Jaguar 2000-06

Brake Caliper 2

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Removal & Installation



With Brembo Brakes

NOTE
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.


WARNING
The Brembo caliper is aligned to the brake disc when it is first installed to the vehicle, therefore, care must be taken not to disturb this alignment. When removing the caliper; remove the bolts that secure the anchor bracket to the vertical link only. DO NOT loosen any other caliper bolts.

  1. Raise front of vehicle and support on stands.
  2.  
  3. Remove front wheels.
  4.  
  5. Open left front and left rear caliper bleed nipples.
  6.  
  7. Connect a bleed tube and container to the calipers.
  8.  
  9. Open bleed nipples.
  10.  
  11. Depress and hold down brake pedal at the specified measurement using the special tool. Position tool between brake pedal and seat frame. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
  12.  
  13. Close bleed nipples on both calipers. Tighten bleed nipples to 9-12 ft. lbs. (12-16 Nm).
  14.  
  15. Remove bleed tubes and containers.
  16.  
  17. Disconnect brake hose from brake tube. Unscrew brake tube union nut.
  18.  
  19. Remove nut from hose.
  20.  
  21. Remove hose from bracket.
  22.  
  23. Remove union bolt. Release brake hose from caliper. Remove and discard sealing washers.
  24.  
  25. Install plugs into caliper and hose.

    Click image to see an enlarged view

    Fig. Brake pads and related parts. (1) R-clips (2) pins (3) anti-rattle spring (4) pads-XJ Range 2002-03 VIN F41863-VIN F59525 with Brembo brakes; XK Range 2002-04 with Brembo brakes

  26.  
  27. Remove R-clips. Remove pins from caliper.
  28.  
  29. Remove anti-rattle spring.
  30.  
  31. Remove brake pads.
    WARNING
    Only remove the bolts securing the caliper anchor bracket to the vertical link.



    Click image to see an enlarged view

    Fig. Remove only these bolts-XJ Range 2002-03 VIN F41863-VIN F59525 with Brembo brakes; XK Range 2002-04 with Brembo brakes

  32.  
  33. Remove bolts. Remove caliper from vertical link.
  34.  
  35. Remove brake dust and clean mating surfaces.
  36.  

To install

  1. Install caliper to vertical link. Install and tighten bolts to 133 ft. lbs. (180 Nm).
    NOTE
    Retracting the caliper piston may cause the fluid reservoir to overflow. Remove brake fluid spillage immediately from paint work, with clean water.


    NOTE
    Note the condition of pins and R-clips and replace if necessary.

  2.  
  3. Install brake pads into caliper.
  4.  
  5. Slowly retract caliper pistons.
  6.  
  7. Install pads.
  8.  
  9. Position anti-rattle spring. Install pins. Install R-clips.
    NOTE
    The brake hose must only be installed with the vehicle's body supported and the suspension hanging.

  10.  
  11. Using new sealing washers, install and tighten union bolt to 16-19 ft. lbs. (22-26 Nm). Make sure the brake hose does not twist when tightening the hose lock-nut.
  12.  
  13. Connect brake hose to brake tube. Position hose thread through bracket. Install and tighten locking nut to 11-15 ft. lbs. (15-20 Nm.)
  14.  
  15. Install and tighten brake-tube union nut to 16-19 ft. lbs. (22-26 Nm).
  16.  
  17. Remove special tool from brake pedal.
  18.  
  19. Install wheels.
    NOTE
    Make sure the brake hose is routed correctly.

  20.  
  21. Remove stands and lower vehicle.
  22.  
  23. Bleed brake hydraulic system.
  24.  

VIN G00442-45703 Without Brembo Brakes
  1. Remove the brake pads.
    NOTE
    The brake caliper must be supported at all times.


    NOTE
    Cap the brake hose to prevent loss of fluid and dirt ingress.

  2.  
  3. To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40 mm (1.6 in).

    Click image to see an enlarged view

    Fig. Brake line union bolt-XJ Range 2003.5-04 from VIN G00442 without Brembo brakes



    Click image to see an enlarged view

    Fig. Brake caliper upper bolt-XJ Range 2003.5-04 from VIN G00442 without Brembo brakes

  4.  
  5. Detach the brake hose.
  6.  
  7. Remove and discard the sealing washers.
  8.  
  9. Remove the brake caliper. Remove and discard the brake caliper upper retaining bolt.
  10.  

