power steering fluid JAGUAR X308 1998 2.G Workshop Manual

Front Suspension -
Lubri
cants, Fluids, Sealants and Adhesives
Press-In Loads
Torques


UnitS
pecification
Loctite27

0
Greas

e
Shell Retin
ax 'A'
Greas

e
Castro
l 'NTR'
Com

ponent
Kn
Ball join

t to upper wishbone
25
- 50
B

all joint to lower wishbone
25
- 50
Com

ponent
Nm
N

ut - ball joint, upper wishbone to vertical link.
60
-80
N

ut - ball joint, lower wishbone to vertical link.
60
-80
Nu

t - fulcrum bolt, upper wishbone.
60
-80
N

ut - ball joint, tie rod to steering arm.
71
-85
Bol

t - wheel speed sensor to vertical link.
8-1
0
Bol

t - front mounting to crossbeam.
22
-28
Bolt

- mounting , stabilizer bar.
30
-40
N

ut - link arm ball joint to stabilizer bar.
60
-80
Bolt

- mounting, steering rack to crossbeam.
41
-54
B

olt - front mounting, crossbeam to body.
22
-28
Bol

t - spring pan to lower wishbone.
70
-90
N

ut - shock absorber to upper mounting
(vehicles with adaptive damping).
16
-18
Nu

t - shock absorber to upper mounting (vehicles without adaptive damping).
30
-40
N

ut - shock absorber lower to wishbone.
43
-57
B

olt - engine Hydramount to crossbeam.
34
-46
B

olt - crossbeam rear mounting to body.
13
1-185
Bol

t - generator cooling du
ct deflector to crossbeam.
17
-23
N

ut - lower steering column to pinion shaft.
22
-28
N

ut - hub, speed sensor rotor.
27
0-330
B

olt - shield, brake disc.
9-1
2
Bol

t - lower wishbone, front arm to rear arm.
77
-103
Nu

t - stabilizer bar link arm to wishbone bracket.
41
-54
N

ut - wishbone front
eccentric bolt.
11
3-153
Nu

t - wishbone rear
eccentric bolt.
11
3-153
N

ut - fulcrum shaft, upper wishbone.
60
-80
Bolt -

power steering pi
pes to pinion housing.
9-1
2

Brake System - General Inform
ation - Brake System
D
iagnosis and Testing
Principles of Operations
The brake system operates by transferring effort applied to th e brake pedal, by the driver to the brakes at each wheel.
The braking effort is distributed to each wheel, using a hydraulic system. The system is assisted using a vacuum brake
booster that reduces pedal effort for a given hydraulic pressure. The parking brake operates on the rear wheels and is
applied using a hand operated control.
I
nspection and Verification
•
NOTE: Prior to carrying out any diagno
sis, make sure that the brake system warning indicator is functional.
Visually examine the front and rear tire and wheel assemblies for damage such as un even wear patterns, tread worn out or
sidewall damage. Verify the tires are th e same size, type and, where possible, same manufacture. Replace the damaged
wheel or excessively worn tire. For a dditional information, refer toSection 204
-0
4 Wheels and Tires
.
W
heels and tires must be cleared of an
y foreign matter and tire pressures ad justed to the correct specification.
If the tires exhibit uneven wear or feathering, the cause must be corrected. Check the steering and suspension components
for damage or wear and, if ne cessary, check and adjust front wheel alignment. For additional information, refer toSection
204
-00 Suspen
sion System
- General Informati
on
.
Road Test


