engine JAGUAR X308 1998 2.G Owner's Manual

Front C
rossbeam
A
fully stressed, pressed steel and tube fa
brication with integral lower wishbone tie bars, the crossbeam is secured to the
body on four resilient mountings.
The crossbeam incorporates mounting points for:
The u
pper and lower wish
bone fulcrum bolts.
The
stabilizer bar
The power steering rack. The engine h

ydramounts.
R

oad springs.
Slots and cam reaction pl ates on the crossbeam provide for ad justment of suspension geometry.
It
em
Par
t Number
De
scription
1—Cro

ssbeam
2—Upper

Wishbone
3—Lower Wi

shbone Arm, Front
4—Lower Wi

shbone Arm, Rear
5—Upper

Wishbone Ball Joint
6—Lower Wi

shbone Ball Joint
7—Ful

crum Bolt

8—Adjuster B
olt, Front
9—Adjuster B

olt, Rear
10—S

pring Pan
11—Shock Absorber Lower M

ounting Plate
12—Vertical Link


13—Hub Assembly
14—Sensor R

otor
15—B

olt, Wishbone to Link Arm

6. Re
lease stabilizer bar from link arms.
R
e
move stabilizer bar to link arm ball joint securing nut.
Repeat operation
at opp
osite
end of stabilizer bar.

7. Slacken stabil
izer bar securing bolts.

8. NO
TE: On vehicles fitted with an engine oil cooler, it may be
necessary to release the stabilizer bar from each ball joint in turn
to achieve the required cl earance from cooler pipes.
Remove stabilizer bar from crossbeam.
R e
move stabilizer bar securing bolts.
R
e
move stabilizer bar and mounting brackets from
crossbeam.
9. Remove mounting brackets and rubbers from stabilizer bar.

I
nstallation


6.
R
elease stabilizer bar from link arms.
R

emove nut securing stabilizer bar to link.
R

elease link arm from stabilizer bar.
Repeat operation

at opposite
end of stabilizer bar.

7. N
OTE: On vehicles fitted with an engine oil cooler, it may be
necessary to release the stabilizer bar from each ball joint in turn
to achieve the required cl earance from cooler pipes.
Remove stabilizer bar from crossbeam.
R
emove stabilizer bar securing bolts.
R

emove stabilizer bar mountin
g brackets and remove bar
from crossbeam.

8. Re
move mounting brackets and
rubbers from stabilizer bar.
1. CAUTION: Make sure the Ca strol NTR grease is only
applied to the inner surface of the mounting bushes. Failure to
follow this instruction may affect the retention of the bushes in
the retaining brackets.

WHE
N CHANGING A WHEEL, ENSURE THAT THE VEHICLE CANNOT MOVE. ALWAYS APPLY THE PARK BRAKE AND
SELECT TRANSMISSION 'P' POSITION.
NEVER RUN THE ENGINE WITH ONE WHEEL OFF THE GROUND, FOR EXAMPLE, WHEN CHANGING THE WHEEL. THE
VEHICLE COULD MOVE.
TIGHTEN THE WHEEL NUTS TO SPECIFICATION. WHEELS MAY COME LOOSE IF OVER OR UNDER TIGHTENED.
USE WHEELS AND WHEEL NUTS DESI GNED FOR XJ SERIES VEHICLES ONLY. AFTERMARKET WHEELS OR WHEEL
NUTS MAY NOT FIT OR FUNCTION PROPERLY AND COULD CAUSE INJURY OR DAMAGE.
In
spection and Verification
To maximize ti
re performance, inspec
t the tires frequently for signs of:
Unev
en wear.
Incorrect
ti
re pressure.
Wh
ee
l imbalance.
Cuts. Abrasi
ons.

