Jaguar 2000-06

Brake Caliper 1

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Removal & Installation



From VIN M45255 Without Brembo Brakes
  1. Remove the luggage compartment floor covering.
  2.  
  3. Remove the luggage compartment trim panel.
  4.  
  5. Remove the luggage compartment side trim panel.
  6.  
  7. Disconnect the parking brake module electrical connector.
  8.  
  9. Connect the special tool to the parking brake module wiring harness electrical connector.
  10.  
  11. Operate the parking brake release tool until an audible noise is heard from the parking brake release actuator.
  12.  
  13. Release the parking brake cable tension.
  14.  
  15. Remove both rear wheels and tires.
  16.  
  17. Reposition the brake caliper lever.
  18.  
  19. Detach the parking brake cable.
  20.  
  21. Release the retaining tangs.
  22.  
  23. Detach the parking brake cable from the bracket.
  24.  


    Click image to see an enlarged view

    Fig. Disconnect the parking brake module electrical connector-S-Type 2002.5-04 from VIN M45255 without Brembo brakes



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    Fig. Connect the special tool to the parking brake module wiring harness electrical connector-S-Type 2002.5-04 from VIN M45255 without Brembo brakes



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    Fig. Operate the parking brake release tool until an audible noise is heard from the parking brake release actuator-S-Type 2002.5-04 from VIN M45255 without Brembo brakes



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    Fig. Detach the parking brake cable from the lever-S-Type 2002.5-04 from VIN M45255 without Brembo brakes



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    Fig. Detach the parking brake cable from the bracket-S-Type 2002.5-04 from VIN M45255 without Brembo brakes



NOTE
The brake caliper must be supported at all times.

  1. 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).
  4.  
  5. Detach the brake hose. Remove and discard the sealing washers.
  6.  
  7. Remove and discard the brake caliper retaining bolts.
  8.  


    Click image to see an enlarged view

    Fig. Remove and discard the brake caliper retaining bolts-S-Type 2002.5-04 from VIN M45255 without Brembo brakes


To install:

  1. Install the brake caliper.
  2.  
  3. Install new brake caliper upper retaining bolts. 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. Attach the parking brake cable to the bracket.
  8.  
  9. Reposition the brake caliper lever. Attach the parking brake cable.
  10.  
  11. Remove the brake pedal hold-down tool.
  12.  
  13. Bleed the brake system.
  14.  
  15. Install both rear wheels and tires.
  16.  
  17. Remove the special tool.
  18.  
  19. Connect the parking brake module electrical connector.
  20.  
  21. Install the luggage compartment side trim panel.
  22.  
  23. Install the luggage compartment side trim panel retaining clips.
  24.  
  25. Install the luggage compartment trim panel.
  26.  
  27. Install the luggage compartment floor covering.
  28.  
  29. Apply the parking brake.
  30.  

From VIN M45255 With Brembo Brakes
  1. Remove the brake pads.
  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).
  4.  
  5. Cap the brake hose to prevent loss of fluid and dirt ingress.
  6.  
  7. Detach the brake hose. Remove and discard the sealing washers.
  8.  
  9. Remove and discard the brake caliper retaining bolts.
  10.  


    Click image to see an enlarged view

    Fig. Brake line bolt-S-Type 2002.5-04 from VIN M45255 with Brembo brakes



    Click image to see an enlarged view

    Fig. Brake caliper bolts-S-Type 2002.5-04 from VIN M45255 with Brembo brakes


To install:

  1. Install the brake caliper. Install new brake caliper retaining bolts. Tighten to 52 ft. lbs. (70 Nm).
  2.  
  3. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
  4.  
  5. Remove the brake pedal hold-down tool.
  6.  
  7. Install the brake pads.
  8.  
  9. Bleed the brake system.
  10.  

