suspension system JAGUAR XFR 2010 1.G Service Manual

Brake System - General Information - Brake System
Diagnosis and Testing

Principle of Operation Published: 11-May-2011

For a detailed description of the brake system, refer to the relevant Description and Operation sections in the workshop
manual. REFER to:

Front Disc Brake (206-03, Description and Operation),
Front Disc Brake (206-03, Description and Operation),
Front Disc Brake (206-03, Description and Operation),
Rear Disc Brake (206-04, Description and Operation),
Rear Disc Brake (206-04, Description and Operation),
Rear Disc Brake (206-04, Description and Operation),
Parking Brake (206-05 Parking Brake and Actuation, Description and Operation), Parking Brake (206-05 Parking Brake and Actuation, Description and Operation), Parking Brake (206-05 Parking Brake and Actuation, Description and Operation), Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Description and Operation), Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Description and Operation), Hydraulic Brake Actuation (206-06 Hydraulic Brake Actuation, Description and Operation), Brake Booster (206-07 Power Brake Actuation, Description and Operation), Brake Booster (206-07 Power Brake Actuation, Description and Operation), Brake Booster (206-07, Description and Operation).

Inspection and Verification

Visually examine the front and rear wheel and tire assemblies for damage such as uneven wear patterns, tread worn out or
sidewall damage. Verify the tires are the same size, type and, where possible, same manufacturer. Replace the damaged
wheel or excessively worn tire.
Wheels and tires must be cleared of any foreign matter and tire pressures adjusted 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 necessary, check and adjust front wheel alignment. REFER to: (204-00 Suspension System - General
Information)
Specifications (Specifications), Front Toe Adjustment (General Procedures).
Visual Inspection
Mechanical Electrical
Brake master cylinder
Brake caliper piston(s)
Brake discs
Wheel bearings
Brake pads
Power brake booster
Brake pedal linkage
Brake booster vacuum hose
Tires
Debris
Parking brake actuator
Parking brake module
Parking brake switch
Damaged or corroded wiring harness
Brake master cylinder fluid level switch Road Test

Carry 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 comparisons 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 detect performance concerns.

An experienced brake technician will always establish a route that will be used for all brake diagnosis road tests. The roads
selected will be reasonably smooth and level. Gravel or bumpy roads are not suitable because the surface does not allow the
tires to grip the road equally. Crowned roads should be avoided because of the large amount of weight shifted to the low set
of wheels on this type of road. Once the 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 suspected condition. From the description, the
technician's experience will allow the technician to match possible causes with symptoms. Certain components will be tagged
as possible suspects while others will be eliminated by the evidence. More importantly, the customer description can reveal
unsafe conditions which should be checked 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 light and heavy pedal pressure. To determine if the concern is in the front or rear braking
system, use the brake pedal and then use the parking brake control. If the condition (pull, vibration, pulsation) occurs only
with the parking brake, the concern is in the rear brake system.

If the concern becomes evident during this check, verify it fits the description given before the road test. If the concern is not
evident, attempt to duplicate the condition using the information from the description.

If a concern exists, use the Symptom Chart in order to isolate it to a specific sub-system and condition description. From this
description, a list of possible sources can be used to further narrow the cause to a specific component or condition.