V
isual Inspection Chart
Carr

y out a road test to compare actual vehicle braking performance with the
performance standards expected by the
driver. The ability of the test driver to make valid compar isons and detect performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of brake system operation and accepted general performance guidelines to
make good comparisons and de tect performance concerns.
An experienced brake technician will always establish a route that will be used for all br ake diagnosis road tests. The roads
selected will be reasonably smooth and level. Gravel or bump y roads are not suitable because the surface does not allow the
tires to grip the road equally. Crowned roads should be avoide d because of the large amount of weight shifted to the low set
of wheels on this type of road. Once th e route is established and consistently used, the road surface variable can be
eliminated from the test results.
Before a road test, obtain a complete description of the customer concerns or suspec ted condition. From the description, the
technician's experience will allow the te chnician to match possible causes with symptoms. Certain components will be
tagged as possible suspects while others wi ll be eliminated by the evidence. More importantly, the customer description can
reveal unsafe conditions which should be ch ecked or corrected before the road test. The description will also help form the
basic approach to the road test by narrowing the concern to specific components, vehicle speed or conditions.
Begin the road test with a general brake performance check. Keeping the description of the concern in mind, test the brakes
at different vehicle speeds using both ligh t and heavy pedal pressure. To determine if the concern is in the front or rear
braking system, use the brake pe dal and then use the parking brake control. If the condition (pull, vibration, pulsation)
MechanicalElectrical
Brake m
aster cylinder
Parkin
g brake switch
Brake ca

liper piston(s)
D
amaged or corroded wiring harness
Brake di

scs
B
rake master cylinder fluid level switch
Wh

eel bearin
gs
Brake pads
Power brake booster
Brake ped

al linkage
Boost

er vacuum hose
Tire

s
De

bris

Stee
ring System - General Information -
S
teering Linkage Specifications
Power Steering Pump Specifications
Lubricants, Fluids, Sealers and Adhesives


S
teering Linkage Free Play
Meas
urement (mm)
Meas
urement (in)
F

ree play (measured at
the steering wheel rim)
0-
6
0
-0.24
It

em
S
pecification
Power steeri

ng pump relief pressure
10
6-114 bar
It

em
S
pecification
Power steeri

ng fluid
De
xtron 3

Steering System - General Inform
ation - Steering System
D
iagnosis and Testing
I

nspection and Verification
1.
1. Verify t
he customer concern by driving the vehicle.
2. 2. Visually inspect for obvious signs of mechanical or electrical damage.
Mec
hanical Inspection Chart
Electrical Inspection Chart
Mechanical Checks
Incorrect
tire pressure, loose whee
l nuts, incorrect wheel alignment
Loose ti
e-rods
Loose dam

per and spring assemblies or ball joint
Loose s

teering column shaft universal joints
Loose pinc

h bolts on steering column shaft
Loose steeri

ng gear assembly
Check f

or external damage to the steering gear.
- Damaged tie-rods
-
CAUTION: If a steering gear assemb ly is returned under warranty with leaking seals, but there is also
damage to the steering gear boot/boots the steering gear warranty will be invalid. This is due to the steering
gear seals being damaged due to fore ign materials entering the steering gear boot and damaging the steering
gear seals thereafter.
Damaged steering gear boot
Damaged accessory driv
e belt
Bin

ding or misaligned steering co
lumn, pump or steering gear
Incorrect fluid
level
Hose leaks o

r line restrictions
Hose fou

ling bodywork
El

ectrical Checks/Tests
Make sure all

connectors are in plac
e (steering gear Servotronic solenoid and steering control module (SCM) - if
applicable)
Make su
re all the fuses are in place and not blown
D

ISCONNECT the steering gear transducer
and the steering should become heavy
TEST e
lectrical values:
- Power Supply to the SCM = 12 Volts
- Steering gear transducer resist ance 7.0 to 7.5 Ohms is normal
(
limits: less than 5 Ohms and greater than 9 Ohms would

be declared unacceptable)

- Steeri
ng gear transducer voltage = 6 Volts
- Steering gear transducer cu rrent = 840 mA at 0 mph reducing to 0 mA at maximum speed

3.3. If an obvi
ous cause for an observed or
reported concern is found, correct th e cause (if possible) before proceeding
to the next step.
4. 4. Check the power steering fluid condit ion. For additional information, REFER to Power Steering Fluid Condition
Check in this section.
5. 5. If the concern is not visually evid ent, verify the symptom and REFER to Steering Fault Diagnosis by Symptom
Charts in this section.
Steering Re
lay Harness Connector

Stee
ring Linkage In
spection and Backlash (Freeplay) Check
CAUTIO

N: Steering gear boots must be
handled carefully to avoid damage. Use new clamps when installing steering
gear boots.
Inspect the boots for cuts, deterioration, tw isting or distortion. Check the steering gear boots to make sure they are tight.
Install new boots or clamps as necessary.
REC O
NNECT all electrical item
s disturbed during testing
Ite
m
De
scr
iption
1Ste
e
rin
g tran
sduc
er
ground
2Igni
ti
on feed
3Steeri
ng transducer feed
4Ground
5Speed s
ensor signal
6Seri
a
l interface

•
NOTE: The following steps must be carried out with assistance.
1. 1. With the wheels in the straight ahead po sition, gently turn the steering wheel to the left and the right to check for
free play.
2. 2. Free play should be between 0 and 6 mm (0 and 0.24 in) at the steering wheel rim. If the free play exceeds this
limit, either the ball joints are worn, the lower steering column joints are worn or the backlash of the steering gear
is excessive.
CAUTION: DO NOT attempt to adjust the stee ring gear yoke. Failure to follow this instruction will result in the steering
gear warranty to become invalid.
3. 3. The backlash of the steering gear cannot be adjusted, in stall a new steering gear. For additional information,
REFER to Section 211
-0
2 Power Steering
.
4. 4. Grasp the steering wheel
firm
ly and move it up and down and to the left and right without turning the wheel to
check for column bearing wear, steering wheel or steering column. For additional information,
REFER to Section 211
-0
4 Steering Column
.
Power Steering Fluid Condition Check
1.
1. R
un the engine for 2 minutes.
2. 2. Check the power steering fluid system level.
3. 3. Observe the color and the odor. The color under normal circumstances should be dark reddish, not brown or
black.
4. 4. Allow the fluid to drip onto a faci al tissue and examine the stain.
5. 5. If evidence of solid material is foun d, the power steering fluid system should be drained for further inspection.
6. 6. If fluid contamination or steering co mponent failure is confirmed by the se diment in the power steering fluid
system, REFER to Steering Fault Diagnosis by Symptom Charts in this section.
Power Steer
ing Pressure Test
Test Equ
ipment

