brake light JAGUAR X308 1998 2.G Workshop Manual

                    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)  

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

wheels
and tires.
Infl
atio
n pressure too high or low.
*
Cor r
ect pressure to specification
*
Uneven ti re wear.
*Re fe
r to Diagnosis and Testing in this section.
*
Wh ee
l and tire assembly imbalance.
*
Balance wheel an d tire assembly.
*
Brake disc imbalan c
e.
*
Check brak e disc co
oling fins for mud and foreign
material. Check for damage or disc heavy spot.
Refer to Section 206-00.
*
Damaged or distor
ted wh
eel.
*
Renew wh eel.
*
Excessive radial run-o
ut of wheel or
tire. Excessive lateral run-out of wheel or
tire.
*
*
Renew wh
eel or tire.
*
Incorrectl y
seated tire.

*
R e
mount the tire.

*
Loose wh eel mo
untings: damaged
wheel studs, whee l nuts, worn or
broken wheel hub face or foreign
material on mounting faces.
*
Tigh
te
n or Renew worn or
damaged parts. Clean
mounting surfaces.
*
De
fe
ctive wheel bearings.
*
Renew worn
or damaged bearing sets: Refer to
Section 204-00.
*
W
a
ter in tires.
*
R e
move water.
*
Damaged wh eel stud
thre
ads.
Sli
d
ing wheel across the wheel studs
during installation. Loose wheel nuts.
*
Renew wh
eel studs.
*
Broken wh eel
studs.
Loose or overti
ght
ened wheel nuts.
*
Renew wh eel studs.
*
C o
rrosion / contamination
streaks from wheel stud
holes.
Loose wh eel
nuts.
*
Chec k com
plete assembly. Renew damaged parts.
Apply correct torque setting.
*
Damaged wh
eel nu
ts.
Loose wh
eel
assembly.
Over-tightened wheel nuts.
*
*
Renew wh
eel nu
ts. Apply correct torque setting.
*
Se ize
d wheel nuts.
Cor
rosion

*
CAUTI O
N: Do not permit lubricant to
contaminate wheel hub stud holes or wheel nut seats.
If corrosion is light, wire brush away corrosion. If
corrosion is excessive renew wheel studs and wheel
nuts. Lubricate th e first three threads of wheel
studs with a graphite based lubricant.
*

P
INPOINT TEST A : BRAKES NOISY
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
A1

: INSPECT BRAKE PADS
Inspect the condi

tion of the front and rear brake
pads. Check for damage to any anti-squeal shims.
1
Are th
e brake pads OK?
Yes GO to A2
.
No

CLEAN the front brake pads or INSTALL new front brak e pads if necessary. For additional information,
refer toSection 206
-03
Front Disc Brake
. CLEA
N the rear brake pads or INSTALL new rear brake pads
if necessary. For additional information, refer toSection 206
-0
4 Rear Disc Brake
.
Test vehicle for
presence of brake squeal.
A2
: INSPECT BRAKE DISCS
Inspe

ct the brake discs for excessive corrosi
on, wear or disc thickness variation.
1
D
oes excessive corrosion, wear or
disc thickness variation exist?
REFER to Specification
- in t
his section.
Yes INSTALL new front brake discs and brake pads. For additional information, refer toSection 206
-03

Fr

ont Disc Brake
. INSTALL n
ew rear brake discs and brake
pads. For additional information, refer
toSection 206
-0
4 Rear Disc Brake
. TEST
the system for normal operation.
No Vehicle is OK.
P
INPOINT TEST B : VIBRATIO
N WHEN BRAKES ARE APPLIED
TE
ST
CONDITIONS
D
ETAILS/RESULTS/ACTIONS
B1

: ROAD TEST VEHICLE
R

oad test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
1
Is th

e vibration present?
Yes TEST for noise vibration and harshness. REPEAT road test if necessary.
No GO to B2
. .

B2

: CHECK FOR BRAKE VIBRATION
R

oad test the vehicle between 40-80 km/h (25-50
mph) with light and medium application on the
brake pedal.
1
Is a vibration
present?
Yes If the vibration is from the front of the vehicle GO to B3
. If
the vibration is
from the rear of the
vehicle or can not be di agnosed between front or rear of the vehicle GO to B6
.
No

Vehicle is OK.
B3: CHECK
THE SUSPENSION
AND STEERING COMPONENTS
Chec
k the condition of the front susp
ension bushes and ball joints
REFER to Section 204
-01
Front Suspension
.
Chec
k the condition of the steering linkage components
REFER to Section 211
-0
2 Power Steering
/

211
-0
3 Steering Linkage
.
1
D

o any of the front suspension components or steering comp
onents require replacement?
Yes INSTALL new components as necessary
REFER to Section 204
-01
Front Suspension
/

211
-0
2 Power Steering
/

211
-0
3 Steering Linkage
.
R
oad test the vehicle between 40-80 km/h (25-50
mph) with light and medium application on the
brake pedal. If vibr ation still exists GO to B4
.
No

GO to B4
.
B4: CHECK
THE FRONT BRAKE PA
DS AND FRONT BRAKE DISCS
Chec
k the condition of the front br
ake pads and front brake discs.
1
D
oes excessive brake disc runout or br
ake disc thickness variation exist?