To install:

  1. Install the brake caliper.
  2.  
  3. Install a new brake caliper upper retaining bolt. Tighten to 25 ft. lbs. (34 Nm).
  4.  
  5. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
  6.  
  7. Remove the brake pedal hold-down tool.
  8.  
  9. Install the brake pads.
  10.  
  11. Bleed the brake system.
  12.  

VIN G45703-99999 Without Brembo Brakes
  1. Remove both front wheels and tires.
  2.  
  3. Remove the anti-rattle spring.
    WARNING
    Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling, as prolonged contact may cause irritation and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.

  4.  
  5. If brake fluid comes into contact with the paintwork, the affected area must be immediately washed down with cold water.
  6.  
  7. Cap the brake hose to prevent loss of fluid and dirt ingress.
    NOTE
    To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40 mm (1.6 in).

  8.  
  9. Detach the brake hose. Remove and discard the sealing washers.
  10.  
  11. Remove the brake caliper retaining bolt dust covers.
  12.  
  13. Remove the brake caliper retaining bolts.
  14.  
  15. Remove the brake caliper.
    CAUTION
    Do not allow the brake caliper to hang on the hydraulic hose, as this will damage the hose. Failure to follow this instruction will result in damage to the hose.

  16.  
  17. Remove the brake pad from the caliper piston.
  18.  
  19. Remove the brake pad.
  20.  

To install:


WARNING
Do not use compressed air to disperse brake dust into the atmosphere.


CAUTION
Brake pads must always be replaced in axle sets.


CAUTION
Make sure the brake disc faces are clean before installation.

  1. Install the brake pad. Using a suitable tool, fully retract the brake caliper piston.
    NOTE
    Make sure the brake pad is correctly installed to the caliper piston.

  2.  
  3. Install the brake pad to the caliper piston.
  4.  
  5. Install the brake caliper.
  6.  
  7. Install the brake caliper retaining bolts. Tighten to 28 Nm.
  8.  
  9. Install the brake caliper retaining bolt dust covers.
  10.  
  11. Attach the brake hose. Install new sealing washers. Tighten to 35 Nm.
  12.  
  13. Install the anti-rattle spring.
  14.  
  15. Remove the brake pedal hold-down tool.
  16.  
  17. Bleed the brake system.
  18.  
  19. Install both front wheels and tires.
  20.  

Vin 45255-N52047 With Brembo Brakes


Click image to see an enlarged view

Fig. Front caliper bolts-S-Type 2002.5 and later VIN45255-N52047 with Brembo brakes



Click image to see an enlarged view

Fig. Brake hose union bolt-S-Type 2002.5 and later VIN45255-N52047 with Brembo brakes

  1. Remove the brake pads.
    NOTE
    To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40 mm (1.6 in).

  2.  
  3. Cap the brake hose to prevent loss of fluid and dirt ingress.
  4.  
  5. Detach the brake hose. Remove and discard the sealing washers.
  6.  
  7. Remove the brake caliper. Discard the brake caliper retaining bolts.
  8.  

To install:

  1. Install the brake caliper.
  2.  
  3. Install new brake caliper retaining bolts. Tighten to 157 ft. lbs. (212 Nm).
  4.  
  5. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
  6.  
  7. Remove the brake pedal hold-down tool.
  8.  
  9. Install the brake pads.
  10.  
  11. Bleed the brake system.
  12.  

VIN N52048-99999 With Brembo Brakes
  1. Remove both front wheels and tires.
  2.  
  3. Remove the anti-rattle spring.
    WARNING
    Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling, as prolonged contact may cause irritation and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.


    CAUTION
    If brake fluid comes into contact with the paintwork, the affected area must be immediately washed down with cold water.


    CAUTION
    Cap the brake hose to prevent loss of fluid and dirt ingress.


    NOTE
    To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40 mm (1.6 in).

  4.  
  5. Detach the brake hose. Remove and discard the sealing washers.
  6.  
  7. Remove the brake caliper retaining bolt dust covers.
  8.  
  9. Remove the brake caliper retaining bolts.
  10.  
  11. Remove the brake caliper.
    CAUTION
    Do not allow the brake caliper to hang on the hydraulic hose, as this will damage the hose. Failure to follow this instruction will result in damage to the hose.

  12.  
  13. Remove the brake pad from the caliper piston.
  14.  
  15. Remove the brake pad.
  16.  