It
em
S
pecial Tool Number
De
scription
12

11-011
Pres
sure Gauge Hose
221

1-011-08
Pump Return Hose
321

1-011-07
Pump Return Hose Connector
42

11-011-03/2
Test Equ
ipment to High
Pressure Hose Adaptor

The
measurement of the maximum system pressure, (which is
governed by the pressure relief valve) is achieved by
inserting the Service Tool (pressure gauge and adaptors) into th e fluid circuit of the power steering system. Run the engine
at idle speed, turn the st eering from lock to lock and read the ma ximum pressure recorded on the gauge.
Installin
g Test Equipment
To
in
stall the pressure test equipment:
Pla
c
e a suitable drain tray be
low the power steering pump.
Install a hose clamp on
the re
servoir to pump hose prior to disconnecting any hoses, to avoid unnecessary loss of
fluid.
Disc
onnect the hose from the power st
eering pump high pressure outlet.
Install the pu
mp outlet to hose adaptor (5
). Do not omit the 'O' ring seal (9).
Connect the power steering
pump
adaptor to control valve hose (6) of the test equipment.
Install th e adaptor (4) in th
e high
pressure hose previously removed from the power steering pump outlet.
Conn
ect the connector (3) of the test equipment hose (2) to the adaptor (4).
R
e
move the hose clamp fro
m the reservoir hose.
Start th
e engine.
With the control valve (7) OPEN and the engine idli ng, the following system pressures may be checked:
Du
ring turning.
W
h
en the steering is
held on full lock.
With
the steeri
ng at rest.
• CAUTIONS:
To avoid excessive heating of the po wer steering pump, do not close the valve for longer than 5 seconds maximum.
Do not drive the vehicle with the test equipment installed.
With the control valve (7) CLOSED the power steering pump maximum ou tput pressure can be checked.
Removing Test Equipment
To
remove the test equipment:
Install a hose clamp
on
the reservoir to power steering pump hose.
Re
movi
ng the test equipmen
t is a reversal of the in stallation instructions.
Install a new '
O
' ring seal (9) to the power steering pump high pressu
re outlet to hose connection.
Instal
l the original hose to
the power steering pump.
Re
move the clamp from the reservoir to
the power steering pump hose.
Top-up the reservoir flui
d.
Ble
e
d the power steerin
g system. For additional information,
REFER to Power Steering System Bleeding
- in thi
s section.
Stee
ring Fault Diagnosis by Sympt
om Charts
Leakage
52
11-0
11-03/1
Pump High Pressure Ou
tlet
to Hose Adaptor
621
1
-011-02
Pump Adaptor
to Contro
l Valve Hose
721
1
-011-01
Control Valve
82
11-
011
Pressure Gauge
9-'O
'
Ring Seal
Cond
iti
on
Possib
l
e Sources
Acti
o
n
Co
nfirm
the position of the fluid
leak.
CLEAN th
e area of the leak.
In
s
pect the area and confirm the exact position of leak.
Make sure the fluid
is not from anoth
er system on
the vehicle.

Function
al
Fl
uid
leakage
O
verfilled system.
CORRECT the
fluid leve
l as necessary.
Compon
ent leak.
•
NOTE: Record the position of the le
ak and some indication of the rate
of the leak on the Warra nty Return Record Sheet.
LOCATE
the suspect component or CHECK hose connections and
repair as necessary.
Damaged fluid cap. INST
ALL a new fluid cap.
Loose or damaged h

ose
fittings.
TI
GHTEN or INSTALL a new hose as necessary.
Leakage at

power
steering pump.
INST
ALL a new power steering
pump as necessary. For
additional information,
REFER to Section 211
-0
2 Power Steering
.
Fl

uid
leakage
Leakage
at steering hose
to steering gear connection.
CHECK
steering hose to
steering gear conn ection for leakage.
CHECK and TIGHTEN the steeri ng hose to steering gear
connection retaining bolt s/bolts as necessary.
Power steeri
ng fluid
leakage at O-ring seals.
CHECK
the power steering system fo
r signs of steering fluid loss
from O-ring seals.
INST
ALL new O-ring seals as necessary.
BLEE

D the power steering system.
For additional information,
REF
ER to Section 211
-0
0 Steering System
- Ge
neral
Informati

on
.
Power steeri

ng fluid
leakage from transfer pipes.
CHECK
the power steering system fo
r signs of steering fluid loss
from the transfer pipes.
CHECK
and TIGHTEN the transfer pipes if required, INSTALL new

transfer pipes as necessary.
BLEE
D the power steering system.
For additional information,
REF
ER to Section 211
-0
0 Steering System
- Ge
neral
Informati

on
.
Power steeri

ng fluid
leakage from the steering
gear.
CHECK
the power steering gear for signs of fluid loss.
INST

ALL a new steering gear as
necessary. For additional
information,
REFER to Section 211
-0
2 Power Steering
.
Power steeri

ng fluid
leakage from steering gear boot.
CHECK
the power steering gear for signs of fluid loss.
INST

ALL a new steering gear as
necessary. For additional
information,
REFER to Section 211
-0
2 Power Steering
.
Cond

ition
Possib
le Sources
Acti
on
F

ree play at steering wheel

Exce
ss play in the steering

linkage.
CHECK
the steering linkage for excess play.