From VIN C00344 Through VIN D55321
  1. Remove the wheel and tire.
  2.  
  3. Release the parking brake tension. Detach the rear parking brake cable. Remove the parking brake cable retaining clip.
  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.
  6.  
  7. Install a bleeder bottle to the bleed nipple and loosen.
  8.  
  9. Remove and discard the brake hose sealing washers.
  10.  
  11. Detach the brake hose.
  12.  
  13. Tighten the bleed nipple and remove the bleeder tube and bottle.
  14.  
  15. Remove the brake caliper damper.
  16.  
  17. Remove and discard the brake caliper retaining bolts. Remove the brake caliper.
  18.  


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    Fig. Detach the rear parking brake cable



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    Fig. Brake hose bolt



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    Fig. Brake caliper damper-X-Type 2001.5-03 from VIN C00344 through VIN D55321



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    Fig. Brake caliper retaining bolts-X-Type 2001.5-03 from VIN C00344 through VIN D55321


To install:

  1. If the piston is pushed back into the housing, brake fluid will be forced out of the inlet port of the brake caliper.
  2.  


    Click image to see an enlarged view

    Fig. The left-hand brake caliper piston retracts counter clockwise and the right-hand retracts clockwise



NOTE
The left-hand brake caliper piston retracts counter clockwise and the right-hand retracts clockwise.

  1. Using the special tools, fully retract the brake caliper piston. Make sure the piston location mark is in the correct position so that the locator pin on the brake pad backing plate locates correctly into the piston.
  2.  


NOTE
Make sure that the brake disc faces are clean before installation.

  1. Install new brake caliper retaining bolts. Install the brake caliper. Tighten to 24 ft. lbs. (32 Nm).
  2.  
  3. Install the brake caliper damper. Tighten to 97 inch lbs. (11 Nm).
  4.  
  5. Install new brake hose sealing washers. Attach the brake hose. Tighten to 28 ft. lbs. (38 Nm).
  6.  
  7. Remove the brake pedal hold down tool.
  8.  
  9. Bleed the brake system.
  10.  
  11. Attach the parking brake cable retaining clip. Attach the rear parking brake cable.
  12.  
  13. Release the tension.
  14.  
  15. Attach the rear parking brake cable.
  16.  
  17. Install the wheel and tire.
  18.  

2001-03 Through XJ Range VIN F59525 Without Brembo Brakes 2001-04 Xk Range Without Brembo Brakes

NOTE
The brake pad adhesive backing must not be reused, therefore always Install new brake pads, irrespective of the condition of the original pads when replacing a brake caliper. Always replace brake pads as an axle set.

  1. Raise vehicle on a four-post lift.
  2.  
  3. Raise rear of vehicle and support on stands.
  4.  
  5. Remove rear wheel.
  6.  
  7. Open left front and left rear caliper bleed nipples.
  8.  
  9. Connect a bleed tube and container to the calipers.
  10.  
  11. Open bleed nipples. Depress and hold down brake pedal at the specified measurement using the special tool.
  12.  
  13. Position tool between brake pedal and seat frame. Turn the tool wheel until the brake pedal is held 60mm down from its released position.
  14.  
  15. Close bleed nipples on both calipers. Remove bleed tubes and containers.
  16.  
  17. Tighten front bleed nipple to 53 inch lbs. (6 Nm).
  18.  
  19. Tighten rear bleed nipple to 97 inch lbs. (11 Nm).
  20.  
  21. Disconnect brake hose from rear caliper housing.
  22.  
  23. Install plugs to caliper and brake hose.
  24.  
  25. Remove anti-rattle spring. Remove dust covers. Remove guide pins. Remove caliper from carrier.
  26.  


NOTE
The inner brake pad is fitted with a clip which secures the pad into the caliper piston.

  1. Remove and discard brake pads.
  2.  
  3. Remove bolts. Remove carrier.
  4.  
  5. Clean all mating surfaces and Remove brake dust.
  6.  