To install:


WARNING
Do not use compressed air to disperse brake dust into the atmosphere.


CAUTION
Brake pads must always be replaced in axle sets.


CAUTION
Make sure the brake disc faces are clean before installation.

  1. Install the brake pad. Using a suitable tool, fully retract the brake caliper piston.
    NOTE
    Make sure the brake pad is correctly installed to the caliper piston.

  2.  
  3. Install the brake pad to the caliper piston.
  4.  
  5. Install the brake caliper.
  6.  
  7. Install the brake caliper retaining bolts. Tighten to 58 Nm.
  8.  
  9. Install the brake caliper retaining bolt dust covers.
  10.  
  11. Attach the brake hose. Install new sealing washers. Tighten to 35 Nm.
  12.  
  13. Install the anti-rattle spring.
  14.  
  15. Remove the brake pedal hold-down tool.
  16.  
  17. Bleed the brake system.
  18.  
  19. Install both front wheels and tires.
  20.  

VIN N52048-99999 Without Brembo Brakes
  1. Remove both front wheels and tires.
  2.  
  3. Remove the anti-rattle spring.
    WARNING
    Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly after handling, as prolonged contact may cause irritation and dermatitis. If brake fluid contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. If taken internally do not induce vomiting, seek immediate medical attention. Failure to follow these instructions may result in personal injury.


    CAUTION
    If brake fluid comes into contact with the paintwork, the affected area must be immediately washed down with cold water.


    CAUTION
    Cap the brake hose to prevent loss of fluid and dirt ingress.


    NOTE
    To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40 mm (1.6 in).

  4.  
  5. Detach the brake hose. Remove and discard the sealing washers.
  6.  
  7. Remove the brake caliper retaining bolt dust covers.
  8.  
  9. Remove the brake caliper retaining bolts.
  10.  
  11. Remove the brake caliper.
    CAUTION
    Do not allow the brake caliper to hang on the hydraulic hose, as this will damage the hose. Failure to follow this instruction will result in damage to the hose.

  12.  
  13. Remove the brake pad from the caliper piston.
  14.  
  15. Remove the brake pad.
  16.  

To install:


WARNING
Do not use compressed air to disperse brake dust into the atmosphere.


CAUTION
Brake pads must always be replaced in axle sets.


CAUTION
Make sure the brake disc faces are clean before installation.

  1. Install the brake pad. Using a suitable tool, fully retract the brake caliper piston.
    NOTE
    Make sure the brake pad is correctly installed to the caliper piston.

  2.  
  3. Install the brake pad to the caliper piston.
  4.  
  5. Install the brake caliper.
  6.  
  7. Install the brake caliper retaining bolts. Tighten to 28 Nm.
  8.  
  9. Install the brake caliper retaining bolt dust covers.
  10.  
  11. Attach the brake hose. Install new sealing washers. Tighten to 35 Nm.
  12.  
  13. Install the anti-rattle spring.
  14.  
  15. Remove the brake pedal hold-down tool.
  16.  
  17. Bleed the brake system.
  18.  
  19. Install both front wheels and tires.
  20.  

VIN N45255-52047 Without Brembo Brakes


Click image to see an enlarged view

Fig. Brake union bolt-S-Type 2002.5 and later VIN 45255-52047 without Brembo brakes



Click image to see an enlarged view

Fig. Caliper mounting bolts-S-Type 2002.5 and later VIN 45255-52047 without Brembo brakes

  1. Remove the brake pads.
    NOTE
    The brake caliper must be supported at all times.

  2.  
  3. Cap the brake hose to prevent loss of fluid and dirt ingress.
  4.  
  5. To prevent the loss of brake fluid, apply the brake pedal hold-down tool and adjust to hold the brake pedal down 40 mm (1.6 in).
  6.  
  7. Detach the brake hose.
  8.  
  9. Remove and discard the sealing washers.
  10.  
  11. Remove the brake caliper.
  12.  
  13. Remove and discard the brake caliper upper retaining bolt.
  14.  

To install:

  1. Install the brake caliper.
  2.  
  3. Install a new brake caliper upper retaining bolt. Tighten to 25 ft. lbs. (34 Nm).
  4.  
  5. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
  6.  
  7. Remove the brake pedal hold-down tool.
  8.  
  9. Install the brake pads.
  10.  
  11. Bleed the brake system.
  12.  

 
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