1994 JAGUAR XJ6 brake

Suspension Systems
1 1.4.8 Diagnostic Procedure
Condition
Hard steering
Shimmy
I----
Bump steer (unequal
side-to-side)
Sawtooth pattern or
t excessive tire wear
Uneven tire wear
(outer or inner
shoulder)
Fronvrear
suspension noises
Possible Cause
Side-to-side difference in caster.
Tire pressure Steering gear or linkage worn or defective.
Tire
conicity
Power steering gear or linkage worn,
damaged, or incorrect adjusted.
Wear of front suspension
lower/upper
wishbone ball joints.
Unequal tire pressure.
Brake system
fault(s)
Wheel/tire imbalance or runout.
Damaged tires, unbalanced or damaged
wheels.
Incorrect wheel alignment.
Steering system malfunction
Front damper malfunction.
Loose front damper mounting.
Damaged front suspension upper
or lower
ball joints.
Damaged or worn sub
-frame to body
mounting. Damaged or worn stabilizer bar insulators.
Damaged or worn stabilizer bar link.
Damaaed or worn wheel bearina.
Rear suspension damage.
Worn steering gear mounting bracket
housing insulators.
Excessive toe
-in (high edges inboard) or
toe-out (high edges outboard).
Incorrect tire pressure.
Excessive toe.
Excessive positive or negative camber.
Loose/missing front dampers and front
damper bolt to front suspension lower
wish bone.
Action
Check the alignment and if incorrect,
adjust the caster
if needed. Inspect
components for wear or damage.
Check for abnormal loading.
Check steering system
Inspect tire for excessive wear.
Check and adjust the tire air pressure.
Note: Excessively worn or uneven tires can
cause
pull/drift.
Check steering system.
Renew ball joints.
Inflate the tires to correct and uniform
pressure.
Check the brakes.
Check wheels and tires.
Check the tires and renew
if necessary.
Balance the wheels
if necessary.
Adjust wheel alignment.
Check steering system.
Renew front damper
if necessary.
Tighten front damper mounting.
-
Renew upper and lower ball joint.
Renew rear suspension bushing.
Renew insulators.
Renew link.
Renew/adjust wheel bearing.
If the caster is uniform, check and compare
the wheelbase at the right and left sides.
If
different, inspect the suspension
components for wear and damage.
Renew bracket housing insulators.
Check and adjust toe
-in.
Correct tire pressure.
Check toe and adjust
if needed.
Check the camber and
if incorrect inspect
the related components for wear or
damage.
Tighten/renew damper bolts.
Inspect wheel hubs.
0
0
0
lssue 1 August 1994 6 X300 VSM

Suspension Systems I.\" b-
1 1.4.8 Diagnostic Procedure (continued)
Condition
30dy 'rolls'
3ody leans
'oor ride comfort
Seneral driving
nstability
Steering wheel does
lot return properly
Steering wheel pulls
:o one side
4bnormal noise
from suspension
system
Possible Cause
Weak front stabilizer bar.
Damaged or worn lower wishbone stabilizer
bar insulator. Damaged or worn stabilizer bar link
Damaged or worn rear suspension
wishbone bushing.
Damper malfunction.
Worn or deteriorated rear stabilizer bar
bushing(s). (supercharged, sports and XJ12
only)
Damaged or worn rear wishbone bushing
and weak springs.
Worn or deteriorated rear stabilizer bar
bushing(s). (supercharged, sports and XJ12
only)
Front or rear damper malfunction.
Weak
spring(s1
Damaged tires or unbalanced wheels.
Incorrect wheel alignment.
Steering system malfunction.
Damaged front suspension lower and upper
ball joints.
Damaged or worn sub
-frame to body
mounting.
Damaged or worn stabilizer bar link
Damaged or worn lower wishbone stabilizer
bar insulator.
Weak
spring(s)
Worn or deteriorated rear stabilizer bushing
(s). (supercharged, sports and XJ12 only)
Damaged tires or unbalanced wheels and
incorrect tire pressure.
Incorrect wheel alignment.
Steering system malfunction.
Damaged front suspension lower and upper
ball joints.
Incorrect tire pressure.
Damaged front suspension lower and upper
ball joints. Braking system malfunction.
Steering system malfunction.
Damaged or worn sub
-frame to body
mounting.
Damaged tires, unbalanced wheels and
incorrect tire pressure.
Poor lubrication /wear of wheel bearing.
Wear of front suspension lower and upper
ball joints.
Damaged or worn front stabilizer bar
Damaged or worn stabilizer bar link.
Damaged or worn stabilizer bar bracket.
Looseness of suspension connections.
Damaged or worn rear wishbone bushing.
Front and rear damper malfunction.
Weak
spring.Worn or deteriorated rear
stabilizer bushing
(s). (supercharged, sports
and
XJ12 only)
Action
3enew front stabilizer bar.
3enew insulators.
3enew link.
Renew bushing.
Renew damper
if necessary.
Renew Bushina
Renew bushings and springs.
Renew Bushings.
Renew dampers.
Renew springs.
Check the tires.
Adjust the wheel alignment.
Check steering system.
Renew ball joints.
Renew bushing.
Renew link.
Renew insulator.
Renew springs.
Renew bushing
Check tires.
Adjust the wheel alignment.
Check steering system.
Renew ball joints.
Check and correct tire pressure.
Renew ball joints.
Check brakes.
Check steering system.
Renew bushing.
Check tires.
Renew wheel bearing.
Renew ball joints.
Renew stabilizer bar.
Renew link.
Renew bracket.
Tighten connections.
Renew bushing.
Renew dampers.
Renew bushing
Issue 1 August 1994 X300 VSM 7