For additional information, REFER to the
Steering Linkage Inspection and Backlash (Freeplay) Check in this section.
S
teering wheel loose.
CHECK
and TIGHTEN the steering wheel
retaining bolt/bolts as necessary. For additional information,
REFER to Section 211
-0
4 Steering Column
.
Lower steeri

ng column
pinch bolt loose.
CHECK
and TIGHTEN the lower steering
column pinch bolts as necessary. For additional information,
REFER to Section 211
-0
4 Steering Column
.
Exce

ssive wear in lower
steering column.
CHECK
for lower steering column for wear in

the universal joints. If wear is present,
INSTALL a new lower steering column as necessary.
W
ear in suspension joints.
CAU
TION: DO NOT attempt to adjust the
steering gear yoke. Failure to follow this instruction
will result in the steering gear warranty to become
invalid.
CHECK
for excess wear in the front
suspension joints. For additional information,
REFER to Section 204
-00
Suspension
Sy

stem
- General
Information
.

sus
pension components
and for damaged coil springs in the front suspension.
as necessary. For addi tional information,
REF
ER to Section 204
-0
2 Rear Suspension
. I

NSTALL new front suspension components
as necessary. For addi tional information,
REFER to Section 204
-01
Front Suspension
.
Chec

k the rear suspension

for loose or worn
suspension components.
TIGHTE
N or INSTALL new components as
necessary. For additi onal information,
REFER to Section 204
-0
2 Rear Suspension
.
Incorre

ct underbody
alignment.
CHECK
underbody alignment. For additional

information,
REFER to Section 502
-00
Uni
-Body, Subframe and M

ounting System
.
Poor r

eturnability of the
steering
Lower steeri
ng column
interference.
CHECK
the steering co
lumn is free from
interference from the en gine harness, sound
proofing or the floor covering.
Incorrect
tire pressure.
CHECK
and ADJUST the tire pressure. For
additional information,
REFER to Section 204
-0
4 Wheels and Tires
.
Incorrect

tire size or type.
IN
STALL a new tire as necessary. For
additional information,
REFER to Section 204
-0
4 Wheels and Tires
.
Steeri

ng column upper
shroud fouling on the steering wheel.
CHECK
steering column upper shroud for
fouling. ADJUST as necessary.
Steeri
ng column universal
joints binding.
IN
STALL a new steering column. For
additional information,
REFER to Section 211
-0
4 Steering Column
.
Steeri

ng column shaft floor

seal binding.
CHE
CK the steering column shaft floor seal
for correct fitm ent and REFIT as necessary.
Steeri
ng column shaft floor

seal may be torn.
IN
STALL a new steering column shaft floor
seal as necessary.
Bin
ding or damaged tie-
rods.
CHECK
tie-rod end for excessive wear or
tightness in ball joint. INSTALL a new tie- rod end. For additional information,
REFER to Section 211
-0
3 Steering Linkage
.
D

amaged or worn front
suspension components.
I
NSTALL new front suspension components
as necessary. For addi tional information,
REFER to Section 204
-01
Front Suspension
.
Incorre

ct toe adjustment.

AD
JUST as necessary. For additional
information,
REFER to Section 204
-00
Suspension
Sy

stem
- General
Information
.
Excessive steeri

ng efforts
required during low speed
manoeuvring and/or during parking manoeuvres
Low power steer
ing fluid.

CHE
CK steering system
for signs of steering
fluid loss.
BLEE
D the power steering system. For
additional information,
REFER to Section 211
-0
0 Steering System
- General Informati

on
.
Damaged accessory driv

e
belt tensioner.
INST
ALL a new accessory drive belt
tensioner.
Hose or cooler li
ne
restriction.
CHECK
hose or cooler lines for correct
routing.
INST
ALL a new hose as necessary.
Fl

uid aeration.
BLEE
D the system. For additional
information,
REFER to Power Steering System Bleeding

in t
his section.