    Click image to see an enlarged view

    Fig. Rear caliper carrier bolts-XJ Range 2001-03 through VIN F59525 without Brembo brakes; 2001-04 XK Range without Brembo brakes



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    Fig. Rear caliper parts (1) anti-rattle spring (2) dust covers (3) caliper pins (4) caliper-XJ Range 2001-03 through VIN F59525 without Brembo brakes; 2001-04 XK Range without Brembo brakes



    Click image to see an enlarged view

    Fig. Rear caliper brake line union bolt-XJ Range 2001-03 through VIN F59525 without Brembo brakes; 2001-04 XK Range without Brembo brakes


To install

  1. Install caliper carrier to hub carrier. Install and tighten bolts to 44 ft. lbs. (60 Nm).
  2.  


NOTE
Make sure piston is fully retracted into caliper housing.

  1. Remove plug from caliper housing.
  2.  
  3. Retract piston.
  4.  
  5. Install brake pads into caliper housing.
  6.  
  7. Remove paper backing from pads to reveal adhesive shim.
  8.  
  9. Install brake pads, insert clip located on back of inner pad into caliper piston.
  10.  
  11. Install caliper housing to caliper carrier.
  12.  
  13. Install and tighten guide pins to 18-22 ft. lbs. (25-30 Nm).
  14.  
  15. Install dust covers.
  16.  
  17. Install anti-rattle spring.
  18.  
  19. Connect brake hose to caliper housing.
  20.  
  21. Install and tighten bolt to 22-29 ft. lbs. (30-40 Nm).
  22.  
  23. Remove special tool from brake pedal.
  24.  
  25. Install wheels.
  26.  
  27. Remove stands and lower vehicle.
  28.  
  29. Bleed brake hydraulic system.
  30.  

From VIN G00442 Without Brembo Brakes
  1. Move the selector lever to the -P- position.
  2.  
  3. Release the parking brake.
  4.  
  5. Remove the luggage compartment floor covering.
  6.  
  7. Remove the luggage compartment side trim panel.
  8.  
  9. Disconnect the parking brake module electrical connector.
  10.  
  11. Connect the special tool to the parking brake module wiring harness electrical connector.
  12.  
  13. Operate the parking brake release tool until an audible noise is heard from the parking brake release actuator.
  14.  
  15. Release the parking brake cable tension.
  16.  
  17. Remove the special tool.
  18.  
  19. Remove both rear wheels.
  20.  
  21. Reposition the brake caliper lever.
  22.  
  23. Detach the parking brake cable.
  24.  
  25. Release the retaining tangs. Detach the parking brake cable.
  26.  
  27. The brake caliper must be supported at all times.
  28.  
  29. Cap the brake hose to prevent loss of fluid and prevent dirt ingress.
  30.  
  31. 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).
  32.  
  33. Detach the brake hose. Discard the sealing washers.
  34.  
  35. Remove and discard the brake caliper retaining bolts. Remove the brake caliper.
  36.  


    Click image to see an enlarged view

    Fig. Parking brake module electrical connector-XJ Range 2003.5-04 from VIN G00442 without Brembo brakes



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    Fig. Parking brake release tool-XJ Range 2003.5-04 from VIN G00442 without Brembo brakes



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



    Click image to see an enlarged view

    Fig. Caliper mounting bolts-XJ Range 2003.5-04 from VIN G00442 without Brembo brakes


To install:

  1. Install the brake caliper. Install new brake caliper upper retaining bolts. Tighten to 25 ft. lbs. (34 Nm).
  2.  
  3. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
  4.  
  5. Reposition the brake caliper lever. Attach the parking brake cable.
  6.  
  7. Remove the brake pedal hold-down tool.
  8.  
  9. Bleed the brake system.
  10.  
  11. Install both rear wheels.
  12.  
  13. Connect the parking brake module electrical connector.
  14.  
  15. Install the luggage compartment side trim panel.
  16.  


NOTE
The brake pedal must be applied when calibrating the parking brake switch.

  1. Apply the parking brake.
  2.  

2001-03 XJ Range Through VIN F59525 With Brembo Brakes 2001-04 Xk Range With Brembo Brakes

NOTE
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 hub carrier only. DO NOT loosen any other caliper bolts.

  1. Raise front of vehicle and support on stands.
  2.  
  3. Open left front and left rear caliper bleed nipples.
  4.  
  5. Connect a bleed tube and container to the calipers.
  6.  
  7. Open bleed nipples.
  8.  
  9. Depress and hold down brake pedal at the specified measurement using the special tool. Position tool between brake pedal and seat frame.
  10.  
  11. 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 12-16 Nm.
  14.  
  15. Remove bleed tubes and containers.
  16.  
  17. Remove union bolt and brake hose. Remove and discard sealing washers. Install plugs into caliper and hose.
  18.  
  19. Remove pins from caliper. Remove anti-rattle spring. Remove brake pads.
  20.  
  21. Remove bolts and remove caliper from hub carrier.
  22.  
  23. Remove brake dust and clean mating surfaces.
  24.  


    Click image to see an enlarged view

    Fig. Brake hose union bolt-XJ Range 2001-03 through VIN F59525 with Brembo brakes; 2001-04 XK Range with Brembo brakes



    Click image to see an enlarged view

    Fig. Brake pads, pins and anti-rattle spring-XJ Range 2001-03 through VIN F59525 with Brembo brakes; 2001-04 XK Range with Brembo brakes



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    Fig. Removing the caliper-XJ Range 2001-03 through VIN F59525 with Brembo brakes; 2001-04 XK Range with Brembo brakes



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    Fig. The brake hose must be aligned as shown-XJ Range 2001-03 through VIN F59525 with Brembo brakes; 2001-04 XK Range with Brembo brakes


To install:

  1. Install caliper to hub carrier. Install and tighten bolts to 44 ft. lbs. (60 Nm).
  2.  
  3. Retracting the caliper piston may cause the fluid reservoir to over-flow.
  4.  
  5. Note the condition of the pins and replace if necessary.
  6.  
  7. Slowly retract caliper pistons. Install pads. Position anti-rattle spring. Install pins. Make sure pin collets are fully engaged into caliper.
  8.  


WARNING
The brake hose must only be installed with the vehicle's body supported and the suspension hanging. It is important that the brake hose is aligned correctly when installed to prevent it fouling on the steering and suspension components. After installation the brake hose must be aligned with the center line as shown.

  1. Install brake hose to caliper.
  2.  
  3. Remove plugs from caliper and hose. Install new sealing washers. Install and tighten union bolt to 16-19 ft. lbs. (22-26 Nm).
  4.  
  5. Remove special tool from brake pedal.
  6.  
  7. Install wheels.
  8.  
  9. Make sure the brake hose is routed correctly.
  10.  
  11. Remove stands and lower vehicle
  12.  

From VIN G00442 With Brembo Brakes
  1. Remove the brake pads.
  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).
  4.  
  5. Cap the brake hose to prevent loss of fluid and prevent dirt ingress.
  6.  
  7. Detach the brake hose. Remove and discard the sealing washers.
  8.  
  9. Remove the brake caliper. Remove and discard the brake caliper retaining bolts.
  10.  


    Click image to see an enlarged view

    Fig. Brake pipe union bolt-XJ Range 2003.5-04 from VIN G00442 with Brembo brakes



    Click image to see an enlarged view

    Fig. Brake caliper mounting bolts-XJ Range 2003.5-04 from VIN G00442 with Brembo brakes


To install:

  1. Install the brake caliper. Install new brake caliper retaining bolts. Tighten to 52 ft. lbs. (70 Nm).
  2.  
  3. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
  4.  
  5. Remove the brake pedal hold-down tool. Install the brake pads.
  6.  
  7. Bleed the brake system.
  8.  

 
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