B
u
lges (blister).
Ply s
e
paration.
Embedded objects. Impact damage.
Inspe c
tion should be
more frequent when:
Continuo
us high speed op
eration is required.
Ra
pid or extreme temperatures changes occur.
R
o
ad surfaces are rough.
Roads ar
e littered
with debris.
Tread W
e
ar Indicator
•
NO
TE: Tire condition must comply with prevailing local legislation.
New tires must be installed if the wear in dicators are exposed or if there is severe shoulder wear. Shoulder wear is usually
caused by either excessive camber or toe on tires.
T i
re Vibration Diagnosis
A
tir
e vibration diagnostic procedure always
begins with a road test. The road test and the custom er interview (if available)
will provide much of the information need ed to find the source of vibration.
During the road test, drive the vehicle on a road that is smooth and free of undulations. If vibration is apparent, note and
record the following:
The s p
eed at which the vibration occurs.
W
h
at type of vibration occurs in each
speed range - mechanical or audible.
How the vibrati
on is affected
by changes in the following:
- -engine torque
- -vehicle speed
- -engine speed.
Type of v i
bration - sensitivity:
- - torque sensitive,
- - vehicle speed sensitive,
- - or engine speed sensitive.

The
following explanations will help isolate the source of vibration.
Torque Sensitive
This

means that the condition can be impr
oved or made worse by accelerating, dece lerating, coasting, maintaining a steady
vehicle speed, or applying engine torque.
Ve
hicle Speed Sensitive
This means th
at the vibration al
ways occurs at the same vehicle speed and is not affected by engine torque, engine speed
or gear selection.
Engine Speed Sensit
ive
This means th
at the vibration
occurs at varying vehicle spee ds when a different gear is selected. It can sometimes be
isolated by increasing or decreasing engine speed with the tran smission in neutral or by stall testing with the transmission in
gear. If the condition is engine speed sensitive, the cause is probably not related to tires.
If the road test indicates that there is tire wine, but no shake or vibration, the noise originates with the contact between th e
tire and the road surface.
A thumping noise usually means that the tire is flat or has soft spots making a noise as they slap the roadway. Tire whine
can be distinguished from axle no ise, as tire whine remains the same over a range of speeds.
Sym
ptom Chart
Sy
mptom Chart
Sy

mptom
Possib
le Sources
Acti
on
Uneven ti

re wear.
Incorrect ti
re inflation.
*
Cor
rect to specification.
*
Exce
ssive radial an
d lateral runout.
*
Renew tire
or wheel.
*
O
ut of specification steering
geometry.
*
R
ealign steering geometry: Refer to Section 204-
00.
*
W
orn ball joint.
*
Renew
damaged component, realign steering
geometry.
*
W
orn tie-rod end.
*
R
enew component, realign steering geometry.
*
Incorrect
tire / wheel usage.
*
Inst
all correct tire and wheel combination.
*
Loose or leaki
ng shock absorbers.
*
Tigh
ten or Renew as nece
ssary: Refer to Section
204-00.
*
Suspensi
on geometry out of
alignment.
*
Che
ck and adjust: Refer to Section 204-00.
*
Loose, worn or da mage
d suspension
components.
*
In
spect, Repair or Renew as necessary.
*
Wh
eel and tire assembly out of
balance.
*
Balance wheel an
d tire assembly.
*
Excessive later
al or radial runout of
wheel or tire.
*
Check, Repair o
r
Renew as required.
*
Tire
s show excess wear on

edge of treads.
Ti
res under-inflated.
*
Cor
rect pressure to specification.
*
Vehi
cle overloaded.
*
Cor
rect to specification.
*
Tire
s show excess wear on

edge of treads (with tire
pressures correct).
Incorre
ct toe setting.
*
Se
t to specification: Refer to Section 204-00.
*
Tire
s show excess wear in
center of tread.
Tire
s over-inflated.
*
Cor
rect pressure to specification
*
W
heel mounting is
difficult.
Incorrect app
lication or mismatched
parts, including wheel studs and
wheel nuts. Corroded, worn or
damaged parts.
*
Fol
low the manufacturer's specifications. Clean or
Renew.
*
Wobble or sh
immy
affecting wheel runout.
Damaged wh
eel (eventually
damaging wheel bearings and causing
uneven tire wear).
*
Inspect wheel rims for
damage and runout. Renew
as required.
*
Vehicle vibrations from

