brake JAGUAR X308 1998 2.G Workshop Manual

                    Rear Drive  Axle and  Diffe rential
 
                 General Procedures  
                     Differential  Output Shaft  End  Float  Check  (51.10.24)  
                 In‐Vehicle  Repair  
                     Axle Shaft  (47.10.01)  
                     Differential  Output Shaft  Bearing  (51.10.22)  
                     Drive Pinion  Flange  and  Drive  Pinion  Seal  (51.20.01)  
                 Removal and  Installation  
                     Axle Assembly  (51.25.13)  
 
        206:  Brake  System  
 
             206‐00:  Brake  System  ‐ Gen
eral Information 
                 Specification  
                 Description  and  Operation  
                     Brake System  
                 Diagnosis  and  Testing  
                     Brake System  
                 General Procedures  
                     Brake System  Bleeding  (70.25.03)  ‐ Vehicles  With: Standard  Brakes 
                     Brake System  Bleeding  (70.25.03)  ‐ Vehicles  With: High  Performance  Brakes  
                     Front Brake  Disc  Runout  Check ‐  Vehicles  With: Standard  Brakes  
                     Front Brake  Disc  Runout  Chec
k ‐ Vehicles  With: High Performance  Brakes 
                     Rear Brake  Disc  Runout  Check  (70.12.36)  ‐ Vehicles  With: Standard  Brakes 
                     Rear Brake  Disc  Runout  Check  (70.12.36)  ‐ Vehicles  With: High Performance   
            Brakes 
 
             206‐03:  Front  Disc Brake  
                 Specification  
                 Description  and  Operation  
                     Front Disc  Brake  
                 Removal and  Installation  
                     Brake Caliper  (70.55.02)  ‐ Vehicles  With: Standard  Brakes  
                     Brake Caliper  (70.55.02)  ‐ Vehicles  With: High  Perfo
rmance  Brakes  
                     Brake Disc  (70.10.10)  ‐ Vehicles  With: Standard  Brakes 
                     Brake Disc  (70.10.10)  ‐ Vehicles  With: High Performance  Brakes 
                     Brake Pads  (70.40.02)  ‐ Vehicles  With: Standard  Brakes 

                    Brake Pads  (70.40.02)  ‐ Vehicles  With:
 
High  Performance  Brakes 
 
             206‐04:  Rear  Disc  Brake  
                 Specification  
                 Description  and  Operation  
                     Rear Disc  Brake  
                 Removal and  Installation  
                     Brake Caliper  (70.55.03)  (70.55.25)  ‐ Vehicles  With: Standard  Brakes  
                     Brake Caliper  (70.55.03)  (70.55.25)  ‐ Vehicles  With: High  Performance  Brakes  
                     Brake Disc  (70.10.11)  ‐ Vehicles  With: Standard  Brakes 
                     Brake Dis
c (70.10.11)  ‐ Vehicles  With: High Performance  Brakes 
                     Brake Pads  (70.40.03)  ‐ Vehicles  With: Standard  Brakes 
                     Brake Pads  (70.40.03)  ‐ Vehicles  With: High Performance  Brakes 
 
             206‐05:  Parking  Brake and  Actuation  
                 Specification  
                 Description  and  Operation  
                     Parking Brake  
                 General Procedures  
                     Parking Brake  Cable  Adjustment  (70.35.10)  
                     Parking Brake  Shoe  and Li
ning  Adjustment  (70.35.37)  
                 Removal and  Installation  
                     Parking Brake  Control  (70.35.08)  
                     Parking Brake  Control  Shroud  (76.13.63)  
                     Parking Brake  Shoes  (70.40.05)  
                     Parking Brake  Warning  Indicator  Switch (86.65.45)  
 
             206‐06:  Hydraulic  Brake Actuation  
                 Specification  
                 Description  and  Operation  
                     Hydraulic Brake  Actuation  
                 Removal and  Installation  
                     Brake Fluid  Reservoir  (70.30.16)  
                     Brake Master  Cylinder  (70.30.
08) 
                     Brake Pedal  and  Bracket  (70.35.03)  
                     Brake Pedal  and  Bracket,  Brake  Booster  and  Brake  Master  Cylinder  (70.35.39)  
 

