wheel JAGUAR X308 1998 2.G Workshop Manual

13
.
CA
UTION:
Retracting the caliper piston may cause the fluid reservoir to over-flow. Remove brake fluid
spillage immediately from paint work with clean water.
CA
UTION:
Note condition of pins and replace if necessary.
Install brake pads to caliper. Slowly retract caliper pistons.
1. Install pads.
2. Position anti-rattle spring.
3. Install pins - make sure pin collets are fully engaged into caliper.
14. Fit wheel. Refer to section <<204-04>>.

Front Disc Brake - Front Disc Brake
Description and Operation


The brake disc is mounted on the wheel studs and is clamped between the wheel and hub. Cooling ducts run through the
center of the brake disc to provide the required ventilation to keep the disc cool under operating conditions.
The caliper carrier, which is se cured to the vertical link by two bolts, carries the single-pis ton caliper housing. The caliper
housing is secured to the caliper carrier by two guide-pins and an anti-rattle spring. When the brakes are applied the
caliper-housing piston pushes th e brake pad in front of it, towards the brake di sc. This movement forces the caliper housing
to move along the guide-pins, in the oppo site direction of the piston, to apply the second brake pad. The brake disc is
therefore gripped between the two pads. As brake pressure is increased the grip on the brake disc is increased to slow-down
the rotation of the road wheel.
The disc brakes requ ire no adjustment.
It
e
m
Par
t
Number
De
scr
iption
1—B
r
ake Disc
2—Caliper Housin
g
3—Caliper Carrier
4—Brake Pads
5—Guide P i
ns
6—Du
st
Covers
7—An
ti
-rattle Spring
8—Du
st
Shield
9—Brake Hos
e

10—Bleed Nipp
le

• C
AUTIONS:
The Brembo caliper is aligned to the brak e disc when it is first installed to the vehicle, therefore, care must be taken
not to disturb this alignment. When removi ng the caliper; remove the bolts that secure the anchor bracket to the vertical
link only. DO NOT loosen any other caliper bolts.
Do not loosen bolts securing brake disc to disc mounting.
Brembo calipers and discs provide higher -performance braking using the existing hydraulic braking system. The brakes are
installed to the vehicle using unique vertical links, hubs, hydraulic hoses and disc shields.
The front brake disc consists of a ventilated, cross-drilled disc, bolted to a disc carrier. The disc assemb ly is mounted on the
wheel studs and clamped be tween the wheel and hub.
A unique feature of the front disc is th e slanted (non radial) ventilation webs which lean the opposite-way to the disc's
direction of rotation. This design enables he at generated by the disc to be dispersed by air entering at the disc's center and
being forced outwards through the cooling ducts.
Due to the use of fixed calipers in place of the standard floating caliper, certain lateral dimensions on the vertical link and
It
em
Par
t Number
De
scription
1—B

rake Disc
2—Caliper


3—Anch

or Bracket
4—Anchor Pl

ate to Vertical Link - Bolts
5—Brake Pad

s
6—Guide P

ins
7—Anti-r

attle Spring
8—Di

sc Shield
9—Brake Hos

e
10—Bleed Nipp

les


Front Disc Brake—
Brembo

Front Disc Brake - Brake CaliperVehicles
With: Standard Brakes
Re
moval and Installation
Remov

al
W
ARNING: BRAKE DUST, IF INHALED CAN DAMAGE YOUR
HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM
BRUSH. DO NOT USE A COMPRESSED-AIR LINE TO DISPERSE BRAKE DUST INTO THE ATMOSPHERE.
• CAUTIONS:
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.
A new brake hose must be installe d when replacing a brake caliper.
The brake pad adhesive backing must not be reused, therefore always install new brake pads, irrespective of the
condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.
S
pecial Tool(s)

Brake Pedal

Hold Tool
JDS 9013
1. O
pen engine compartment and fit
paint work protection covers
to fenders.
2. Raise vehicle on a four-post lift.
3. Raise front of vehicle and support on stands. Refer to Section
100-02.
4. Remove front wheels. See Section 204-04.

5. NOTE
: The following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake hose.
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.
6. Depress and hold down brak e pedal at the specified
measurement using special tool.
1. Position tool between brake pedal and seat frame.
2. Turn the tool wheel unti l the brake pedal is held

2.
Remove paper backing from pads to reveal adhesive
shim. Install brake pads, insert clip located on back of
inner pad into caliper piston.

3. Inst al
l caliper housing to caliper carrier.
Align hou
s
ing to carrier.
1. Install and tighten guide pins to 25-30 Nm.
2. Install dust covers.
3. Install anti-rattle spring.

4. NOTE : Th
e brake hose must only be installed with the vehicle's
body supported and the suspension hanging.
Install and tighten brake hose to caliper housing to 10-14 Nm.

5. NO
TE: Make sure the brake
hose does not twist when
tightening the hose lock-nut.
Connect brake hose to brake tube.
1. Position hose thread through bracket.
2. Install and tighten locking nut. Refer to Specifications, section 206-03.
3. Install and tighten brake- tube union nut. Refer to
Specifications, section 206-03.
6. Remove special tool from brake pedal.
7. Fit wheels. Refer to section 204-04.
8. NOTE: Make sure the brake hose is routed correctly.
Remove stands and lower vehicl e. Refer to section 100-02.
9. Bleed brake hydraulic system. See operation 70.25.03.

