Jaguar 2000-06

Upper Control Arms

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Removal & Installation




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.

  1. Raise front of vehicle and support on stands.
  2.  
  3. Remove front wheel.
  4.  
  5. Release ABS speed sensor harness from upper control arm.
  6.  
  7. Remove tie straps. Reposition harness.
  8.  
  9. Remove nut from upper ball joint.
  10.  


NOTE
Do not allow the weight of the vertical link to hang on the brake hose.

  1. Release upper ball-joint from vertical link.
  2.  
  3. Using a strong length of wire secure the vertical link to the shock absorber.
  4.  
  5. Install special tool to ball joint. Tighten tool bolt to release ball joint pin-taper.
  6.  
  7. Remove tool and disengage ball joint from vertical link.
  8.  


NOTE
For installation reference, note the position of washers and shims before removing fulcrum bolt.

  1. Remove nut. Remove fulcrum bolt. Collect washers and shims. Remove control arm.
  2.  

To install:

  1. Align control arm to crossbeam.
  2.  
  3. Install fulcrum bolt, shims and washers to their original positions as noted in the removal section. Install and tighten nuts to (80 Nm).
  4.  
  5. Install upper ball joint to vertical link.
  6.  
  7. Engage ball joint stud into vertical link. Install and tighten nut to (80 Nm).
  8.  
  9. Release vertical link from shock absorber.
  10.  
  11. Secure ABS harness to upper control arm.
  12.  
  13. Position harness and secure with tie clips.
  14.  
  15. Install wheel.
  16.  
  17. Remove stands and lower vehicle.
  18.  


    Click image to see an enlarged view

    Fig. Shim and washer positioning- XK Range



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.

  1. Raise front of vehicle and support on stands.
  2.  
  3. Remove front wheel.
  4.  
  5. Release ABS speed sensor harness from upper control arm.
  6.  
  7. Remove tie straps. Reposition harness.
  8.  
  9. Remove nut from upper ball joint.
    NOTE
    Do not allow the weight of the vertical link to hang on the brake hose.

  10.  
  11. Release upper ball-joint from vertical link.
  12.  
  13. Using a strong length of wire secure the vertical link to the shock absorber.
  14.  
  15. Install special tool to ball joint. Tighten tool bolt to release ball joint pin-taper.
  16.  
  17. Remove tool and disengage ball joint from vertical link.
    NOTE
    For installation reference, note the position of washers and shims before removing fulcrum bolt.

  18.  
  19. Remove nut. Remove fulcrum bolt. Collect washers and shims. Remove control arm.
  20.  

To install:

  1. Align control arm to crossbeam.

    Click image to see an enlarged view

    Fig. Shim and washer positioning- XK Range

  2.  
  3. Install fulcrum bolt, shims and washers to their original positions as noted in the removal section. Install and tighten nuts to (80 Nm).
  4.  
  5. Install upper ball joint to vertical link.
  6.  
  7. Engage ball joint stud into vertical link. Install and tighten nut to (80 Nm).
  8.  
  9. Release vertical link from shock absorber.
  10.  
  11. Secure ABS harness to upper control arm.
  12.  
  13. Position harness and secure with tie clips.
  14.  
  15. Install wheel.
  16.  
  17. Remove stands and lower vehicle.
  18.  

Right Side
  1. Remove the shock absorber and spring assembly.
  2.  
  3. Remove the cabin air filter.
  4.  
  5. Remove the cabin air filter housing retaining nut.
  6.  
  7. Remove the cabin air filter housing.
  8.  
  9. Remove the engine compartment support.
  10.  
  11. Remove the engine compartment panel.
  12.  
  13. Detach the wiring harness mounting bracket.
  14.  
  15. Remove the upper arm-to-knuckle ball stud nut.
  16.  
  17. Detach the engine compartment battery junction box.
  18.  
  19. Release the engine compartment battery junction box retaining clips.
  20.  
  21. Detach the engine compartment battery junction box.
  22.  
  23. Detach the hydraulic control unit.
  24.  
  25. Remove the upper arm-to-frame retaining nuts.
  26.  
  27. Remove the upper arm.
  28.  

To install:

  1. Install the upper arm.
  2.  
  3. Install the upper arm-to-knuckle ball stud retaining nut. Use a new cotter pin. Torque to 67 ft. lbs. (90 Nm).
  4.  
  5. Install the upper arm-to-frame retaining nuts. Torque to 35 ft. lbs. (47 Nm).
  6.  
  7. Install the shock absorber and spring assembly.
  8.  


NOTE
The final tightening of the upper arm retaining nut must be carried out with the vehicle on its wheels.

  1. Attach the hydraulic control unit.
  2.  
  3. Attach the engine compartment battery junction box.
  4.  
  5. Attach the engine compartment battery junction box.
  6.  
  7. Attach the wiring harness mounting bracket.
  8.  
  9. Install the engine compartment panel.
  10.  
  11. Install the engine compartment support.
  12.  
  13. Install the cabin air filter housing.
  14.  
  15. Install the cabin air filter housing retaining nut.
  16.  
  17. Install the cabin air filter.
  18.  

Through VIN F59525
  1. Raise front of vehicle.
  2.  
  3. Position camber tie down special tool 204-114 on suspension.
  4.  
  5. Fully loosen tool adjuster nut.
  6.  
  7. Position tool in road spring and pass upper dowel through slot in suspension turret.
  8.  
  9. Lower front of vehicle.
  10.  
  11. Rotate stem of special tool 204-114 to locate dowel in suspension turret slot.
  12.  


    Click image to see an enlarged view

    Fig. Position camber tie down special tool 204-114 on suspension-2001-03 through VIN F59525



    Click image to see an enlarged view

    Fig. Rotate stem of special tool 204-114 to locate dowel in suspension turret slot-2001-03 through VIN F59525



NOTE
When tightening tool nut, use lower dowel as a guide to ensure that the tool stem does not rotate and disturb position of dowel in suspension turret.

  1. Fully tighten nut of special tool to achieve suspension mid-laden position.
  2.  
  3. Raise front of vehicle and support on stands.
  4.  
  5. Remove appropriate road wheel.
  6.  
  7. Remove tie straps securing wheel speed sensor harness to upper control arm.
  8.  
  9. Move steering to appropriate full lock for access to suspension.
  10.  
  11. Remove nut securing upper control arm ball joint to vertical link.
  12.  


NOTE
Do not use special tool 211-098 in the following procedure as this will damage the ball joint boot.

  1. Release control arm ball joint from vertical link.
  2.  
  3. Install special tool 204-192 on upper control arm ball joint. Tighten bolt of special tool to release ball joint taper from vertical link.
  4.  
  5. Remove special tool from ball joint.
  6.  
  7. Lift upper control arm to withdraw ball joint from vertical link.
  8.  


    Click image to see an enlarged view

    Fig. Ball joint separator tool-2001-03 through VIN F59525



NOTE
To prevent damage to lower ball joint, secure vertical link to road spring using strong wire.

  1. Remove upper control arm fulcrum nut and shaft and withdraw control arm from crossbeam. Check that ball joint boot is not punctured or deeply abraded.
  2.  

To install:

  1. Position control arm on crossbeam.
  2.  
  3. Install fulcrum shaft with threaded end rearward. Install nut and tighten to 59 ft. lbs. (80Nm).
  4.  
  5. Remove wire temporarily securing vertical link to road spring.
  6.  
  7. Position control arm to engage ball joint taper in vertical link.
  8.  
  9. Install nut securing ball joint to vertical link and tighten nut to 59 ft. lbs. (80Nm).
  10.  
  11. Reposition wheel speed sensor harness on control arm and secure with two tie straps.
  12.  
  13. Install road wheel.
  14.  
  15. Raise vehicle, remove stands and fully lower vehicle.
  16.  
  17. Fully loosen nut on special tool. Release dowel of special tool 204-114 from suspension turret slot.
  18.  
  19. Raise vehicle for access and remove special tool from suspension.
  20.  
  21. Fully lower vehicle.
  22.  
  23. Carry out steering geometry and wheel alignment checks and if necessary adjust.
  24.  

From VIN G00442
  1. Remove the air spring assembly.
  2.  
  3. Remove the cowl vent screen access panel.
  4.  
  5. Remove the upper arm rear retaining nut.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the upper arm front retaining nut.
  10.  
  11. Note the position of the upper arm retaining bolt locating tangs to aid installation.
  12.  
  13. Remove the upper arm.
  14.  

To install:



Click image to see an enlarged view

Fig. Make sure the upper arm retaining bolt locating tangs are correctly located-2003.5-04 FROM VIN G00442

  1. Make sure the upper arm retaining bolt locating tangs are correctly located.
  2.  


WARNING
Failure to follow this instruction may result in damage to the vehicle.

  1. Position the upper arm.
  2.  
  3. Install the upper arm front retaining nut.
  4.  
  5. Install the upper arm rear retaining nut.
  6.  
  7. Connect the arm to the knuckle. Torque the nut to 66 ft. lbs. (90 Nm).
  8.  
  9. Install the air spring assembly.
  10.  


NOTE
The final tightening of the upper arm-to-frame retaining nuts must be carried out with the vehicle on its wheels.

  1. Tighten the arm-to-frame nuts to 35 ft. lbs. (47 Nm).
  2.  
  3. Install the cowl vent screen access panel.
  4.  
  5. Install the air cleaner assembly.
  6.  

From VIN M45255 Left Side
  1. Remove the shock absorber and spring assembly.
  2.  
  3. Remove the cowl vent screen.
  4.  
  5. Disconnect the electrical connector.
  6.  
  7. Remove the brake pedal travel sensor.
  8.  
  9. Remove the brake pedal travel sensor retaining clip.
  10.  
  11. Remove the brake pedal travel sensor.
  12.  
  13. Remove the upper arm ball stud nut. Separate the upper arm from the knuckle.
  14.  
  15. Remove the air cleaner assembly.
  16.  
  17. Remove the upper arm-to-frame retaining nuts.
  18.  
  19. Remove the upper arm.
  20.  

To install:

Click image to see an enlarged view

Fig. Upper arm-to-frame nuts-2002.5-06 S-Type from VIN M45255

  1. Install the upper arm. Install the upper arm-to-frame retaining nuts. Tighten to 35 ft. lbs. (47 Nm).
  2.  
  3. Install the upper arm-to-knuckle stud nut retaining nut. Use a new cotter pin. Torque to 67 ft. lbs. (90 Nm).
  4.  
  5. Install the shock absorber and spring assembly.
    NOTE
    The final tightening of the upper arm-to-frame retaining nuts must be carried out with the vehicle on its wheels.

  6.  
  7. Install the air cleaner assembly.
  8.  
  9. Install the brake pedal travel sensor.
  10.  
  11. Install the brake pedal travel sensor retaining clip.
  12.  
  13. Connect the electrical connector.
  14.  
  15. Install the cowl vent screen.
  16.  

From VIN M45255 Right Side
  1. Remove the shock absorber and spring assembly.
  2.  
  3. Remove the cabin air filter.
  4.  
  5. Remove the cabin air filter housing retaining nut.
  6.  
  7. Remove the cabin air filter housing.
  8.  
  9. Remove the engine compartment support.
  10.  
  11. Remove the engine compartment panel.
  12.  
  13. Detach the wiring harness mounting bracket.
  14.  
  15. Remove the upper arm-to-knuckle ball stud nut.
  16.  
  17. Detach the engine compartment battery junction box.
  18.  
  19. Release the engine compartment battery junction box retaining clips.
  20.  
  21. Detach the engine compartment battery junction box.
  22.  
  23. Detach the hydraulic control unit.
  24.  
  25. Remove the upper arm-to-frame retaining nuts.
  26.  
  27. Remove the upper arm.
  28.  

To install:

  1. Install the upper arm.
  2.  
  3. Install the upper arm-to-knuckle ball stud retaining nut. Use a new cotter pin. Torque to 67 ft. lbs. (90 Nm).
  4.  
  5. Install the upper arm-to-frame retaining nuts. Torque to 35 ft. lbs. (47 Nm).
  6.  
  7. Install the shock absorber and spring assembly.
    NOTE
    The final tightening of the upper arm retaining nut must be carried out with the vehicle on its wheels.

  8.  
  9. Attach the hydraulic control unit.
  10.  
  11. Attach the engine compartment battery junction box.
  12.  
  13. Attach the engine compartment battery junction box.
  14.  
  15. Attach the wiring harness mounting bracket.
  16.  
  17. Install the engine compartment panel.
  18.  
  19. Install the engine compartment support.
  20.  
  21. Install the cabin air filter housing.
  22.  
  23. Install the cabin air filter housing retaining nut.
  24.  
  25. Install the cabin air filter.
  26.  

Through VIN M45254
  1. Raise and support the vehicle.
  2.  
  3. Remove the wheel.
  4.  
  5. Detach the upper arm from the wheel knuckle.
  6.  
  7. Remove the upper arm-to-frame bolts.
  8.  
  9. Remove the upper arm.
  10.  
  11. To install, reverse the removal procedure. Torque all fasteners to 90 Nm.
  12.  

 
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