            206‐07:  Powe r Brake  Actuation  
                 Specif
ication
 
                 Description  and  Operation  
                     Brake Booster  
                 Removal and  Installation  
                     Brake Booster  (70.50.17)  
                     Brake Booster  and  Brake  Master  Cylinder  (70.50.18)  
 
             206‐09:  Anti ‐Lock  Control  
                 Specification  
                 Description  and  Operation  
                     Anti‐Lock  Control  
                 Diagnosis  and  Testing  
                     Anti‐Lock  Control  
                 Removal and  Installation  
                     Anti‐Lock  Brake  System  (ABS)  Module  (70.60.02)  
                     Front Wheel  Speed  Sensor  (70.60.03)  
                     Hydraulic Cont
rol Unit  (HCU) 
                     Rear Wheel  Speed  Sensor  (70.60.04)  
                     Wheel Speed  Sensor  Ring  (70.60.25)  
 
        211:  Steering  System  
 
             211‐00:  Steering  System ‐ General  Information  
                 Specification  
                 Description  and  Operation  
                     Steering System  
                 Diagnosis  and  Testing  
                     Steering Sy
stem  
                 General Procedures  
                     Power Steering  System Filling  and  Bleeding  
                     Power Steering  System Flushing  (57.15.08)  
                     Power Steering  System Vacuum  Filling  and  Bleeding  
                     Steering Gear  Centralizing  
 
  

                Diagnosi
s
 and  Testing  
                     External Controls  
                 General Procedures  
                     Brake Shift  Interlock  Actuator Adjustment  (44.15.49)  
                     Brake Shift  Interlock  Actuator Manual  Override  
                     Kickdown Switch  Adjustment  (44.15.38)  
                     Selector Lever  Cable  Adjustment  (44.15.07)  
                 Removal and  Installation  
                     Brake Shift  Interlock  Actuator (44.15.48)  
                     Kickdown Switch  (44.15.23)  
                     Selector Lever  Cable  and  Bracket  (44.15.08)  
                     Selector Lev
er Gate  Finish  Panel  (76.25.24)  
                     Selector Lever  Indicator  Assembly  (44.15.14)  
                     Selector Lever  Indicator  Disc  (44.15.15)  
                     Selector Lever  Switch  (44.15.52)  
                     Selector Lever  Knob  (44.15.06)  
                 Disassembly  and  Assembly  
                     Selector Lever  Assembly  (44.15.05)  
 
             307‐05B : Automatic  Transmission/Transaxle  External  Controls  ‐ 4.0L  SC  V8 ‐ AJ26  
                 Description  and  Operation  
                     External Controls  
                 Diagnos
is and  Testing  
                     External Controls  
                 General Procedures  
                     Brake Shift  Interlock  Actuator Manual  Override  
                     Kickdown Switch  Adjustment  (44.15.38)  
                     Selector Lever  Cable  Adjustment  (44.15.07)  
                 Removal and  Installation  
                     Brake Shift  Interlock  Actuator (44.15.48)  
                     Kickdown Switch  (44.15.23)  
                     Selector Lever  Cable  and  Bracket  (44.15.08)  
                     Selector Lever  Gate  Finish  Panel  (76.25.24)  
                     Selector Lev
er Indicator  Disc  (44.15.15)  
                     Transmission  Control Switch  (TCS)  (44.15.12)  
                     Selector Lever  Knob  (44.15.06)  
 

                    Rear Door  Speaker  (86.50.14)  
                     Rear Door  Tweeter  Speaker  (86.50.62)  
                     Subwoofer
 
Speaker  (86.51.05)  
 