Symptom Chart

Symptom Possible Cause Action Brakes noisy
Brake pads
Brake discs GO to Pinpoint Test A. Vibration when brakes are
applied
Wheels/tires out of balance
Wheel hub nuts loose
Brake caliper mounting bolts loose
Brake pads
Foreign material/scratches/corrosion
on brake disc contact surfaces
Excessive brake disc thickness
variation
Excessive brake disc runout
Wheel bearing wear or failure
Suspension bushing wear or failure
Steering bushing wear or failure GO to Pinpoint Test B. The brakes pull or drift
Tire pressures/wear
Brake calipers
Brake pads
Brake discs
Wheel alignment adjustment
Wheel bearing
Suspension bushings and ball joints GO to Pinpoint Test C. The pedal feels spongy
Air in brake hydraulic system
Leak in hydraulic system
Brake booster/master cylinder
Brake pads GO to Pinpoint Test D. The pedal goes down fast
Air in brake hydraulic system
Leak in hydraulic system
Brake booster/master cylinder
Brake pads GO to Pinpoint Test E. The pedal goes down
slowly
Air in brake hydraulic system
Brake booster/master cylinder GO to Pinpoint Test F. Excessive brake pedal
effort required
Brake pads
Brake booster GO to Pinpoint Test G. Brake lockup during light
brake pedal force
Brake pads
Brake calipers GO to Pinpoint Test H. Brakes drag
Parking brake control
applied/malfunction
Seized parking brake cables
Seized brake caliper slide pins
Seized brake caliper
Brake booster
Pedal gear GO to Pinpoint Test I. Excessive/Erratic brake
pedal travel
Hydraulic system
Brake pads Brake
discs
Hub and bearing assembly GO to Pinpoint Test J. The red brake warning
indicator is always on
Fluid level
Brake master cylinder fluid level
sensor
Parking brake control Fill the system to specification. Check for leaks.
Install a new brake master cylinder fluid reservoir as
required.
REFER to: Brake Fluid Reservoir (206-06 Hydraulic Brake Actuation, Removal and Installation).

TEST
CONDITIONS DETAILS/RESULTS/ACTIONS C1: ROAD TEST VEHICLE 1 Road test the vehicle and apply the brake pedal. Does the vehicle pull or drift?
Yes
GO to C2. No
No action required, vehicle is OK. C2: INSPECT TIRE CONDITION/PRESSURE 1 Check for excessive tire wear or incorrect pressures. Are the tires at the correct pressure and in good condition?
Yes
GO to C3. No
Adjust the tire pressures or install new tires if excessively worn. Re-test the system for normal operation. C3: CHECK CALIPERS 1 Check the disc brake caliper pistons and pins for binding, leaking or sticking. Do the disc brake caliper pistons and pins bind, leak or stick?
Yes
Rectify sticking pins and install new brake calipers as required. REFER to:
Brake Caliper - Vehicles With: Standard Brakes (206-03A Front Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Caliper - Vehicles With: High Performance Brakes (206-03A Front Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Caliper (206-04A Rear Disc Brake - V6 3.0L Petrol, Removal and Installation), Brake Caliper - Vehicles With: High Performance Brakes (206-04, Removal and Installation).
Re-test the system for normal operation.
No
GO to C4. C4: INSPECT BRAKE DISCS 1 Check the brake discs for excessive damage, thickness variation or runout. REFER to: Brake Disc Runout Check (206-00 Brake System - General Information, General Procedures). Does excessive damage or runout exist?
Yes
Install new brake discs and brake pads as required. Re-test the system for normal operation.
No
GO to C5. C5: INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY 1 Check the front hub and wheel bearing assembly. Are the wheel bearings OK?
Yes
GO to C6. No
Install new wheel bearings as required.
REFER to: Front Wheel Bearing and Wheel Hub - V6 3.0L Petrol (204-01 Front Suspension, Removal and Installation).
Re-test the system for normal operation. C6: CHECK SUSPENSION BUSHINGS AND BALL JOINTS. 1 Check all suspension bushings and ball joints. Are the suspension bushings and ball joints OK?
Yes
GO to C7. No
Install new front suspension bushings and ball joints as required. Install new rear suspension bushings
and ball joints as required. Refer to the relevant section in the workshop manual. C7: CHECK VEHICLE ALIGNMENT 1 Check the vehicle alignment. REFER to: Front Subframe - 2.7L Diesel (502-00, Removal and Installation),
Front Subframe - V6 3.0L Petrol (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation),
Front Subframe - 4.2L (502-00, Removal and Installation). Is a vibration present?
Yes
Check for wear or failure of steering gear bushings. Check for wear or failure of steering gear ball joints.
Check for wear or failure of front wheel bearings, suspension bushings and ball joints. Check for wear or
failure of rear wheel bearings, suspension bushings and ball joints. Refer to relevant section in workshop
manual and install new components as required.
No
No action required, vehicle is OK.
www.JagDocs.com

