battery replacement JAGUAR X308 1998 2.G Workshop Manual

Hydraulic Br
ake Actuation
- Brake Fluid Reservoir
Remo
val and Installation
Remov
a
l
• C
A
UTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
1. Position vehicl
e on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Remove reservoir filler cap and empty residual brake fluid into
a container. Refit cap.

7. Re
move fluid reservoir from master cylinder.
R
e
move locating pin.
Pull reservoir

from master cylinder.

8. Install plugs into f
luid reservoir ports.
9. Remove and discard seal s from master cylinder.

Hydraulic B
rake Actuation
- Brake Master Cylinder
Re
moval and Installation
Remov

al
• C
AUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
1. Position vehi
cle on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, refer to
operation 86.15.19 for fu rther information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Place assembly on a work bench.

7. R
emove nuts securing master cylinder to brake booster.

8. R
emove master cylinder from brake booster.
Re

move master cylinder.
Remove an

d discard seal.
9. Remove filler cap and empty residual brake fluid into a
container. Fit cap.
10. Remove fluid reservoir from master cylinder.
R
emove locating pin.
Pull

reservoir from master cylinder.

Hydrau
lic Brake Actuation - Brake Pedal and Bracket
Re
mo
val and Installation
Remov
a
l
• C
A
UTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
In
stallation
1.
Position vehicl
e on a four-post lift.
2. Open hood and fit suitable pa intwork protection equipment.
3. Disconnect battery ground cabl e. (IMPORTANT, see 86.15.19
for further information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Remove brake booster and master cylinder assembly. Refer to
operation 70.50.18.

7. Remove brake wa
rning-light switch.
Remove n
u
t and bolt.
Slide sw

itch forward to release from locating tag.

8. Re
move throttle pedal assembly.
1. Remove and discard retaining wire.
2. Remove pivot pins.
3. Remove throttle pedal assembly.
4. Remove return spring.
9. Clean components and mating surfaces.
1. Apply grease to pivot pins.
2. Install throttle pedal assembly.
1. Align throttle assembly.

Hydrau
lic Brake Actuation - Brake Pedal and Bracket, Brake Booster and
Brake Master Cylinder
Re mo
val and Installation
Remova

l
• C
A
UTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
1. Position vehi cl
e on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, refer to
operation 86.15.19 for fu rther information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.

5. Reposi
tion the mounting bracket of the cruise control vacuum-
valves for access (if installed).
R e
move screws.
Reposition bracket.


6. Disc
onnect low-level warning connector from master cylinder.
7. Disconnect vacuum pipe from brake booster.
1. Disconnect pipe.
2. Remove and discard seal.

Power Brake Actuatio
n - Brake Booster
Re
moval and Installation
Remov

al
• C
AUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
I
nstallation
1.
Position vehi
cle on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Remove brake booster and master cylinder assembly. Refer to
operation 70.50.18.

7. R
emove nuts securing master cylinder to brake booster.

8. R
emove master cylinder from brake booster.
Re

move master cylinder.
Remove an

d discard seal.
9. Remove filler cap and empty residual brake fluid into a
container.
10. Clean components and mating surfaces.
1. Install master cylinder to brake booster.
Inst
all seal to master cylinder.

Power Brake Actuatio
n - Brake Boos
ter and Brake Master Cylinder
Re
moval and Installation
Remov

al
• C
AUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
1. Position vehi
cle on a four-post lift.
2. Move driver's seat fully rearward.
3. Open engine compartment and fit paint work protection covers
to fenders.
4. Disconnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
5. Remove engine compartment rear cover. Refer to operation
76.11.35.
6. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
7. Remove reservoir filler cap and po ur residual brake fluid into a
container. Refit cap.

8. R
emove the clevis pin connecting the brake pedal to the
master cylinder push-rod fork.
1. Remove grommets from access holes.
2. Remove retaining clip.
3. Remove clevis pin.

9. Re
position the brake pedal to access the nuts securing the
brake booster to the pedal housing.
1. Remove pivot pin nut.
2. Remove pivot pin.
Reposition brake pedal.
10
.
Remove brake booster from pedal housing.
1. Remove grommet from access hole.
2. Remove nuts.

