Jaguar 2000-06

Brake Caliper 2

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Removal & Installation



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.

    Click image to see an enlarged view

    Fig. Brake hose union bolt-XJ Range 2002-03 through VIN F59525 with Brembo brakes; 2002-04 XK Range with Brembo brakes



    Click image to see an enlarged view

    Fig. Brake pads, pins and anti-rattle spring-XJ Range 2002-03 through VIN F59525 with Brembo brakes; 2002-04 XK Range with Brembo brakes



    Click image to see an enlarged view

    Fig. Removing the caliper-XJ Range 2002-03 through VIN F59525 with Brembo brakes; 2002-04 XK Range with Brembo brakes



    Click image to see an enlarged view

    Fig. The brake hose must be aligned as shown-XJ Range 2002-03 through VIN F59525 with Brembo brakes; 2002-04 XK Range with Brembo brakes

  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.  

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.
    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.

  8.  
  9. Install brake hose to caliper.
  10.  
  11. Remove plugs from caliper and hose. Install new sealing washers. Install and tighten union bolt to 16-19 ft. lbs. (22-26 Nm).
  12.  
  13. Remove special tool from brake pedal.
  14.  
  15. Install wheels.
  16.  
  17. Make sure the brake hose is routed correctly.
  18.  
  19. Remove stands and lower vehicle
  20.  

VIN G00442-45703 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.

    Click image to see an enlarged view

    Fig. Brake pipe union bolt-XJ Range 2003.5-06 VIN G00442-45703 with Brembo brakes



    Click image to see an enlarged view

    Fig. Brake caliper mounting bolts-XJ Range 2003.5-06 VIN G00442-45703 with Brembo brakes

  10.  

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.  

VIN G00442-G45703 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.

    Click image to see an enlarged view

    Fig. Parking brake module electrical connector-XJ Range 2003.5-06 VIN G00442-45703 without Brembo brakes



    Click image to see an enlarged view

    Fig. Parking brake release tool-XJ Range 2003.5-06 VIN G00442-45703 without Brembo brakes

  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.

    Click image to see an enlarged view

    Fig. Brake pipe union bolt-XJ Range 2003.5-06 VIN G00442-45703 without Brembo brakes



    Click image to see an enlarged view

    Fig. Caliper mounting bolts-XJ Range 2003.5-06 VIN G00442-45703 without Brembo brakes

  36.  

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

  16.  
  17. Apply the parking brake.
  18.  

VIN G45708-G99999 With Or Without Brembo Brakes
  1. All vehicles:
    1. Carry out the parking brake cable tension release procedure.
    2.  
    3. Remove both rear wheels and tires.
    4.  
    5. Detach the parking brake cable.
    6.  

  2.  
  3. Vehicles with high performance brakes: Remove the logo badge.
  4.  
  5. All vehicles:
    1. Remove the anti-rattle spring.
      CAUTION
      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 prevent 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).

    2.  
    3. Detach the brake hose. Remove and discard the sealing washers.
    4.  
    5. Remove the brake caliper retaining bolt dust covers.
    6.  
    7. Remove the brake caliper retaining bolts.
    8.  
    9. Remove the brake caliper.
    10.  
    11. Remove the brake pads.
    12.  

  6.  

To install:

  1. All vehicles
    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.


    NOTE
    Make sure that the brake pad with the anti-rattle spring is installed to the inboard side of the brake disc.

    1. Install the brake pads.
      CAUTION
      As the piston is pushed back into the caliper housing, the brake fluid level in the reservoir will rise. Do not allow the reservoir to overflow.


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


      NOTE
      Only the extraction bolt from special tool 303-588 is used.


      NOTE
      Only the forcing plate from special tool 206-080 is used.

    2.  
    3. Using the special tools, fully retract the brake caliper piston.
    4.  
    5. Install the brake caliper. Tighten to 28 Nm.
    6.  
    7. Install the brake caliper retaining bolt dust covers.
    8.  
    9. Attach the brake hose. Install new sealing washers. Tighten to 28 ft. lbs. (35 Nm).
    10.  
    11. Install the anti-rattle spring.
    12.  

  2.  
  3. Vehicles with high performance brakes: Install the logo badge. Tighten to 44 inch lbs. (5 Nm).
  4.  
  5. All vehicles:
    1. Attach the parking brake cable.
    2.  
    3. Remove the brake pedal hold-down tool.
    4.  
    5. Bleed the brake system.
    6.  
    7. Install both rear wheels and tires.
    8.  

  6.  