Yes
Inspect the brake calipers and parking brake cables. Install new components as required. Re-test the
system for normal operation.
No
GO to I3. I3: CHECK BRAKE BOOSTER 1 Check the brake booster connecting rod alignment and travel. Is the connecting rod OK? Yes
Vehicle is OK.
No
Install a new brake booster as required. REFER to:
Brake Booster (206-07 Power Brake Actuation, Removal and Installation), Brake Booster - RHD (206-07, Removal and Installation).
Re-test the system for normal operation.
PINPOINT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL TEST
CONDITIONS DETAILS/RESULTS/ACTIONS J1: TEST ON ROUGH ROAD 1 Road test the vehicle on rough road conditions. 2 Apply the brakes slowly. Is the brake pedal effort and brake pedal travel normal?
Yes
No action required, vehicle is OK.
No
GO to J2. J2: CHECK BRAKE FLUID LEVEL 1 Check the brake master cylinder reservoir fluid level. Is the fluid level OK?
Yes
GO to J3. No
Check brake master cylinder reservoir sealing points. For additional information, refer to Brake master
cylinder component test in this section. Add brake fluid and bleed the brake system.
REFER to: Brake System Bleeding (206-00 Brake System - General Information, General Procedures). Re-test the system for normal operation. J3: CHECK BRAKE PEDAL RESERVE 1 Run engine at idle speed. 2 Apply the brake pedal lightly three or four times. 3 Wait 15 seconds for the vacuum to replenish. 4 Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs. 5 Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min. 6 Release the accelerator pedal. Does the brake pedal move downward as the engine speed returns to idle?
Yes
GO to J4. No
Check the vacuum to the brake booster. J4: CHECK THE FRONT WHEEL BEARING ASSEMBLY 1 Check the front wheel bearing assembly. Are the front wheel bearings loose/damaged?
Yes
Tighten to specification or install a new front wheel bearing as required.
REFER to: Front Wheel Bearing and Wheel Hub - V6 3.0L Petrol (204-01 Front Suspension, Removal and Installation).
Re-test the system for normal operation.
No
Check the front brake discs for thickness variances.
PINPOINT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN TEST
CONDITIONS DETAILS/RESULTS/ACTIONS K1: CHECK FOR BRAKE PEDAL RETURN 1 Run the engine at idle while making several brake applications. 2 Pull the brake pedal rearward with approximately 44.5 N (10lb) force. 3 Release the brake pedal and measure the distance to the toe board. 4 Make a hard brake application. 5 Release the brake pedal and measure the brake pedal to toe board distance. The brake pedal should return to its original position.

Brake System - General Information - Brake Disc Runout Check
General Procedures

Check Published: 01-Jul-2014

1. Remove the wheel and tire.
For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

2. Install all the wheel nuts and tighten equally to 20 Nm (15 lb.ft).
Make sure that the brake disc is fully seated against the hub
face.

3. Install a dial test indicator gauge and holding fixture to a suitable
mounting point.


4. NOTE: If the runout is outside specification, check the hub face
runout.

Using the dial test indicator, measure the inner and outer faces of the
brake disc. For additional information, refer to: (206-00 Brake System -
General Information)
Specifications - 3.0L NA V6 - AJ27 (Specifications), Specifications - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol (Specifications).
1. Position the gauge so that it contacts the disc 10 mm (0.4 in)
from the outer edge.
2. Slowly rotate the hub/disc assembly. Note the reading.

5. If a front hub runout check is required, remove the front brake disc. For
additional information, refer to:
Brake Disc - Vehicles With: Standard Brakes (206-03A Front Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Disc - Vehicles With: Standard Brakes (206-03B Front Disc Brake - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and
Installation),
Brake Disc - Vehicles With: High Performance Brakes (206-03A Front Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Disc - Vehicles With: High Performance Brakes (206-03B Front Disc Brake - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal
and Installation).

6. If a rear hub runout check is required, remove the rear brake disc. For
additional information, refer to:
Brake Disc (206-04A Rear Disc Brake - V6 3.0L Petrol, Removal and Installation),
Brake Disc - Vehicles With: High Performance Brakes (206-04B Rear Disc Brake - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal
and Installation),
Brake Disc - Vehicles With: Standard Brakes (206-04B Rear Disc Brake - TDV6 3.0L Diesel /V8 5.0L Petrol/V8 S/C 5.0L Petrol, Removal and
Installation).


