brake system bleeding JAGUAR XFR 2010 1.G Workshop Manual

Diagnosis and TestingBrake SystemGeneral ProceduresBrake Disc Runout Check
Brake System Bleeding (70.25.03)
Front Brake Disc Runout Check - With Wheel On - Vehicles With: High Performance Brakes
Rear Brake Disc Runout Check - With Wheel On206-03B: Front Disc Brake - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionRemoval and InstallationBrake Caliper - Vehicles With: High Performance Brakes
Brake Disc - Vehicles With: High Performance Brakes
Brake Pads - Vehicles With: High Performance Brakes
Brake Disc Shield (70.10.18) - Vehicles With: High Performance Brakes206-04B: Rear Disc Brake - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L PetrolSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionRemoval and InstallationBrake Caliper - Vehicles With: High Performance Brakes
Brake Disc - Vehicles With: High Performance Brakes
Brake Pads - Vehicles With: High Performance Brakes
Brake Disc Shield (70.10.19)206-05: Parking Brake and ActuationSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingParking BrakeGeneral ProceduresParking Brake Cable Tension ReleaseRemoval and InstallationParking Brake Cable LH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol
Parking Brake Cable RH - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol

System - V6 3.0L Petrol, Removal and Installation).

19. Refill the fuel tank.
For additional information, refer to: Fuel Tank Draining (310-00 Fuel System - General Information, General Procedures).

20. Bleed the brake system.
For additional information, refer to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).

21. Install the rear wheels and tires.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

22. Connect the battery ground cable.
For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

23. Using only four-wheel alignment equipment approved by Jaguar, check
and adjust the wheel alignment.
For additional information, refer to: Camber and Caster Adjustment (204-00 Suspension System - General Information, General Procedures).

9. Torque: 115 Nm
1. To install, reverse the removal procedure.

2. Refer to: Brake System Bleeding (206-00, General Procedures).

TEST
CONDITIONS DETAILS/RESULTS/ACTIONS D1: CHECK FOR SPONGY PEDAL (ENGINE OFF) 1 Check for a firm brake pedal. Is the brake pedal effort and brake pedal travel normal? Yes
No action is required, vehicle is OK.
No
GO to D2. D2: CHECK BRAKE PEDAL RESERVE (ENGINE OFF) 1 Pump the brake pedal 10 times and hold on the final application. Does the brake pedal feel firm on final application? Yes
GO to D3. No
Bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). D3: CHECK BRAKE PEDAL RESERVE (ENGINE ON) 1 With engine running at idle speed. 2 Apply the brake pedal lightly three or four times. 3 Wait 15 seconds for the vacuum to recover. 4 Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs. 5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min. 6 Release the accelerator pedal. Does the brake pedal move downward as the engine speed returns to idle? Yes
GO to D4. No
Check the vacuum to brake booster. D4: CHECK BRAKE FLUID LEVEL 1 Check the brake master cylinder reservoir fluid level. Is the fluid level OK? Yes
Bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation.
No
Check for leaking brake system and rectify as required. Add fluid and bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation.
PINPOINT TEST E : THE PEDAL GOES DOWN FAST TEST
CONDITIONS DETAILS/RESULTS/ACTIONS E1: ROAD TEST VEHICLE 1 Road test the vehicle and apply the brake pedal. Is the brake pedal effort and brake pedal travel normal? Yes
No action required, vehicle is OK.
No
GO to E2. E2: CHECK BRAKE PEDAL TRAVEL-PRESSURIZE SYSTEM 1 Pump the brake pedal rapidly (five times). Does the brake pedal travel build up and then hold? Yes
Bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation.
No
GO to E3. E3: CHECK FOR BRAKE SYSTEM LEAKS Is the alignment within specification?
Yes
No action is required, vehicle is OK.
No
Adjust the alignment as required. REFER to:
Front Subframe - 2.7L Diesel (502-00, Removal and Installation),
Front Subframe - V6 3.0L Petrol (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation),
Front Subframe - 4.2L (502-00, Removal and Installation).