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

Road test the veh
icle and a
pply the brake pe dal lightly.
1
Do th
e brakes lockup?
Yes GO to H2
.
No
Vehicle is OK.
H2: INSPECT BRAKE PADS
Inspect brake pads for con
t
amination,
correct installation , damage and type.
1
Ar
e any concerns found?
Yes CHECK the front brake pads. For additi onal information, refer toSection 206
-03 Fr
ont Disc Brake
.
CHECK
the rear brake pads. For additi
onal information, refer toSection 206
-04
Rear Disc Brake
.
INST ALL new brake pads as ne ce
ssary. REPEAT
road test.
No GO to H3
.
H3: INSPECT BRAKE CALI
PERS
Inspect brake cali
pers for bindi
ng, leaking or sticking.
1
A
r
e any concerns found?
Yes CHECK the front brake calipers. For addi tional information, refer toSection 206
-03 Fr
ont Disc Brake
.
CHECK
the rear brake calipers. For addi
tional information, refer toSection 206
-04
Rear Disc Brake
.
IN ST
ALL the brake calipers correctly or INSTALL new
brake calipers as necessary. TEST the system for
normal operation. REPEAT road test if necessary.
No Vehicle is OK.
PI
NPOINT TEST I : BRAKES DRAG
TE
S
T
CONDITIONS
D E
TAILS/RESULTS/ACTIONS
I1
:
ROAD TEST VEHICLE
Ro
ad t
est the vehicle
and apply the brakes.
1
Are the brakes
functioning correctly?
Yes Vehicle is OK.
No GO to I2
.
I2
: CHECK CALIPERS
Check the fr
on
t caliper pistons for binding, leakin
g or sticking. For additional information, refer
toSection 206
-03 Fr
ont Disc Brake
. Check the rear cal
i
per pistons for
binding, leaking or sticking. For
additional information, refer toSection 206
-04
Rear Disc Brake
.
1
Do t
h
e disc brake caliper pistons
and pins bind, leak or stick?
Yes INSPECT the brake calipers and pa rking brake cables. INSTALL new co mponents as necessary. Road
test vehicle.
No GO to I3
.
I3
: CHECK BRAKE BOOSTER
Check the brake booster con
n
ecting rod alignment
and travel. For additional information, refer
toSection 206
-0 7
Power Brake Actuation
. 1
Is the co
nnecti
ng rod OK?
Yes Vehicle is OK.
No INSTALL a new brake booster. For addi tional information, refer toSection 206
-07
Power Brake
Actuation. TEST
the system for
normal operation.
PINPO
I
NT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
TE
S
T
CONDITIONS
D E
TAILS/RESULTS/ACTIONS
J
1
: TEST ON ROUGH ROAD
R
oad test the vehi
cle on rough road conditions.
1
Apply the brakes slowly. 2
Is th
e brake pedal ef
fort an
d brake pedal travel normal?

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

cap ven
t holes clogged or air in the hydraulic system.
Brake ped

al effort is excessive. This ma
y be caused by a bind or obstruction in the pedal/linkage, a faulty non return
valve, booster or insuffi cient booster vacuum.
R
ear brakes lock up during light pedal force. This may
be caused by damaged brake pads, an incorrectly adjusted
parking brake, a partially applied parking brake, a damaged ABS sensor or bearing failure.
Brake ped
al effort erratic. This condition could be caused by the brake booste
r or incorrectly installed brake pads.
Brake warning indicator i
s on. This may be caused
by low fluid level or float assembly damaged.
No
n Pressure Leaks
Any reduced fluid v
olume in the brake ma
ster cylinder reservoir condition may be caused by two types of none pressure
external leaks.
Type 1: An external leak may be occur at the master cylinder reservoir cap because of incorre ct positioning of gasket and
cap. Reposition cap and gasket.
Type 2: An external leak may occur at th e reservoir mounting seals. Repair such a leak by installing new seals and make
sure that the reservoir retainin g bolt is correctly installed.

Parking Brake and Ac
tu
ation - Parking Brake
Description an
d Operation

Parts List
The parking-brake hand lever is mounted on the transmission tunnel and incorporates the ratchet mechanism and release
button.
The front cable is routed from the hand lever, under the carpet through to an abutment bracket adjacent to the
transmission tunnel, and then connected to the relay lever. The relay lever is attached to a mounting plate by a center bolt
on which it rotates The relay lever mounting plate straddles the transmission tunnel, the plate is secured by four bolts. The
relay lever acts as a center pu ll system to transmit the force from the hand lever to the rear brakes shoes. The equalizer
which is positioned in the center of the rear brake cables balances the force that is applied to the rear brakes.
The rear brake cables are linked together: each cable passes through the rear hub carrier and connects to a brake shoe
expander lever. Application of the parking brake causes the rear cables to pu ll on the expander levers, the expander lever
mechanism rotates on a pivot pin to force the brake shoes outwards to contact the brake drums.
The parking brake cables are adjusted by the rotation of a nu t on the adjuster rod. The parking brake shoes are adjusted by
It
em
Par
t Number
De
scription
1—Hand Le

ver
2—Front Cable


3—R

elay Lever and Mounting Plate
4—Drivesh

aft Center Mounting
5—Cable Adjuster Rod


6—Equalize

r
7—Cable Connector
8—Rear Ca

ble RH
9—Rear Ca

ble LH
10—Warn

ing Light Switch and Harness
11—War

ning Lamp

Parking Brake and Actuation - P
arking Brake Control
Re
mo
val and Installation
Remov
a
l
W
A
RNING: 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.
CAUTION: Replacement of nuts and bolts: Various thread-locking devices 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.
1. Position vehi cl
e on a four-post lift.
2. Release parking brake.

3. Releas
e tension on parking brake cable.
Slacken bu

t do not remove adjustment nut.

4. Releas
e parking brake cable.
Remo

ve clip.
Re
mo
ve clevis pin.
5. Remove driver seat for access . Refer to operation 76.70.01.
6. Remove trim from hand lever. Refer to operation 76.13.63.
7. Carefully reposition carpet from around hand lever for access.

8. Disconnect park ing-br
ake, warning-light switch connector.
9. Remove hand lever from vehicle.