7. NOTE: The hub surface should be free from dirt and corrosion. Do not
use abrasive cloths to clean hub faces.
Using the dial test indicator, measure the hub face runout.
1. Position the gauge so that it contacts the mounting tube
between the stud and the chamfer.
2. Slowly rotate the hub and note the runout. For additional
information, refer to the specification chart.
If the front hub runout exceeds the specifications, install a new
hub, brake disc and recheck. For additional information, refer to:
(204-01 Front Suspension)
Front Wheel Bearing and Wheel Hub - V6 3.0L Petrol (Removal and Installation),

7. Position the DTI probe 5 mm from the inner edge of the
disc.
Zero DTI and rotate road wheel one complete
revolution to measure disc runout.


















8. NOTE: The disc runout limit is 0.075 mm.

If the disc runout exceeds the limit check the hub drive flange and
bearing runout.
For additional information, refer to: Front Wheel Bearing and Wheel Hub Runout Check - Vehicles With: High Performance Brakes (204-00 Suspension System - General Information, General Procedures).

9. If hub runout is within the limit replace the brake disc.

10. Install the wheel.
Tighten the road wheel nuts in sequence as shown
above to the following:
Stage 1: 4 Nm.
Stage 2: 60 Nm.
Stage 3: 125 Nm.










11. Re-check the disc runout as detailed above.

7. Position the DTI probe in the centre of the disc.
Zero DTI and rotate road wheel one complete
revolution to measure disc runout.























8. Position the DTI probe 5 mm from the inner edge of the
disc.
Zero DTI and rotate road wheel one complete
revolution to measure disc runout.


















9. NOTE: The disc runout limit is 0.09 mm.

If the disc runout exceeds the limit check the hub drive flange and
bearing runout.
For additional information, refer to: Rear Wheel Bearing and Wheel Hub Runout Check - Vehicles With: High Performance Brakes (204-00 Suspension System - General Information, General Procedures).

10. If hub runout is within the limit replace the brake disc.

Steering System - General Information - Steering System
Diagnosis and Testing

Principle of Operation Published: 11-May-2011

For a detailed description of the steering system operation, refer to the relevant Description and Operation sections of the
workshop manual. REFER to:

Power Steering (211-02 Power Steering, Description and Operation), Power Steering (211-02 Power Steering, Description and Operation), Power Steering (211-02 Power Steering, Description and Operation), Steering Linkage (211-03 Steering Linkage, Description and Operation), Steering Linkage (211-03 Steering Linkage, Description and Operation), Steering Linkage (211-03 Steering Linkage, Description and Operation), Steering Column (211-04 Steering Column, Description and Operation), Steering Column (211-04 Steering Column, Description and Operation), Steering Column (211-04 Steering Column, Description and Operation), Steering Column Switches (211-05 Steering Column Switches, Description and Operation), Steering Column Switches (211-05 Steering Column Switches, Description and Operation), Steering Column Switches (211-05 Steering Column Switches, Description and Operation).
Inspection and Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of damage and system integrity.

Visual Inspection
Mechanical Electrical
Tire condition/pressure
Fluid level
Leaks
Security, condition and correct installation of suspension components
Security, condition and correct installation of steering system components
Fuses
Harnesses for damage/corrosion
Electrical connector(s)
Damaged/corroded pins
CAUTION: If a steering gear assembly is returned under warranty with leaking output shaft 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 output
shaft seals being damaged due to foreign materials entering the steering gear boot and damaging the steering gear output
shaft seals thereafter.

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to
the next step.
4. If the concern is not visually evident, verify the symptom and refer to the symptom chart.

Symptom Charts


WARNING: It is not possible to CHECK the torque of a patchlock bolt, if the torque is suspected to be low, the bolt must
be REMOVED/DISCARDED and a new bolt MUST be INSTALLED and torque to the correct value.


NOTE: If the module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to
the installation of a new module/component.

Fluid Leakage


NOTE: Confirm the location of the fluid leak. CLEAN the area of the leak, inspect the area and confirm the exact position.
Ensure the fluid is not from another system on the vehicle.