Check for external brake system leaks. For additional information, refer to brake master cylinder component test in this section. Is there a leak present? Yes
Repair as necessary, add fluid and bleed brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation.
No
No action required, system is OK.
PINPOINT TEST F : THE PEDAL GOES DOWN SLOWLY TEST
CONDITIONS DETAILS/RESULTS/ACTIONS F1: ROAD TEST VEHICLE - CHECK BRAKE PEDAL OPERATION 1 Check if the condition occurs during actual stopping application by applying the brake pedal while the vehicle is moving. Does the condition occur when the vehicle is moving? Yes
GO to F2. No
GO to F3. F2: CHECK FOR BRAKE SYSTEM LEAKS 1 Check for external brake system leaks. For additional information, refer to brake master cylinder component test in this section. Are there any external brake system leaks? Yes
Rectify as necessary. Add fluid and bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation.
No
GO to F3. F3: CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST 1 Test for brake master cylinder bypass condition. Refer to Brake master cylinder component test in this section. Has a concern been identified? Yes
Install a new brake master cylinder, add fluid and bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation.
No
No action required, system is OK.
PINPOINT TEST G : EXCESSIVE BRAKE PEDAL EFFORT TEST
CONDITIONS DETAILS/RESULTS/ACTIONS G1: CHECK BRAKE PADS 1 Check the brake pads for wear, contamination, correct installation, damage and type. Has a concern been identified?
Yes
Correctly install or install new brake pads as required. REFER to:
Brake Pads - Vehicles With: Standard Brakes (206-03A Front Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Pads - Vehicles With: High Performance Brakes (206-03A Front Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Pads (206-04A Rear Disc Brake - V6 3.0L Petrol, Removal and Installation), Brake Pads - Vehicles With: High Performance Brakes (206-04, Removal and Installation).
Re-test the system for normal operation.
No
GO to G2. G2: CHECK VACUUM 1 Disconnect the vacuum hose from the brake booster. 2 Connect a vacuum/pressure tester to the vacuum hose. 3 Run the engine at normal operating temperature. 4 Record the vacuum reading. Is the reading 40.5 kPa (12 in-Hg) or greater?
Yes
GO to G3. No
Locate and rectify the source of low vacuum. Re-test the system for normal operation. G3: INSPECT SYSTEM 1 Switch the engine off. 2 Reconnect the vacuum hose.

Yes
Inspect the brake calipers and parking brake cables. Install new components as required. Re-test the
system for normal operation.
No
GO to I3. I3: CHECK BRAKE BOOSTER 1 Check the brake booster connecting rod alignment and travel. Is the connecting rod OK? Yes
Vehicle is OK.
No
Install a new brake booster as required. REFER to:
Brake Booster (206-07 Power Brake Actuation, Removal and Installation), Brake Booster - RHD (206-07, Removal and Installation).
Re-test the system for normal operation.
PINPOINT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL TEST
CONDITIONS DETAILS/RESULTS/ACTIONS J1: TEST ON ROUGH ROAD 1 Road test the vehicle on rough road conditions. 2 Apply the brakes slowly. Is the brake pedal effort and brake pedal travel normal?
Yes
No action required, vehicle is OK.
No
GO to J2. J2: CHECK BRAKE FLUID LEVEL 1 Check the brake master cylinder reservoir fluid level. Is the fluid level OK?
Yes
GO to J3. No
Check brake master cylinder reservoir sealing points. For additional information, refer to Brake master
cylinder component test in this section. Add brake fluid and bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation. J3: CHECK BRAKE PEDAL RESERVE 1 Run engine at idle speed. 2 Apply the brake pedal lightly three or four times. 3 Wait 15 seconds for the vacuum to replenish. 4 Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs. 5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min. 6 Release the accelerator pedal. Does the brake pedal move downward as the engine speed returns to idle?
Yes
GO to J4. No
Check the vacuum to the brake booster. J4: CHECK THE FRONT WHEEL BEARING ASSEMBLY 1 Check the front wheel bearing assembly. Are the front wheel bearings loose/damaged?
Yes
Tighten to specification or install a new front wheel bearing as required.
REFER to: Front Wheel Bearing and Wheel Hub - V6 3.0L Petrol (204-01 Front Suspension, Removal and Installation).
Re-test the system for normal operation.
No
Check the front brake discs for thickness variances.
PINPOINT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN TEST
CONDITIONS DETAILS/RESULTS/ACTIONS K1: CHECK FOR BRAKE PEDAL RETURN 1 Run the engine at idle while making several brake applications. 2 Pull the brake pedal rearward with approximately 44.5 N (10lb) force. 3 Release the brake pedal and measure the distance to the toe board. 4 Make a hard brake application. 5 Release the brake pedal and measure the brake pedal to toe board distance. The brake pedal should return to its original position.

Does the brake pedal return to its original position? Yes
No action required, vehicle is OK.
No
GO to K2. K2: CHECK FOR BRAKE PEDAL BINDING 1 Disconnect the brake booster from the brake pedal. Check the brake pedal to ensure free operation. Is the brake pedal operating freely? Yes
Install a new brake booster as required. REFER to:
Brake Booster (206-07 Power Brake Actuation, Removal and Installation), Brake Booster - RHD (206-07, Removal and Installation).
Re-test the system for normal operation.
No
Repair or install new brake pedal. Re-test the system for normal operation. Component Tests

Brake Booster

1. Check all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should
be correctly secured and in good condition with no holes and no collapsed areas. Inspect the valve on the brake booster
for damage.
2. Check the hydraulic brake system for leaks or low fluid.