        417:  Lighting  
 
             417‐01:  Exterior  Lighting  
                 Specification  
                 Description  and  Operation  
                     Exterior Lighting  
                 Diagnosis  and  Testing  
                     Exterior Lighting  
                 Removal and  Installation  
                     Brake Pedal  Position  (BPP)  Switch  
                     Fog Lamp  Switch  (86.65.10)  
                     Front Fog  Lamp  (86.
40.96)  
                     Front Fog  Lamp  Bulb  (86.40.94)  
                     Front Side  Marker  Lamp  (86.40.59)  
                     Front Side  Marker  Lamp  Bulb  (86.40.58)  
                     Front Turn  Signal  Lamp Bulb  (86.40.41)  
                     Headlamp Assembly (86.41.33)  
                     Headlamp Leveling Motor  (86.42.04)  
                     High Beam  Headlamp  (86.41.34)  
                     High Beam  Headlamp  Bulb  (86.40.12)  
                     High Mounted  Stoplamp  (86.41.01)  (86.41.32)  
                     High Mo
unted  Stoplamp  Bulb (86.41.02)  
                     License Plate  Lamp  (86.40.86)  
                     License Plate  Lamp  Bulb  (86.40.85)  
                     Low Beam  Headlamp  (86.41.35)  ‐ Vehicles  Without:  Headlamp  Leveling 
                     Low Beam  Headlamp  (86.41.35)  ‐ Vehicles  With: Headlamp  Leveling  
                     Low Beam  Headlamp  Bulb  (86.40.08)  
                     Rear Lamp  Assembly  (86.40.70)  
                     Rear Lamp  Assembly  Bulb  (86.40.73)  
                     Rear Side  Marker  La
mp  (86.41.08)  
                     Rear Side  Marker  Lamp  Bulb (86.41.07)  
                     Side Lamp  Bulb  (86.40.27)  
                     Side Lamp/Front  Turn  Signal  Lamp  (86.40.39)  

Torque Specifications
Torque sp
ecifications are shown in maintenance procedure illustra
tions and also in the torque specifications chart located at
the front of the relevant section.
Disconnecting/Connecting the Battery
Ow ing t
o the electronic components used on the vehicle, it is important that the battery is disconnected when specified in a
maintenance procedure.
When the battery is connected, the specified procedure must be followed, to ensure the correct operation of all vehicle
systems; refer to Section 414-01.
Use of Control Modules
Control modu les may
only be used on the ve
hicle to which they were originally fitted. Do not attempt to use or test a control
module on any other vehicle.
Function
al Test
On
completion of a maintenance procedure, a thorough test should be carried out, to ensu
re that the relevant vehicle
systems are working correctly.
Protecting the Vehicle
Al ways
fit covers to protect
the fenders before commencing work in the engi ne compartment. Cover the seats and carpets,
wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic fluid,
antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water imme diately. Use polythene sheets
in the trunk to protect carpets. Always use the recommended service tool, or a satisfactory equivalent, where specified.
Protect temporarily exposed screw thread s by replacing nuts or fitting caps.
Preparation
Before disassembly, clean the surrounding ar ea
as thoroughly as possible. When co
mponents have been removed, blank off
any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when
separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oilways, exposed
by component removal, with tapered hardw ood plugs or readily visible plastic plugs. Immediately a component is removed,
place it in a suitable container; use a se parate container for each component and its associated pa rts. Before dismantling a
component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the
materials within the component. Clean the bench and obtain ma rking materials, labels, containers and locking wire before
dismantling a component.
Dismantling
O b
serve scrupulous cleanliness when dismantling components,
particularly when parts of the brake, fuel or hydraulic
systems are being worked on. A particle of dirt or a fragment of cloth could caus e a dangerous malfunction if trapped in
these systems. Clean all tapped holes, crev ices, oilways and fluid passages with compressed air. Do not permit compressed
air to enter an open wound. Always use ey e protection when using compressed air.
Ensure that any O-rings used for sealing are correctly refitted or renewed if disturbed. Mark mating parts to ensure that
they are replaced as dismantled. Whenever possible use markin g materials which avoid the possibilities of causing distortion
or the initiation of cracks, which could occur if a center pu nch or scriber were used. Wire together mating parts where
necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to
parts requiring further inspection before being passed fo r reassembly. Place labelled parts and other parts for rebuild in
separate containers. Do not disc ard a part which is due for renewal until it ha s been compared with the new part, to ensure
that the correct part has been obtained.

Before inspecting a component for wear or per
forming a dimensional check,
ensure that it is absolutely clean; a slight smear
of grease can conceal an incipient failure. When a component is to be checked dimensionally against figures quoted for it,
use the correct equipment (surface plates, micrometers, dial gauges etc.) in serviceable condition. The use of makeshift
equipment can be dangerous. Reject a component if its dimensio ns are outside the limits quoted, or if damage is apparent.
A part may be refitted if its critical di mension is exactly to the limit size and it is otherwise satisfactory. Use Plastigauge 12
Type PG-1 for checking bearing surface clearance, e.g. big end bearing shell to crank jour nal. Instructions for the use of
Plastigauge and a scale giving bearing clearances in steps of 0.0025 mm (0.0001 in) are supplied with the package.
Safety
Precautions
• WAR
NINGS:
WORKING ON THE FUEL SYSTEM RESULTS IN FUEL AND FUEL VAPOUR BEING PRESENT IN THE ATMOSPHERE. FUEL
VAPOUR IS EXTREMELY FLAMMABLE, HENCE GREAT CARE MUST BE TAKEN WHILST WORKING ON THE FUEL SYSTEM.
ADHERE STRICTLY TO THE FOLLOWING PRECAUTIONS:
DO
NOT SMOKE IN THE WORK AREA.
DISP

LAY 'NO SMOKING' SIGNS AROUND THE AREA.
DISCONNECT TH

E BATTERY BEFORE WORKING ON THE FUEL SYSTEM.
DO NOT CONNEC

T/DISCONNECT ELECTRICAL CIRCUITS
, USE ELECTRICAL EQUIPMENT OR OTHER TOOLS OR
ENGAGE IN WORKING PRACTICES WHICH IN ANY WAY MAY RESULT IN THE PRODUCTION OF SPARKS.
ENS
URE THAT A CO2 FIRE EXTINGUISHER IS CLOSE AT HAND.
ENS

URE THAT DRY SAND IS AVAILABLE TO SOAK UP ANY FUEL SPILLAGE.
EMP

TY FUEL USING SUITABLE FIRE PROOF EQUIPMENT IN
TO AN AUTHORIZED EXPLOSION PROOF CONTAINER.
DO NOT EMP
TY FUEL WHILE WORKING IN A WORKSHOP OR A PIT.
ENS

URE THAT WORKING AREA IS WELL VENTILATED.
ENS

URE THAT ANY WORK ON THE FUEL SYSTEM IS ON
LY CARRIED OUT BY EXPERIENCED AND WELL QUALIFIED
MAINTENANCE PERSONNEL.
ENS
URE THAT FUME EXTRACTION EQUIPMENT IS USED WHERE APPROPRIATE.
FUME EXTRACTION EQUIPMENT MUST BE IN OPERATION WHEN SOLVENTS ARE USED E.G. TRICHLOROETHANE,
WHITE SPIRIT, SBP3, METHYLENE CHLORIDE, PERCHLORETHY LENE. DO NOT SMOKE IN THE VICINITY OF VOLATILE
DEGREASING AGENTS.
General workshop practices:
Disc
onnect the grounded termin
al of the vehicle battery.
D
o not apply heat in an attempt to free seized nuts or fitt
ings; as well as causing damage to protective coatings,
there is a risk of damage from stray heat to electronic equipment and brake lines.
Keep oils and solven
ts away from naked flames and other sour
ces of ignition.
Adhere str
ictly to handling and safety inst
ructions given on containers and labels.
E
nsure that a suitab
le form of fire extinguisher is conveniently located.
Wh
en using electrical tools and equipment, inspect the power
lead for damage and check that it is properly earthed.
D
o not leave tools, equipment, spilt oil etc. around the work area.
Working beneath a vehicle:
Wh
enever possible, use a ramp or
pit in preference to jacking.
Posit
ion chocks at the wheels as we
ll as applying the parking brake.
N
ever rely on a jack alone to support a
vehicle; use axle stands, or blocks care fully placed at the jacking points, to
provide a rigid location.
Ch
eck that any lifting equipment used has adeq
uate capacity and is fully serviceable.
Working on air conditioning systems:
D
o not disconnect any pipes of the refrigeration system
unless you are trained and instructed to do so; a refrigerant
is used which can cause blindness if allowed to come into contact with the eyes.
Health Protection