Symptom Possible Causes Action

Power steering
fluid leakage
Overfilled system
Correct the fluid level as required
Steering gear
Check and install new steering gear as required, refer to the new
module/component installation note at the top of the Symptom
Charts

Symptom Possible Causes Action
Damaged fluid
cap/reservoir
Check and install a new fluid cap/reservoir as required

Loose or damaged
hoses and fittings
O-ring or Dowty seals
Tighten the hose connection or latch plate fixing to the
recommended torque.
REFER to: Specifications (211-00 Steering System - General Information, Specifications).
Check and install new components as required
Install new O-ring or Dowty seals as required
Fluid cooler
Check and install a new fluid cooler as required, refer to the new
module/component installation note at the top of the Symptom
Charts
Power steering pump
Check and install a new power steering pump as required, refer to
the new module/component installation note at the top of the
Symptom Charts Functional

Symptom Possible Causes Action

Steering wheel
misalignment

Steering not correctly centred
Check the steering alignment.
REFER to: Specifications (204-00 Suspension System - General
Information, Specifications).


















Excessive free play at
steering wheel (refer to
the Steering Linkage
Inspection and Backlash
(Free play) Check in this
section)

Steering wheel loose
Check and tighten the steering
wheel retaining bolt as required.
REFER to: Specifications (211-00 Steering System - General
Information, Specifications).
Excess play in the steering linkage
Check and install new
components as required



Steering gear not correctly adjusted (causing
excessive backlash)
CAUTION: DO NOT attempt to
adjust the steering gear yoke. Failure to
follow this instruction will invalidate the
steering gear warranty

Check and install a new steering
gear as required, refer to the
new module/component
installation note at the top of
the Symptom Charts

Lower steering column universal joint pinch
bolts loose
Check and tighten the lower
steering column pinch bolts as
required.
REFER to: Specifications (211-00 Steering System - General
Information, Specifications).

Excessive wear in steering column universal
joints
Check and install a new steering
column or steering column lower
shaft as required, refer to the
new module/component
installation note at the top of
the Symptom Charts

Steering gear mounting bolts loose or
damaged
Check/tighten and install new
steering gear mounting bolts as
required.
REFER to: Specifications (211-00 Steering System - General
Information, Specifications). www.JagDocs.com

Symptom Possible Causes Action

Wear in steering gear tie-rod end ball joints
Check and install new tie-rod
ends as required, refer to the
new module/component
installation note at the top of
the Symptom Charts
NOTE: Inner ball joint wear is rare. The steering
gear installed to all Jaguar vehicles has a spring
loaded pinion to ensure the correct level of
engagement between the rack and pinion. This play
is optimized with the steering gear in the central
position and should not be confused with inner ball
joint wear. Check for vertical motion in the inner ball
joint with the steering gear in the central position.
Wear in steering gear inner ball joints


Check and install new steering
gear as required, refer to the
new module/component
installation note at the top of
the Symptom Charts
Wear in suspension ball joints/bushings
Check and install new
components as required















Veer under braking




Steering gear not correctly adjusted
CAUTION: DO NOT attempt to
adjust the steering gear yoke. Failure to
follow this instruction will invalidate the
steering gear warranty

Check and install a new steering
gear as required, refer to the
new module/component
installation note at the top of
the Symptom Charts


Contamination of brake pads and discs
Check and rectify the source of
the contamination and install
new brake pads and discs as
required, refer to the new
module/component installation
note at the top of the Symptom
Charts




Seized front brake caliper slide pins or piston
Damaged brake discs
Check and rectify sticking slide
pins and install new calipers as
required, refer to the new
module/component installation
note at the top of the Symptom
Charts
Check and install new brake discs
as required, refer to the new
module/component installation
note at the top of the Symptom
Charts








Vehicle pulls to one side
when driving on a level
surface




Uneven tire wear
Incorrect tire pressure
For information on diagnosis of
uneven tire wear.
REFER to: Suspension System (204-00 Suspension System -
General Information, Diagnosis
and Testing).
Check and adjust tire pressures
as required.
REFER to: Specifications (204-04 Wheels and Tires,
Specifications).


Incorrect geometry settings
NOTE: Dealerships must keep a
copy of the BEFORE and AFTER
geometry figures with job card for future
reference

Check and adjust geometry as
required. REFER to: (204-00