3. With the automatic transmission in PARK, stop the engine and apply the parking brake. Pump the brake pedal several
times to exhaust all vacuum in the system. With the engine switched off and all vacuum in the system exhausted,
apply the brake pedal and hold it down. Start the engine. If the vacuum system is operating, the brake pedal will tend
to move downward under constant foot pressure. If no motion is felt, the vacuum booster system is not functioning.

4. Remove the vacuum hose from the brake booster. Manifold vacuum should be available at the brake booster end of the
hose with the engine at idle speed and the automatic transmission in PARK. Make sure that all unused vacuum outlets
are correctly capped, hose connectors are correctly secured and vacuum hoses are in good condition. When it is
established that manifold vacuum is available to the brake booster, connect the vacuum hose to the brake booster and
repeat Step 3. If no downward movement of the brake pedal is felt, install a new brake booster.

5. Operate the engine for a minimum of 10 seconds at a fast idle. Stop the engine and allow the vehicle to stand for 10
minutes. Then, apply the brake pedal with approximately 89 N (20lb) of force. The pedal feel (brake application) should
be the same as that noted with the engine running. If the brake pedal feels hard (no power assist), install a new valve
and then repeat the test. If the brake pedal still feels hard, install a new brake booster. If the brake pedal movement
feels spongy, bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Brake Master Cylinder

Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal. In
diagnosing the condition of the brake master cylinder, check pedal feel as evidence of a brake concern. Check for brake warning
lamp illumination and the brake fluid level in the brake master cylinder reservoir.
Normal Conditions
The following conditions are considered normal and are not indications that the brake master cylinder is in need of repair.

Modern brake systems are designed to produce a pedal effort that is not as hard as in the past. Complaints of light
pedal efforts should be compared to the pedal efforts of another vehicle of the same model and year.
The fluid level will fall with brake pad wear.

Abnormal Conditions

Changes in the brake pedal feel or brake pedal travel are indicators that something could be wrong in the brake system. The
diagnostic procedure and techniques use brake pedal feel, warning indicator illumination and low brake fluid level as indicators
to diagnosing brake system concerns. The following conditions are considered abnormal and indicate that the brake master
cylinder is in need of repair:

NOTE: Prior to carrying out any diagnosis, make sure the brake system warning indicator is functional.
Brake pedal goes down fast. This could be caused by an external or internal leak.
Brake pedal goes down slowly. This could be caused by an internal or external leak.
Brake pedal is low or feels spongy. This condition may be caused by no fluid in the brake master cylinder, reservoir cap
vent holes clogged or air in the hydraulic system.
Brake pedal effort is excessive. This may be caused by a bind or obstruction in the pedal/linkage, a faulty non-return
valve, booster or insufficient booster vacuum.
Rear brakes lock up during light pedal force. This may be caused by damaged brake pads, a partially applied parking
brake, a damaged ABS sensor or bearing failure.
Brake pedal effort erratic. This condition could be caused by the brake booster or incorrectly installed brake pads.
Brake warning indicator is on. This may be caused by low fluid level or float assembly damaged. www.JagDocs.com

Brake System - General Information - Brake System Bleeding
General Procedures
CAUTIONS:

The brake fluid reservoir must remain full with new, clean brake fluid at all times during bleeding. Published: 11-May-2011

Brake fluid will damage paint finished surfaces. If spilled, immediately remove the fluid and clean the area with water.


NOTE:

All vehicles

1. WARNING: Do not work on or under a vehicle supported only by a
jack. Always support the vehicle on safety stands.

Raise and support the vehicle.

2. Check that the brake fluid lines are secure and that there are no signs of
a brake fluid leak. If a brake fluid leak is detected, investigate and
rectify the cause of the leak before bleeding the brakes.

3. Remove the brake master cylinder cover.
Carefully release the clip.
















4. WARNING: Do not allow dirt or foreign liquids to enter
the reservoir. Use only new brake fluid of the correct
specification from airtight containers. Do not mix brands of
brake fluid as they may not be compatible.


CAUTION: Brake fluid will damage paint finished
surfaces. If spilled, immediately remove the fluid and clean
the area with water.
Remove the brake fluid reservoir cap.

8.
9. CAUTIONS:


Make sure that the road wheels are in the straight
ahead position.


Make sure that excessive force is not used. Failure to
follow this instruction may result in damage to the vehicle.


Make sure that the brake hose is not twisted and is
correctly located.
Pull downwards at the position shown.









10. Refer to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).

11. Refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

Installation
9.

























10.
WARNING: If the brake caliper piston seal is damaged
a new brake caliper must be installed.


CAUTION: Do not allow the brake caliper to hang on
the brake hose.


NOTE: Left-hand shown, right-hand similar.

Torque: 28 Nm














NOTE: Left-hand shown, right-hand similar.

1. To install, reverse the removal procedure.

2. Refer to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures).