefully and methodically; also observe
scrupulous cleanliness when overhauling any
part of the hydraulic system. Always renew
components (in axle sets, where applicable) if
in any doubt about their condition, and use
only genuine Rover or Unipart replacement
parts, or at least those of known good quality.
Note the warnings given in “Safety First” at the
beginning of this manual and at relevant points
in this Chapter concerning the dangers of
asbestos dust and hydraulic fluid.
2 Hydraulic system - bleeding
3
Warning: Hydraulic fluid is
poisonous; wash off
immediately and thoroughly in
the case of skin contact, and
seek immediate medical advice if any fluid
is swallowed or gets into the eyes. Certain
types of hydraulic fluid are inflammable,
and may ignite when allowed into contact
with hot components; when servicing any
hydraulic system, it is safest to assume
that the fluid IS inflammable, and to take
precautions against the risk of fire as
though it is petrol that is being handled.
Finally, it is hygroscopic (it absorbs
moisture from the air). The more moisture
is absorbed by the fluid, the lower its
boiling point becomes, leading to a
dangerous loss of braking under hard use.
Old fluid may be contaminated and unfit
for further use. When topping-up or
renewing the fluid, always use the
recommended type, and ensure that it
comes from a freshly-opened sealed
container.
General
1 The correct functioning of the brake
hydraulic system is only possible after
removing all air from the components and
circuit; this is achieved by bleeding the
system.
2 During the bleeding procedure, add only
clean, fresh hydraulic fluid of the specified
type; never re-use fluid that has already been
bled from the system. Ensure that sufficient
fluid is available before starting work.
3 If there is any possibility of incorrect fluid
being used in the system, the brake lines and
components must be completely flushed with
uncontaminated fluid and new seals fitted to
the components.
4 If brake fluid has been lost from the master
cylinder due to a leak in the system, ensure
that the cause is traced and rectified before
proceeding further.
5 Park the vehicle on level ground, switch off
the ignition and select first gear (manual
transmission) or Park (automatic transmission)
then chock the wheels and release the
handbrake.
6 Check that all pipes and hoses are secure,
unions tight, and bleed screws closed.
Remove the dust caps and clean any dirt from
around the bleed screws.
Hydraulic fluid is an
effective paint stripper, and
will attack plastics; if any is
spilt, it should be washed off
immediately, using copious quantities
of clean water.
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