Tire
s / wheels mismatched.
*
Inst
all correct tire / wheel combination.
*

Vehicle Dynamic Suspension - Vehicle Dynamic Suspension
Diagn
osis and Testing
Refer to the PDU User Guide for details of diagnosing and testing the Adaptive Damping System. The PDU interrogates the
ADCM directly via the K and L lines to the J1962 diagnostic socket.
The PDU will give an indication of the integrity of each electron ic and electrical component. It will indicate, for example, that
the accelerometers are not broken, but not that they functionin g correctly when the vehicle is in motion. However, it is
exceptional for an accelero meter to function incorrectly in its dynamic mode if it is proved to be functioning when static.
Basic Checks
The accele
rometers have the following ch
aracteristics. At 0g (no movement of the body) each vertical accelerometer
outputs approximately 2.5V steady voltage; the lateral acce lerometer outputs approximately 1.5V. The voltage output due
to body movement is proportional to acceleration in the acceleration axis, up to approximately 4.5V and down to
approximately 0.5V.
Before changing any component, refer to the circuit diagrams and check the cont inuity of relevant harness circuits; in some
instances, the PDU will not different iate between a faulty component an d a damaged connection or wiring.
Check the following fuses:
En
gine compartment fuse
box, fuse F5 (10A).
Engine m
anagement fuse
box, fuse F1 (20A).
Check the following ADCM input/output lines:
Sy stem erro
r output from the ADCM
to the instrument cluster.
Vehicl
e speed output from the inst
rument cluster to the ADCM.
Foo
tbrake signal to the ADCM.
Check any relevant connections to confirm that the connection is electrically sound and that a terminal pin has not been
pushed back into the connector shell, ie. not ma king a connection to its mating pin or socket.

Do t
he disc brake caliper pistons
and pins bind, leak or stick?
Yes INSTALL new calipers as necessary. TE ST the system for normal operation.
No GO to C4
.
C4: INSPECT BR
AKE DISCS
Check the brake discs fo

r excess
ive damage, thickness variatio n or runout. For additional
information, refer to General Procedures in this section.
1
D
oes excessive damage or runout exist?
Yes INSTALL new brake discs and brak e pads as necessary. TEST the system for normal operation.
No GO to C5
.
C5: INSPECT THE FRONT HU
B AND WHEEL BEARING ASSEMBLY
Check the fr

ont hub and wheel bearing assembly.
For additional information, refer toSection 204
-00

Su

spension System
- General
Information
. 1
Are th

e wheel bearings OK?
Yes GO to C6
.
No

INSTALL new wheel bearings. For additional inform ation, refer toSection 204
-01
Front Suspension
.
TEST the system
for normal operation.
C

6: CHECK SUSPENSION BUSHES AND BALL JOINTS.
Chec

k all suspension bu
shes and ball joints.
1
Are th
e suspension bushes and ball joints OK?
Yes Vehicle is OK.
No INSTALL new front suspension bushes and ball joints as required. For additional information, refer
toSection 204
-01
Front Suspension
. INSTALL n
ew rear suspension bush
es and ball joints as required.
For additional informat ion, refer toSection 204
-0
2 Rear Suspension
.
P

INPOINT TEST D : THE PEDAL FEELS SPONGY
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
D

1: CHECK FOR SPONGY PEDAL (ENGINE OFF)
Check f

or a firm brake pedal.
1
Is th

e brake pedal effort an
d brake pedal travel normal?
Yes Vehicle is OK.
No GO to D2
.
D2:
CHECK BRAKE PEDAL RESERVE (ENGINE OFF)
Pump th

e brake pedal 10 times and
hold on the final application.
1
Does th
e brake pedal feel fi
rm on final application?
Yes GO to D3
.
No

