JAGUAR X308 1998 2.G Workshop Manual

• 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

hub are critical to achieve correct clearan
ce and operation of
the brakes. Therefore special vertical links and hubs set within
a certain tolerance are inst alled with Brembo brakes.
The front discs are handed and must be fitt ed to the correct side of the vehicle. The left-hand disc can be identified by a
groove running around the circumference of the outer disc wall as shown in the illustration below.
Left hand disc - identification mark

Modified disc shields are installed to accommodate the larger diameter discs.
The four cylinder brake caliper is rigidly attached to the vert ical link via an anchor bracket. The caliper is a split assembly
with each side of the caliper, housing two pistons. The two-pairs of opposed pistons act direct ly on the brake pads mounted
one each side of the disc.
Stainless steel hydraulic hoses connect the calipers to the existi ng brake tubes. It is important that these hoses are aligned
correctly when installed to pr event them fouling on the steering and suspen sion components. Refer to operation 70.55.24
for information.
The Brembo disc brakes require no adjustment.

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

60
mm down from its released position.

7. Close bleed nipples on both calipers.
Remove bleed tub e
s and containers.
Tigh
ten front bleed nipple
to 4-6 Nm.
Tigh
ten rear bleed n
ipple to 8-11 Nm.

8. CAUTIO
N: A new brake hose
must be installed when
replacing a brake caliper.
Disconnect brake hose from brake tube.
1. Unscrew brake tube union nut.
2. Remove nut from hose.
3. Remove hose from bracket.
Fit plug to brake tube.


9.
Re
move brake hose from caliper.
Remove an
d discard brake h
ose.
Fit plugs
to caliper por
t.
10. Remove caliper housing from caliper carrier.
1. Remove anti-rattle spring.
2. Remove dust covers.
3. Remove guide pins.

I
nstallation

R
emove housing from carrier.

11
.
NOTE: The inner brake pad is fitt ed with a clip which secures
the pad into the caliper piston.
Remove and discard brake pa ds. (See Caution above).

12
.
Remove brake carrier from vertical link.
Re
move bolts.
R

emove carrier.
13. Remove brake dust and clean caliper mating surfaces. See
Warning above.

1. Install
caliper carrier to vertical link.
Al

ign carrier to vertical link .
Install and tigh

ten bolts to 140 Nm.
2. Install brake pads in to caliper housing. (See Caution above).
1. Remove plug from port and 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.

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.

I
nstallation

4
. Remove brake pads.

11
.
CAUTION: Only remove the bolts securing the caliper
anchor bracket to the vertical link. Refer to caution above for
more information.
Remove caliper from vertical link.
Re
move bolts.
12

.
Remove brake dust and clean mating surfaces. See Warning
above.

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

ten bolts to 180 Nm.

2. CAUTI
ONS:
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 into caliper.
Sl
owly retract caliper pistons.
1. Install pads.

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.