206 JAGUAR X308 1998 2.G Owner's Manual

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.

Front Dis
c Brake - Brake DiscVehicles With: High Performance Brakes
Re
moval and Installation
Remov

al
1.
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 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.
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.
The front brake discs are dire ctional and must be installed
to the correct side of the vehi cle. Refer to Description and
Operation, section 206-03 for further information.
Do not loosen bolts securing brake disc to disc mounting.
Open engine compartment and in stall paint work protection
covers to fenders.
2. R
aise front of vehicle and suppo
rt on stands. See Section 100-
02.
3. Remove front wheels. Refe r to operation 74.20.05.

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. CAUTI
ON: Always install new brake pads, irrespective of
the condition of the original pads, when renewing brake discs.

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

4. Install
caliper to vertical link.
Install and tigh

ten bolts to 140 Nm.

5. 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 the condition of pins and 'R' clips and replace if
necessary.
Install brake pads in to caliper housing.
Sl
owly retract caliper pistons.
1. Install pads.
2. Position anti-rattle spring.
3. Install pins.
4. Install 'R' clips.
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.

In
stallation

6.
Clean all mating su rfaces and remove brake du
st, see
WARNING above.
7. Repeat above procedure to remo ve opposite side brake pads.

1. CAUTIO
N: Make sure grease does not contact brake-pad
friction surface or brake disc.
To prevent brake squeal apply grease to the shoulders of the
brake-pad backplate.
For additional information, refer to: Specifications
(206-0
4 Rear
Disc Brake, Specifications).
Apply a un iform
layer of grea
se to backplate shoulders,
making sure the whole sh oulder is covered.

2. CAUTIO
N: Make sure the brake pads are fitted with the
direction arrow following the direction of wheel rotation.
Make sure the brake pads are fi tted with the direction arrow
following the direction of wheel rotation.

3. CAUTI O
NS:
Retracting the caliper piston may cause the fluid reservoir
to over-flow. Remove brake flui d spillage immediately from paint
work, with clean water.
Make sure the brake pads are installed to the correct
orientation.
Make sure the brake pads ar e fitted with the direction
arrow following the direction of wheel rotation.
Note condition of pins an d 'R' clips and replace if
necessary.

In
stallation

11
. R
emove brake dust from calipers, and from area of parking
brake shoes, see WARNING above.
12. Repeat above procedure to remo ve opposite side brake disc.
13. Thoroughly clean the area of both hubs where they mate
against the br ake discs.

1. Inst al
l brake disc to wheel studs.
Make su
re hu
b and brake disc
access holes are aligned.
2. Set the parking brake, refer to operation 70.35.37.
3. Check brake disc run-out. Refer to General Procedures section
206-04.

4. Instal
l caliper carri
er to hub carrier.
Position carrier.
Install and tigh ten bolts to 6
0 Nm.
5. CAUTION: Retracting the caliper piston may cause the
fluid reservoir to over-flow. Remove brake fluid spillage
immediately from paint work, with clean water.
Slowly retract piston into caliper housing.

In
stallation

10
. R
emove brake dust from calipers, and from area of parking
brake shoes, see WARNING above.
11. Repeat above procedure to remo ve opposite side brake disc.
12. Thoroughly clean the area of both hubs where they mate
against the br ake discs.

1. Inst al
l brake disc to wheel studs.
Make su
re hu
b and brake disc
access holes are aligned.
2. Set the parking brake, refer to operation 70.35.37.
3. Check brake disc run-out. Refer to General Procedures section
206-04.

4. Inst al
l caliper to hub carrier.
Install and tigh
ten bolts to 6
0 Nm.
5. CAUTIONS:
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.

In
stallation

6.
Clean all mating surfaces and remove brake du
st, see
WARNING above.
7. Repeat above procedure to remo ve opposite side brake pads.

1. CAUTIO
N: Make sure grease does not contact brake-pad
friction surface or brake disc.
To prevent brake squeal apply grease to the shoulders of the
brake-pad backplate.
For additional information, refer to: Specifications
(206-0
4 Rear
Disc Brake, Specifications).
Apply a un iform
layer of grea
se to backplate shoulders,
making sure the whole sh oulder is covered.

2. CAUTIO
N: Make sure the brake pads are fitted with the
direction arrow following the direction of wheel rotation.
Make sure the brake pads are fi tted with the direction arrow
following the direction of wheel rotation.

3. CAUTI O
NS:
Retracting the caliper piston may cause the fluid reservoir
to over-flow. Remove brake flui d spillage immediately from paint
work with clean water.
Make sure the brake pads are installed to the correct
orientation.
Make sure the brake pads ar e fitted with the direction
arrow following the direction of wheel rotation.
Note the condition of pins and replace if necessary.
• NOTE: Slowly retract caliper pistons.

means of a manual adjustment
mechanism
at each set of shoes. Refer to General Procedur es in section 206-05.
If the vehicle is driven above 5 km/h with the parking brake applied, a warning lamp and text message will appear on the
message center. The message clears when the brake is released or the speed drops below 3 km/h.
Parking Brake Shoe Arrangement

The adjuster mech
anism enables manual
adjustment of the brake shoes.
Retai
ning pins keep the shoes in contact with the dust shield.
The brake

shoes locate into the expander lever and the adjuster mechanism.
R
e
turn springs retr
act the brake shoes when the parking brake is released.
Th
e expander lever mechanism moves the brake shoes outwar
ds, in contact with the brake drum when the parking
brake is applied.


It e
m
Par
t
Number
De
scr
iption
1—Adjust
er Me
chanism
2—R
e
taining Pins
3—Brake Sh
oe
s
4—Upper
Return
Spring
5—Lower Return Spring
6—Expander

Lever Mechanism

Hydraulic Br
ake Actuation -
Hydraulic Brake Actuation
Description and Operation

The hydraulic brake system is split in to two independent circuits: the primary ci rcuit operates the front brakes and the
secondary circuit operates the re ar brakes. This type of system prevents comple te brake failure in the event of a brake tube
fracture.
The hydraulic brake system consists of the following components:

Ite
m
Descr
iption
1Pedal Housi

ng / Booster - refer to 206-07
2Vacu

um Hose - refer to 206-07
3Mast
er Cyl
inder / Reservoir
4Primary Brake Circu
i
t
5Secon
dary Brake Circuit
6Hydrauli c
Pump / Motor Unit - refer to 206-09
7ABS/Traction

Control Control Modu
le (ABS/TCCM) - refer to 206-09
8Hydraulic Cont
rol Unit (HCU) - refer to 206-09
6/
7/
8
Br
ak
e Control Modulator
9Brake
Di
sc - refer to 206-03 or 206-04
10Brake
Cali
per - refer to 206-03 or 206-04
11W
h
eel Speed Sensor - refer to 206-09
12ABS Warning Lamp -
refer to 206
-09
13Brake F
l
uid Level Warning-Lamp

Install peda
l housing to vehicle.
Make sure ped

al housing apertu
re is positioned correctly.
Inst
all and tighten nuts to 15-20 Nm.
3. Position cloth underneath master cylinder to collect brake fluid
spillage.

4. Inst
all brake tubes to master cylinder.
Re

move plugs.
Connect

and tighten brake tubes. Refer to Specification
section 206-06 for torque setting.
R
emove cloth from underneath master cylinder.

5. Con
nect throttle cabl
e to pedal housing.
Inst
all cable to grommet.
Inst

all cable to
pedal housing.

6. Conne
ct throttle inner ca
ble to pedal grommet.
7. Connect vacuum pipe elbow to brake booster.
1. Install new seal.
2. Connect pipe.