From VIN D55322
  1. Remove the wheel and tire.
  2.  
  3. Release the tension.
  4.  
  5. Detach the parking brake cable.
  6.  
  7. Remove the parking brake cable retaining clip.
  8.  
  9. To prevent the loss of brake fluid, apply the brake pedal hold down tool and adjust to hold the brake pedal down 40mm.
  10.  
  11. Install a bleeder bottle to the bleed nipple and loosen.
  12.  
  13. Remove and discard the brake hose sealing washers.
  14.  
  15. Detach the brake hose.
  16.  
  17. Tighten the bleed nipple and remove the bleeder tube and bottle.
  18.  
  19. Remove the brake caliper. Discard the brake caliper retaining bolts.
    NOTE
    If the piston is pushed back into the housing, brake fluid will be forced out of the inlet port of the brake caliper.


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

  20.  
  21. 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.
  22.  
  23. Make sure that the brake disc faces are clean before installation.

    Click image to see an enlarged view

    Fig. Caliper mounting bolts-X-Type 2004-06

  24.  

To Install:

  1. Install new brake caliper retaining bolts. Install the brake caliper. Tighten to 24 ft. lbs. (32 Nm).
  2.  
  3. Install new brake hose sealing washers. Attach the brake hose. Tighten to 28 ft. lbs. (38 Nm).
  4.  
  5. Remove the brake pedal hold-down tool.
  6.  
  7. Bleed the brake system.
  8.  
  9. Attach the parking brake cable.
  10.  
  11. Install the wheel and tire.
  12.  

From VIN M45255-N52047 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.

    Click image to see an enlarged view

    Fig. Disconnect the parking brake module electrical connector-S-Type 2002.5-06 VIN M45255-N52047 without Brembo brakes

  6.  
  7. Disconnect the parking brake module electrical connector.

    Click image to see an enlarged view

    Fig. Connect the special tool to the parking brake module wiring harness electrical connector-S-Type 2002.5-06 VIN M45255-N52047 without Brembo brakes

  8.  
  9. Connect the special tool to the parking brake module wiring harness electrical connector.

    Click image to see an enlarged view

    Fig. Operate the parking brake release tool until an audible noise is heard from the parking brake release actuator-S-Type 2002.5-06 VIN M45255-N52047 without Brembo brakes

  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.

    Click image to see an enlarged view

    Fig. Detach the parking brake cable from the lever-S-Type 2002.5-06 VIN M45255-N52047 without Brembo brakes

  18.  
  19. Detach the parking brake cable.

    Click image to see an enlarged view

    Fig. Detach the parking brake cable from the bracket-S-Type 2002.5-06 VIN M45255-N52047 without Brembo brakes

  20.  
  21. Release the retaining tangs.
  22.  
  23. Detach the parking brake cable from the bracket.
    NOTE
    The brake caliper must be supported at all times.

  24.  
  25. Cap the brake hose to prevent loss of fluid and dirt ingress.
  26.  
  27. 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).
  28.  
  29. Detach the brake hose. Remove and discard the sealing washers.

    Click image to see an enlarged view

    Fig. Remove and discard the brake caliper retaining bolts-S-Type 2002.5-06 VIN M45255-N52047 without Brembo brakes

  30.  
  31. Remove and discard the brake caliper retaining bolts.
  32.  

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.  

Through VIN M45254
  1. Remove the wheel.
  2.  
  3. Release the retaining tangs. Detach the parking brake cable.
  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. Install a bleeder bottle to the bleed nipple and loosen.
  8.  
  9. Remove the brake pipe.

    Click image to see an enlarged view

    Fig. Brake pipe-S-Type 2002 through VIN M45254



    Click image to see an enlarged view

    Fig. Rear caliper retaining bolts-S-Type 2002 through VIN M45254

  10.  
  11. Remove the caliper guide pin retaining bolts.
    NOTE
    If the pistons are pushed back into the housing, brake fluid will be forced out of the inlet port of the brake caliper.

  12.  
  13. Using the Snap On tool KS326, or equivalent, fully retract the brake caliper piston.
  14.  
  15. Make sure the piston location mark is in the correct position so that the locator pin on the pad backplate locates correctly into the piston.
    NOTE
    Caliper guide pin bolts must be replaced.

  16.  
  17. Install the caliper. Torque the new bolts to 24 ft. lbs. (33 Nm).
  18.  
  19. Install the new brake hose. Torque to 35 ft. lbs. (47 Nm).
  20.  
  21. Remove the brake hold down tool.
  22.  
  23. Bleed the brake system.
  24.  
  25. Install the wheel.
  26.  