BLEED the brake system. For additional information, re fer to General Procedures in this section. TEST
the system for normal operation.
D3:
CHECK BRAKE PEDAL RESERVE (ENGINE ON)
Engine is

idle.
1
Apply the brake pedal ligh

tl
y three or four times.
2
W
ait 15 seconds for the vacuum to recover.
3
Push down on

the brake pedal until it stops moving
downward or an increased resistance to the brake
pedal travel occurs.
4
Hol
d the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
5
Re

lease the accelerator pedal.
6
Does th

e brake pedal move downward as
the engine speed returns to idle?
Yes GO to D4
.
No

CHECK the vacuum to brake booster. For additional information, refer toSection 206
-0
7 Power Brake
Actuation.

Are th
ere any external brake system leaks?
Yes REPAIR as necessary. ADD fluid and BLEED the brak e system. For additional information, refer to
General Procedures in this section. TEST the system for normal operation.
No GO to F3
.
F
3: CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST
Te

st for brake master cylinder bypass condition. Re
fer to Brake Master Cylinder Component Test in
this section.
1
A
re any concerns found?
Yes INSTALL a new brake master cylinder, ADD flui d and BLEED the brake system. For additional
information, refer to General Proc edures in this section. TEST the system for normal operation.
No System is OK.
PINPO
INT TEST G : EXCESSIVE BRAKE PEDAL EFFORT
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
G1

: CHECK BRAKE PADS
Check the brake pads for wear, contamin

atio
n, correct installation, damage and type.
1
A
re any concerns found?
Yes INSTALL the front brake pads correctly or INSTALL ne w front brake pads if necessary. For additional
information, refer toSection 206
-03
Front Disc Brake
. INSTALL the
rear brake pads correctly or
INSTALL new rear brake pads if necessary. For additional information, refer toSection 206
-04
Rear
Di

sc Brake
. REPEAT road test.
No

GO to G2
.
G2:
CHECK VACUUM
Di

sconnect the vacuum booster hose from the booster.
1
Conne

ct a vacuum/pressure tester to the vacuum hose.
2
Ru

n the engine at normal operating temperature.
3
Re

cord the vacuum reading.
4
Is

the reading 40.5kPa (1
2 in-Hg) or greater?
Yes GO to G3
.
No

LOCATE and REPAIR the source of low vacuum . TEST the system for normal operation.
G3
: INSPECT SYSTEM
Swi

tch the engine off.
1
Re

connect the vacuum hose.
2
Inspect th

e brake booster, rubber grommet, and al
l vacuum plumbing for cracks, holes, damaged
connections, or missing clamps.
3
Pump th
e brake pedal several time
s to exhaust the vacuum. Push down on the brake pedal and hold.
4
Does th
e brake pedal move down
when the engine is started?
Yes Vacuum system is OK.
No GO to G4
.
G4
: CHECK POWER BRAKE BOOSTER VALVE
Check the brake booster valve. For
add
itional information, refer to
Brake Booster in this section.
1
Is th
e power brake booster valve OK?
Yes CHECK the brake booster. Fo r additional information, refer to Brak e Booster in this section. INSTALL a
new brake booster if necessary. TEST the system for normal operation.
No INSTALL a new brake booster valve. TEST the system for normal operation.
P
INPOINT TEST H : BRAKE LOCKUP
DURING LIGHT BRAKE PEDAL FORCE
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
H1

: TEST BRAKE LOCKUP

Yes

Vehicle is OK.
No GO to J2
.
J
2: CHECK BRAKE FLUID LEVEL
Check the brake master cyli

nder reservoir fluid level.
1
Is the fl

uid level OK?
Yes GO to J3
.
No

CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake
Master Cylinder in this section. ADD brake fl uid and BLEED the brake system. For additional
information, refer to General Proc edures in this section. TEST the system for normal operation.
REPEAT road test if necessary.
J
3: CHECK BRAKE PEDAL RESERVE
Engine is

idle.
1
Apply the brake pedal ligh

tl
y three or four times.
2
W
ait 15 seconds for the vacuum to replenish.
3
Push down on

the brake pedal until it stops moving
downward or an increased resistance to the brake
pedal travel occurs.
4
Hol
d the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
5
Re

lease the accelerator pedal.
6
Does th

e brake pedal move downward as
the engine speed returns to idle?
Yes GO to J4
.
No