Anti-Lock Control - Anti-Lock Brake System (ABS) Module
Remo
val and Installation
Remov
a
l
• C
A
UTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
Sp
ecial Tool(s)

Brake Pedal
H
old Tool
JDS 9013
1. Disc onne
ct battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
2. Position vehicle on a four-post lift.
3. Open engine compartment and fit paint work protection covers
to fenders.

4. NOTE : Th
e following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake tubes.
Open Left-Hand-Front and Left-H and-Rear caliper bleed nipples.
Connect a
bleed tube and co
ntainer to the calipers.
Op
en bleed nipples.

5. Depress and hold down brake pedal u s
ing special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held
60mm down from its released position.
6. Tighten bleed nipples to:
Front caliper blee d nipple 4-6 Nm.

Rear
caliper bleed nip
ple 8-11 Nm.

Anti-Lock Control - Hydraulic Contro
l Unit (HCU)
Re
moval and Installation
Remov

al
• C
AUTIONS:
Replacement of nuts and bolts: Various thread-locking de vices are used on nuts and bolts throughout the vehicle.
These devices restrict the number of times a nut or bolt can be used. See section 100-00 for information.
Remove brake fluid spilla ge immediately from paint work, with clean water.
S
pecial Tool(s)

Brake Pedal

Hold Tool
JDS 9013
1. Disc
onnect battery ground cable (IMPORTANT, see operation
86.15.19 for further information).
2. Position vehicle on a four-post lift.
3. Open engine compartment and fit paint work protection covers
to fenders.

4. NOTE
: The following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake tubes.
Open Left-Hand-Front and Left-H and-Rear caliper bleed nipples.
Connect
a bleed tube and co
ntainer to the calipers.
O
pen bleed nipples.

5. Depress and hold down brake pedal u
sing special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held
60mm down from its released position.
6. Tighten bleed nipples to:
Front caliper blee d nipple 4-6
Nm.
Rear

caliper bleed nipple 8-11 Nm.

E
ngine - Cylinder Head LH
In-ve
hicle Repair
Remova

l
CAU
TION: If a replacement cylinder head is to be installed to a
vehicle with variable camshaft timing (VCT) the cylinder head m ust have the
oil gallery blind rivet removed before installation.
Spe
cial Tool(s)

Cams

haft setting
303-530

Ti
ming chain tensioning
303-532

Wedges, prim
ary chain
303-533

Cr
ankshaft setting
303-531
1.
Open the engine compartment and install paintwork protection sheets.
2. Set the engine compartment cover to the service access position.

3.
Disconnect the battery ground cable.
Re

move the battery cover.
4. Remove the engine fron cover.For additional information, refer to: Engine
Front Cover (303-01 Engi
ne, In-vehicle Repair).
5. Remove the Inlet Manifold. Refer to Operation 30.15.01 in this Section. This operation includes depressurising the fuel system and removing the throttle
housing.
6. Disconnect the hoses and multi-plug from the coolant outlet pipe.
1. Release and reposition the hose clip, and disconnect the heater hose.
2. Disconnect the multi-plug from the temperature sensor.
3. Release and reposition the hose clip along the bypass hose.

E
ngine - Cylinder Head RH
In-ve
hicle Repair
Remova

l
CAU
TION: If a replacement cylinder head is to be installed to a
vehicle with variable camshaft timing (VCT) the cylinder head m ust have the
oil gallery blind rivet removed before installation.
Spe
cial Tool(s)

Cams

haft setting
303-530

Ti
ming chain tensioning
303-532

Wedges, prim
ary chain
303-533

Cr
ankshaft setting
303-531
1.
Open the engine compartment and install paintwork protection sheets.
2. Set the engine compartment cover to the service access position.

3.
Disconnect the battery ground cable.
Re

move the battery cover.
4. Remove the engine front cover.For additional information, refer to: Engine
Front Cover (303-01 Engi
ne, In-vehicle Repair).
5. Remove the Inlet Manifold. Refer to Operation 30.15.01 in this Section. This operation includes depressurising the fuel system and removing the throttle
housing.
6. Disconnect the hoses and multi-plug from the coolant outlet pipe.
1. Release and reposition the hose clip, and disconnect the heater hose.
2. Disconnect the multi-plug from the temperature sensor.
3. Release and reposition the hose clip along the bypass hose.