VIN N52048-N99999 With Or Without Brembo Brakes
  1. All vehicles:
    1. Carry out the parking brake cable tension release procedure.
    2.  
    3. Remove both rear wheels and tires.
    4.  
    5. Detach the parking brake cable.
    6.  

  2.  
  3. Vehicles with high performance brakes: Remove the logo badge.
  4.  
  5. All vehicles:
    1. Remove the anti-rattle spring.
      CAUTION
      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 prevent 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).

    2.  
    3. Detach the brake hose. Remove and discard the sealing washers.
    4.  
    5. Remove the brake caliper retaining bolt dust covers.
    6.  
    7. Remove the brake caliper retaining bolts.
    8.  
    9. Remove the brake caliper.
    10.  
    11. Remove the brake pads.
    12.  

  6.  

To install:

  1. All vehicles:
    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.


    NOTE
    Make sure that the brake pad with the anti-rattle spring is installed to the inboard side of the brake disc.

    1. Install the brake pads.
      CAUTION
      As the piston is pushed back into the caliper housing, the brake fluid level in the reservoir will rise. Do not allow the reservoir to overflow.


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


      NOTE
      Only the extraction bolt from special tool 303-588 is used.


      NOTE
      Only the forcing plate from special tool 206-080 is used.

    2.  
    3. Using the special tools, fully retract the brake caliper piston.
    4.  
    5. Install the brake caliper. Tighten to 21 ft. lbs. (28 Nm).
    6.  
    7. Install the brake caliper retaining bolt dust covers.
    8.  
    9. Attach the brake hose. Install new sealing washers. Tighten to 26 ft. lbs. (35 Nm).
    10.  
    11. Install the anti-rattle spring.
    12.  

  2.  
  3. Vehicles with high performance brakes: Install the logo badge. Tighten to 44 inch lbs. (5 Nm).
  4.  
  5. All vehicles:
    1. Attach the parking brake cable.
    2.  
    3. Remove the brake pedal hold-down tool.
    4.  
    5. Bleed the brake system.
    6.  
    7. Install both rear wheels and tires.
    8.  

  6.  

VIN M45255-N52047 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.

    Click image to see an enlarged view

    Fig. Brake line bolt-S-Type 2002.5-06 VIN M45255-N52047 with Brembo brakes



    Click image to see an enlarged view

    Fig. Brake caliper bolts-S-Type 2002.5-06 VIN M45255-52047 with Brembo brakes

  10.  

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.  

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

  26.  
  27. Remove and discard brake pads.
  28.  
  29. Remove bolts. Remove carrier.
  30.  
  31. Clean all mating surfaces and Remove brake dust.

    Click image to see an enlarged view

    Fig. Rear caliper carrier bolts-XJ Range 2002-03 through VIN F59525 without Brembo brakes; 2002-06 XK Range without Brembo brakes



    Click image to see an enlarged view

    Fig. Rear caliper parts (1) anti-rattle spring (2) dust covers (3) caliper pins (4) caliper-XJ Range 2002-03 through VIN F59525 without Brembo brakes; 2002-06 XK Range without Brembo brakes



    Click image to see an enlarged view

    Fig. Rear caliper brake line union bolt-XJ Range 2002-03 through VIN F59525 without Brembo brakes; 2002-06 XK Range without Brembo brakes

  32.  

To install

  1. Install caliper carrier to hub carrier. Install and tighten bolts to 44 ft. lbs. (60 Nm).
    NOTE
    Make sure piston is fully retracted into caliper housing.

  2.  
  3. Remove plug from caliper housing.
  4.  
  5. Retract piston.
  6.  
  7. Install brake pads into caliper housing.
  8.  
  9. Remove paper backing from pads to reveal adhesive shim.
  10.  
  11. Install brake pads, insert clip located on back of inner pad into caliper piston.
  12.  
  13. Install caliper housing to caliper carrier.
  14.  
  15. Install and tighten guide pins to 18-22 ft. lbs. (25-30 Nm).
  16.  
  17. Install dust covers.
  18.  
  19. Install anti-rattle spring.
  20.  
  21. Connect brake hose to caliper housing.
  22.  
  23. Install and tighten bolt to 22-29 ft. lbs. (30-40 Nm).
  24.  
  25. Remove special tool from brake pedal.
  26.  
  27. Install wheels.
  28.  
  29. Remove stands and lower vehicle.
  30.  
  31. Bleed brake hydraulic system.
  32.  

 
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