CHECK the vacuum to the brake booster. Fo r additional information, refer toSection 206
-0
7 Power
Brake Ac

tuation
.
J

4: CHECK THE FRONT HUB AND BEARING ASSEMBLY
Check the fr

ont hub and bearing assembly. Fo
r additional information, refer toSection 204
-01
Front
Suspe

nsion
. 1
Are th

e front wheel bearings loose?
Yes INSTALL a new front wheel bearin g if damaged. For additional information, refer toSection 204
-01

F

ront Suspension
. TEST
the system for normal operation.
No CHECK the front brake discs for thickness variances. For additional information, refer to General
Procedures in this section.
PINPO
INT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
K1: C

HECK FOR BRAKE PEDAL RETURN
Ru

n the engine at fast idle while
making several brake applications.
1
Pull the
brake pedal rearward with approximately 44.5 N (10lb) force.
2
Relea

se the brake pedal and measure
the distance to the toe board.
3
Make a hard brake
application.
4
Relea

se the brake pedal and measure the brake
pedal to toe board distance. The brake pedal
should return to its original position.
5
Does th
e brake pedal return
to its original position?
Yes Vehicle is OK.
No GO to K2
.
K
2: CHECK FOR BRAKE PEDAL BINDING
Check the brake pedal to make
s
ure it is operating freely.
1
Is th

e brake pedal operating freely?
Yes INSTALL a new brake booster. For addi tional information, refer toSection 206
-0
7 Power Brake
Actuation. TEST

the system for normal operation.
No REPAIR or INSTALL new brake pedal. TE ST the system for normal operation.

Comp
onent Tests
Bra
k
e Booster
1.
1. Chec k 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. 2. Check the hydraulic brake system for leaks or low fluid.
3. 3. With the transmission in PARK, stop the engine and apply the parking brake. Pump the brake pedal several times
to exhaust all vacuum in the system.
4. 4. With the engine switched off and all vacuum in the system exhausted, appl y 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.
5. 5. 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 transm ission in PARK or NEUTRAL. 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.
6. 6. 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 th e 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 re peat the test. If the brake pedal still feels hard, in stall a new brake booster.
If the brake pedal movement feels spongy, bleed the brak e system. For additional information, refer to General
Procedures in this section.
Bra k
e Master Cylinder
Usual
l
y, the first and strongest
indicator of anything wrong in the brake syst em 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 le vel in the brake master cylinder reservoir.
Normal Conditio
ns
The fo
llowing conditions are considered norm
al and are not indications that the brake master cylinder is in need of repair.
New bra
ke systems are designed to produc
e a pedal effort that is not as hard as in the past. Complaints of light
pedal efforts should be compared to the pedal effort s of another vehicle of the same model and year.
The fl
uid level will fall with brake pad wear.
Abnormal Conditions
•

NOTE: Prior to carrying out any diag
nosis, make sure the brake system warning indicator is functional.
Changes in the brake pedal feel or brake pedal travel are in dicators that something could be wrong in the brake system. The
diagnostic procedure and techniques use brake pedal feel, warning indicator illu mination and low brake fluid level as
indicators to diagnosing brake system co ncerns. The following conditions are cons idered abnormal and indicate that the
brake master cylinder is in need of repair:
Brake ped a
l goes down fast. Th
is could be caused by an ex ternal or internal leak.
Brake pedal goes down slowly
. This could be
caused by an internal or external leak.
Brak
e pedal is low or feels spongy. This condition may be ca
used by no fluid in the brake master cylinder, reservoir