JAGUAR X308 1998 2.G Workshop Manual

Hydraulic B
rake Actuation
- Brake Master Cylinder
Re
moval and Installation
Remov

al
• C
AUTIONS:
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.
1. Position vehi
cle on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, refer to
operation 86.15.19 for fu rther information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Place assembly on a work bench.

7. R
emove nuts securing master cylinder to brake booster.

8. R
emove master cylinder from brake booster.
Re

move master cylinder.
Remove an

d discard seal.
9. Remove filler cap and empty residual brake fluid into a
container. Fit cap.
10. Remove fluid reservoir from master cylinder.
R
emove locating pin.
Pull

reservoir from master cylinder.

In
stallation


11
. Install
plugs into fluid reservoir ports.

12 . Remove an
d discard seal
s from master cylinder.

13 . Inst
all plugs into master cylinder ports.
14. Clean components and mating surfaces.
1. Install seals into master cylinder.
Remo
ve plugs.

Lubricate seals with cl
ean brake fluid.
Inst

all seals.

2. Install
fluid reservoir to master cylinder.
R

emove plugs from reservoir
Install

reservoir, making sure
reservoir is fully seated.
Inst
all locating pin.

3. Inst
all master cylinder to brake booster.
Inst

all seal.
Inst

all master cylinder, make sure master cylinder rod
locates brake booster rod.

4. Inst
all and tighten nuts to 21-29 Nm.
5. Install pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Install engine compartment rear cover. Refer to operation
76.11.35.
7. Connect battery ground cable (IMPORTANT, see operation
86.15.15 for further information).
8. Bleed brake system. Refer to operation 70.25.03.
9. Remove paint-work protection covers and close engine


com

partment.

Hydrau
lic Brake Actuation - Brake Pedal and Bracket
Re
mo
val and Installation
Remov
a
l
• C
A
UTIONS:
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.
In
stallation
1.
Position vehicl
e on a four-post lift.
2. Open hood and fit suitable pa intwork protection equipment.
3. Disconnect battery ground cabl e. (IMPORTANT, see 86.15.19
for further information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.
5. Remove pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Remove brake booster and master cylinder assembly. Refer to
operation 70.50.18.

7. Remove brake wa
rning-light switch.
Remove n
u
t and bolt.
Slide sw

itch forward to release from locating tag.

8. Re
move throttle pedal assembly.
1. Remove and discard retaining wire.
2. Remove pivot pins.
3. Remove throttle pedal assembly.
4. Remove return spring.
9. Clean components and mating surfaces.
1. Apply grease to pivot pins.
2. Install throttle pedal assembly.
1. Align throttle assembly.

2
. Align return spring.
3. Install pivot pins.
4. Install retaining wire: bend ends of wire to secure
pivot pins.

3. Inst
all brake warning-light switch.
Inst

all switch onto locating tag.
Install and tigh

ten nut and bolt to 3Nm.
4. Install brake booster and master cylinder assembly. Refer to
operation 70.50.18.
5. Install pedal housing, brake booster and master cylinder
assembly. Refer to operation 70.35.39.
6. Bleed brake system. Refer to operation 70.25.03.
7. Install engine compartment rear cover. Refer to operation
76.11.35.
8. Connect battery ground cable. (IMPORTANT, see 86.15.19 for
further information).

Hydrau
lic Brake Actuation - Brake Pedal and Bracket, Brake Booster and
Brake Master Cylinder
Re mo
val and Installation
Remova

l
• C
A
UTIONS:
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.
1. Position vehi cl
e on a four-post lift.
2. Open engine compartment and fit paint work protection covers
to fenders.
3. Disconnect battery ground cable (IMPORTANT, refer to
operation 86.15.19 for fu rther information).
4. Remove engine compartment rear cover. Refer to operation
76.11.35.

5. Reposi
tion the mounting bracket of the cruise control vacuum-
valves for access (if installed).
R e
move screws.
Reposition bracket.


6. Disc
onnect low-level warning connector from master cylinder.
7. Disconnect vacuum pipe from brake booster.
1. Disconnect pipe.
2. Remove and discard seal.

8. Posi
tion absorbent cloth underneath master cylinder to collect
brake fluid spillage.

9. Di
sconnect brake tubes from master cylinder.
Install plugs to brake tu

bes an
d master cylinder ports.

10
.
From driver footwell, disconne ct throttle inner cable from
pedal.
Re
move grommet.
Relea

se cable from pedal.

11
.
Disconnect stop-lamp-switch connector.
Move carpet.
Disc
onnect electrical connector.
12. From engine compartment, remo ve throttle cable from pedal
housing.
Re
lease grommet.

In
stallation

Pull cabl
e from
pedal housing.

13 . Remove pedal h
ousing, brake
booster and master cylinder
assembly from vehicle.
F rom
driver footwell, remove nuts.
Carefull
y remove assembly.

14 . Remove an
d discard gask
et from pedal housing.
15. Clean components and mating surfaces.

1. Inst al
l gasket to pe
dal housing assembly.
2. CAUTION: Make sure no pipe s or cables become trapped
when fitting the pedal housing assembly.

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.

8. Conne ct
low-level warning connector to master cylinder.

9. Inst al
l cruise control vacuum-valves, mounting bracket.
Install and tigh
ten bolts.

10 . Conne
ct stop lamp switch connector.
Conne
ct
connector.
Re
posi
tion carpet.
11. Connect battery ground cable (IMPORTANT, see operation
86.15.15 for further information).
12. Bleed brake system. See operation 70.25.03.
13. Install engine compartment rear cover. Refer to operation
76.11.35.
14. Remove paint-work protection covers and close engine
compartment.

15 . Conne
ct battery ground cable (I
MPORTANT, refer to operation
86.15.19 for further information).