Front Disc Brake - Brake CaliperVehicles With: High Performance Brakes
Re
moval and Installation
Remov

al
S
pecial Tool(s)

Brake Pedal

Hold Tool
JDS 9013
1. WARNING: BRAKE DUST, IF INHALED CAN DAMAGE
YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM
BRUSH. DO NOT USE A COMPRE SSED-AIR LINE TO DISPERSE
BRAKE DUST INTO THE ATMOSPHERE.
• CAUTIONS:
Replacement of nuts and bolts: Various thread-locking
devices are used on nuts and bolts throughout the vehicle. These
devices restrict the number of ti mes a nut or bolt can be used.
See section 100-00 for information.
Remove brake fluid spillage immediately from paint work,
with clean water.
The Brembo caliper is aligned to the brake disc when it is
first installed to the vehicle, therefore, care must be taken not to
disturb this alignment. When removing the caliper; remove the
bolts that secure the anchor bracket to the vertical link only. DO
NOT loosen any other caliper bolts.
Open engine compartment and fit paint work protection covers
to fenders.
2. R
aise vehicle on a four-post lift.
3. Raise front of vehicle and support on stands. Refer to Section
100-02.
4. Remove front wheels. Refe r to operation 74.20.05.

5. NOTE
: The following three pictorial procedures must be
carried-out to minimize brake fl uid loss when disconnecting the
brake hose.
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.
6. Depress and hold down brak e pedal at the specified
measurement using the 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.

7. Close bleed nipples on both calipers.
Tigh ten bleed n
ipples to 12-16 Nm.
Remove bleed tub
e
s and containers.

8. Disc
onnect brake hose from brake tube.
1. Unscrew brake tube union nut.
2. Remove nut from hose.
3. Remove hose from bracket.
Fit plugs to brake tu
be and hose.

9. Re
lease brake hose from caliper.
R
e
move union bolt.
Remove an
d discard se
aling washers.
Inst
al
l plugs into caliper and hose.
10. Remove brake pads from caliper.
1. Remove 'R' clips.
2. Withdraw pins from caliper.
3. Remove anti-rattle spring.

2.
Po
sition anti-rattle spring.
3. Install pins.
4. Install 'R' clips.

3. CAUTIO
N: The brake hose must
only be installed with the
vehicle's body supported and the suspension hanging.
Install brake hose to caliper.
Remove plugs f rom caliper and hose.
Instal
l new sealing washers.
Install and tigh
ten un
ion bolt to 22-26 Nm.

4.
NO
TE: Make sure the brake
hose does not twist when
tightening the hose lock-nut.
Connect brake hose to brake tube. 1. Position hose thread through bracket.
2. Install and tighten locking nut. Refer to Specifications, section 206-03.
3. Install and tighten brake- tube union nut. Refer to
Specifications, section 206-03.
5. Remove special tool from brake pedal.
6. Fit wheels. Refer to operation 74.20.05.
7. NOTE: Make sure the brake hose is routed correctly.
Remove stands and lower vehicl e. Refer to section 100-02.
8. Bleed brake hydraulic system. See operation 70.25.06.

Front Dis
c Brake - Brake DiscVe
hicles With: Standard Brakes
Re
moval and Installation
Remov

al
• WAR
NINGS:
BRAKE DISCS MUST ALWAYS BE REPLACED IN PAIRS.
BRAKE DUST, IF INHALED CAN DAMAGE YOUR HEALTH. ALWAYS REMOVE BRAKE DUST USING A VACUUM BRUSH.
DO NOT USE A COMPRESSED-AIR LINE TO DI SPERSE BRAKE DUST INTO THE ATMOSPHERE.
CAUTION: Replacement of nuts and bolts: Various thread-locking devices 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.
1. O
pen engine compartment and in
stall paint work protection
covers to fenders.
2. Raise front of vehicle and suppo rt on stands. See Section 100-
02.
3. Remove front wheels. Re fer to Section 204-04.

4. CAUTI
ON: Remove brake flui
d spillage immediately from
paint work, with clean water.
Loosen brake fluid reservoir-cap.
Position a cloth around the
reservoir to collect any fluid
spillage.

5. CAU
TION: Tie caliper housing aside. Do not allow the
caliper housing to hang on the hydraulic hose, as this will damage
the hose.
Remove caliper housing from caliper carrier.
1. Remove anti-rattle spring.
2. Remove dust covers.
3. Remove guide pins.
Re
move and tie caliper housing aside.
6.
CAUTI
ON: Always install new brake pads, irrespective of
the condition of the original pads, when renewing brake discs.
• NOTE: The inner brake pad is fitted with a clip which secures
the pad into the caliper piston.
Remove brake pads from caliper housing.

2. Check brak
e disc run-out. Refer
to General Procedures section
206-03.

3. Install
caliper carrier to vertical link.
Al

ign carrier to vertical link .
Install and tigh

ten bolts to 140 Nm.

4. CAUTI
ONS:
Always install new brake pads, irrespective of the condition
of the original pads, when renewing brake discs.
Retracting the caliper piston may cause the fluid reservoir
to over-flow. Remove brake flui d spillage immediately from paint
work, with clean water.
• NOTE: Clean caliper piston to pad mating surface.
Install brake pads in to caliper housing.
1. Slowly retract piston into caliper housing.
2. Remove paper backing from pads to reveal adhesive shim. Install brake pads, insert clip located on back of
inner pad into caliper piston.

5. Inst
all caliper housing to caliper carrier.
Align hou

sing to carrier.
1. Install and tighten guide pins to 25-30 Nm.
2. Install dust covers.
3. Install anti-rattle spring.
6. Repeat above procedure to inst all opposite side brake disc.
7. Fit wheels. Refer to operation 74.20.05.
8. Remove stands and lower vehicl e. Refer to section 100-02.
9. CAUTION: Remove brake flui d spillage immediately from
paint work, with clean water.
Check brake fluid level.
Check brak
e fluid level is
at the maximum mark.