Steeri
ng transducer not
closed - no feed voltage.
CHECK
the steering transducer circuit. For
additional information, REFER to the wiring diagrams.
Carry ou
t the electrical checks and tests.
For additional information, REFER to the
Electrical Checks and Tests in this section.
Steeri
ng transducer not
closed - cable fault.
CHECK
the steering transducer circuit. For
additional information, REFER to the wiring diagrams.
Carry ou
t the electrical checks and tests.

Fo
r additional information, REFER to the
Electrical Checks and Tests in this section.
Steering control
module
(SCM) defective.
CHECK
the SCM and INSTALL a new SCM as

necessary.
Power steeri ng f
luid
delivery pressure or flow too low.
CHECK
the power stee
ring pressure. For
additional information, REFER to the Power Steering Pressure Test in this section.
INSTALL a ne
w power steering pump as
necessary. For additi onal information,
REFER to Section 211
-0 2
Power Steering
.
Internal steering gear
leakage.
CHECK
the power stee
ring pressure. For
additional information, REFER to the Power Steering Pressure Test in this section.
INSTALL a ne
w steering
gear as necessary.
For additional information,
REFER to Section 211
-0 2
Power Steering
.
Steeri
ng operati
on is very
heavy when driving, but when stationary
manoeuvring is good
Steering transducer open earl
y.
CHECK

steering transducer and INSTALL a
new steering transducer as necessary.
Carry out th
e electrical checks and tests.
For additional information, REFER to the
Electrical Checks and Tests in this section.
Steering transducer open
early,
steering control
module (SCM) fault.
CHECK
SCM and INSTALL a new SCM as
necessary.
Steering transducer open
earl
y, speedo signal error.
CHECK
speedo
circui
t. For additional
information, REFER to the wiring diagrams.

Steeri ng operati
on is very
light when driving, but when
stationary manoeuvring is good
Steering transducer not
o
pen, (no power steering
fluid flow).
CHECK
the power steering fluid condition.
For additional information, REFER to the
Power Steering Fluid condition check in this section.
Steering transducer not o
pen, steering control
module (SCM) fault.
CHECK
the SCM and INSTALL a new SCM as

necessary.
Carry out th
e electrical checks and tests.
For additional information, REFER to the
Electrical Checks and Tests in this section.
Steering transducer not
o
pen, speedo signal error.
CHECK

the speedo circ
uit. For additional
information, REFER to the wiring diagrams.

CHECK
the power steering
fluid low pressure pipe for restricted flow.
INSTALL a ne
w power steering fluid low
pressure pipe.
S t
eering heavy operation
during rapid manoeuvring
Ai r i
n power steering
system.
CHECK for an air l
eak into the power
steering system and re pair as necessary.
BLEED the
power steering system. For
additional information,
REFER to Power Steering System Bleeding
- in t hi
s section.
Fluid loss at the power
steering pump shaft seal.
CHECK the power steer
ing pump for signs o
f steering fl
ui
d loss.
INST
ALL a ne
w power steering pump as
necessary. For additi onal information,
REFER to Section 211
-0 2
Power Steering
.
Power steeri
ng f
luid
delivery pressure or flow too low.
CHECK the power steer
ing pump for signs o
f steering fl
ui
d loss.
CHECK

the power stee
ring pressure. For
additional information, REFER to the Power Steering Pressure Test in this section.
INSTALL a ne
w power steering pump as
necessary. For additi onal information,
REFER to Section 211
-02
Power Steering
.
Lower steeri
ng col
umn
interference.
CHECK
the steering co
lumn is free from
interference from the en gine harness, sound
proofing or the floor covering.
Incorrect steering geometry. CHE
CK the front wheel alignment. For
additional information,
REFER to Section 204
-00 Sus
pension
Sy
ste
m
- General

Information
.
CHECK

the power stee
ring pressure. For