P

rolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness,


In
spection

General Information - Terminology Glossary

Description an
d Operation

This glossary of terms is intended to cover emissions-related (to SAE J 1930) term inology, and other abbreviations that may
be used in this manual.
The required term may be looked-up in th e left-hand column, and subsequent columns give the standard acronym, unit or
abbreviation, and definition.
Te rm
(s)
Acr
ony
m /
Unit /
Abbreviation
De fi
nition
A
Accel
e
rator Pedal
AP
Af
ter Botto
m Dead
Center
ABDCEvent occurri ng after
BDC
Af
ter Top Dead CenterATDCEvent occurri ng after
TDC
Ai
rbag /
Supplementary
Restraint System
Airbag, SRSAi rbag restraint system for
dr
iver and front seat passenger
Air Cleane rACL
Air ConditioningA/C
Air Conditioning Con t
rol
Module
A/CCMModule c
ontrolling air conditioning, heating and ventilation
Air Conditioning SignalACSA
i
r conditioning compressor clutch operation is signalled to the ECM which
induces idle speed corrections to co mpensate for engine load changes
Alternating cu
rrent
ac
Ai
r Fuel R
atio
AFRN
omi
nally 14.7 parts air to one part fuel
Ampe
reASI unit of current
Ampere hourAhA current of one ampere
fl
owing for one hour
Anti-Lock Braking SystemABSS
y
stem which prevents wheel lock-up
under braking by sensing lack of
rotation of a wheel(s) and divertin g fluid pressure away from it (them)
ABS Control Mo
dule
ABS CM
ABS /
T
raction Control
Control Module
ABS / T
C CM
Atmosph
e
re
atmU
n
it of pressure (1.01325 bar)
Au
to
matic Stability
Control
ASCA form of vehicle
control
in which the ECM reduces en gine torque to control
wheel-spin
B
Baro me
tric Absolute
Pressure Sensor
BAR OSensor measuring the pressure of surr ou
nding air at any given temperature
and altitude
Bat t
ery positive voltage
B+The posi
ti
ve voltage from a battery or
any circuit connected directly to it
Before Bottom Dead
CenterBBDCEvent occurri ng before BD
C
Before Top Dead

Center
BTD
CEvent (usual ly
ignition) occurring before TDC
Blowe
rBLRDe
vice which supplies a current of air at
moderate pressure, e.g. heater or
A/C blower
Body Processor M
odule
BPMControl modu
le
for body electrical systems, e.g. interior lamps, windshield
wash / wipe control
Bott om D
ead Center
BD
CLowest poin t of piston
travel in a reciprocating engine
Brake hors
epowe
r
bhpEffecti
ve horsepower devel
oped by an
engine or motor, as measured by a
brake applied to its output shaft
Brake Mean Effective
Pres sureBME PThat p
art of the effective
pressure developed in a cyli nder that would result in
a cylinder output equal to the bhp of the engine
Brake On/ O
ff
BOOIn
dic
ates the position of the brake pedal
Br
it
ish Standard
BSStan
dar
d specification issued by the British Standards Institution
Br
it
ish Standard
Automotive
BSAu
BusTopology of a commu n
ication network
Bypass
AirBPAMechanica l
control of throttle bypass air
C
Camshaft Posit
i
on Sensor
CMPSIndi
cat
es camshaft position
Canadian Motor
V
ehicle
CMVSS

Jacking and Lifting - Safety Precautions
Description and Operation

The following safety precautions must be observed wh en raising the vehicle to perform service operations:
Ne
ver rely on a jack alone to suppo
rt a vehicle; use suitable vehicle stands to provide rigid support.
When working ben
eath a vehicle, whenev
er possible use a ramp or inspection pit instead of a jack and vehicle
stands.
En
sure that the vehicle is
standing on firm, level grou nd before using a jack.
Do not rely
on the parking brake alon
e; chock the wheels and put the transmission into Park if possible.
Check that
any lifting equipment used has adequate capacity
for the load being lifted and is in proper working order.

Jacking and Lifting - Vehicle Recovery
Description an
d Operation
• NOTE: Prior to recovery, ensure that the vehicle keys are available and the security system disarmed.
Vehicle recovery methods are:
By fl
at-bed transporter.
By rear suspended tow.


By emergency to

wing for
very short distances.
Gears
hift Interlock
The
gear selector lever can only be moved
from the Park position by turning the igni tion key to position II and depressing
the brake pedal.
To remove the key from the ignition switch, the gear select or lever must be moved to the Park position. With the key
removed, the gear selector is locked in the Park position.
The selector lever can be manually unlocked from the Park position in the event of electrical failure or when moving the
vehicle without power. Refer to the general procedure in this section.
Transporter or Trailer Recovery

When the vehicle is being recove red by transporter or trailer:
The parking brake must be
be applied and the wheels chocked.
The

gear selector lever must be in Ne
utral. Do not select Park as the park ing lock mechanism may be damaged by
the forward and backward rocking motion of the vehicle.
The ve
hicle must be securely tied down to the transporter or
trailer. There are four tie-down brackets on the vehicle
underbody. Do not use the vehicle towing points or crossbeam tie bar.