SECTION CONTENTS
Subsection Tit/e SRO Page
i to iv ............ Preliminary Pages .................................................................... i
12.1 ............. Anti-Lock Braking System (ABS) General Description ................................... 12.1
12.1.2.
........... Anti-lock Braking/ Traction Contd Operation ........................................ 12.3
12.1.3
............ Anti-lock Braking Operation ........................................................ 12.4
12.1.4
............ Actuation Components ............................................................. 12.5
12.1.5
............ ABSComponents ................................................................. 12.6
12.1.6
............ Calipers ........................................................................\
. 12.7
12.1.7
............ Parking Brake .................................................................... 12.9
12.1.8
............ Wheel Speed Sensors ............................................................. 12.11
12.1.9
............ Hydraulic Operation - ABS CM .................................................... 12.12
12.2
............. Fault Diagnosis and Testing ........................................................ 12.16
12.4
............. Brake System Bleeding ............................................................ 12.19
12.1.10
.......... Hydraulic Operation - ABS /TC CM ................................................. 12.14
12.3
............. Brake Fluid Level Check .......................................................... 12.18
12.4.1
............ System Bleeding - General Instructions .............................................. 12.19
12.4.2.
........... System Bleeding After Brake Fluid Renewal .......................................... 12.19
12.4.3
............ System Bleeding After Tandem Master Cylinder Renewal ............................... 12.19
12.4.4.
........... System Bleeding Afier Hydraulic Control Module Renewal ............................. 12.20
12.4.5.
........... Bleeding After Renewal of Caliper .................................................. 12.20
12.5
............. General Fitting Instructions ........................................................ 12.2 1
12.5.1 ............ General Fitting Instructions, Brake Fluid ............................................. 12.2 1
12.5.2. ........... General Fitting Instructions, Hoses .................................................. 12.2 1
12.5.3 ............ General Fitting Instructions, Pipes ................................................... 12.2 1
12.6 ............. Rear Wheel Speedsensor- Renew ............................... 70.60.04 ......... 12.22
12.7
............. Hydraulic Control Module- Renew ............................... 70.60.18/ 19 ..... 12.23
12.8
............. Pressure Conscious Reducing Valves .............................. 70.60.21 ......... 12.25
12.9
............. ABS/TCCM - Renew .......................................... 70.60.02/20 ..... 12.26
X300 VSM i Issue 1 August 1994

1. SERVICE TOOLS & EQUIPMENT
Description
Parking brake cable remover
Illustration
Notes
not
illustrated
Pipe connectors to hydraulic module:
M12
M10
Jaguar Number
JD.142
15
- 19
12 - 16
186.672
Description
U-
Molykote 11 1 Caliper to carrier securing bolts
6947017
Notes
JDS.9013
Replacer disc brake
piston seal
I
Brake hose clamp, Girling
Brake pedal hold down tool
11. TORQUE TIGHTENING SPECIFICATIONS
Fixing 1 Tightening Torque
(Nm)
Vacuum booster to pedal box I 21 -29 I
Tandem master cylinder to booster I 21 -29 I
Hvdraulic module to module bracket I 18 - 26 I
Caliper guide pins I 25 - 35 I
Caliper to vertical link I 120 - 160 I
Caliper to hub carrier I 54 - 66 I
111. SERVICE MATERIALS
Iv. SERVICE DATA
Front brake disc run out
Front brake
disc parallelism
Rear brake disc
run out
Rear brake disc parallelism 0.101
mm (0.004 in) max.
0.0127mm (0.0005in) max.
0.101
mm (0.004 in) max.
0.0127mm (0.0005in) max.
Issue 1 August 1994 ii X300 VSM

12.1 ANTI-LOCK BRAKING SYSTEM (ASS), GENERAL DESCRIPTION
The anti-lock braking system (ABS) components are combined with a hydraulic booster and tandem master cylinder (TMC) to provide a two-circuit braking system. The anti-lock braking system comprises the following components:
0 Four inductive wheel speed sensors, hub end mounted
0 ABS warning light
0 Hydraulic module.
The hydraulic module consists of an electric motor driven pump,
two low pressure accumulators, valve block and an
ABS electronic control module.
m: Electronic control modules for vehicles without traction control are designated ABS CM. Control modules for
vehicles with traction control are designated ABS /TC CM.
The valve block houses solenoid operated valves which are activated by voltage signals from the control module. The
signals are generated using wheel speed information received from the wheel speed sensors.
For vehicles without traction control the valves operate on three circuits, two front and one rear, as necessary to pre
- vent wheel locking during braking. Brake pressure is modulated individually at thefront wheels and collectively at the
rear. Rear wheel control operates on a 'select low' principle i.e. locking in either wheel is sensed, and controlled brake
pressure is applied to both wheels.
For vehicles with traction control the valves operate on four circuits. During ABS control the rear wheel are controlled
on a 'select low' principle (as above), but during traction control operation the rear wheels are controlled individually.
0
1yQfB: Functional and diagnostic information for the ABS CM and the ABS/TC CM is contained in the Electrical Diag-
nostic Manual (EDM), Section 12.
ABS Warning lamp / Traction Control Warning lamp /Fluid level Indicator
The ABS and traction control warning lamps, mounted in the instrument panel, indicate a fault in the ABS or traction
control. These systems are inhibited or disabled when the lamps are lit, although conventional braking is unaffected.
When the ignition is switched on, an ABS self test is initiated. During this test, the ABS and traction control warning
lamps are
lit for approximately 1.7 seconds and then extinguish. A fault is indicated if the warning lamps remain lit or
come on whilst the vehicle is being driven.
W: The ABS self test is masked by the 5 second lamp test initiated when the ignition is switched on.
The fluid level indicator lamp, mounted in the instrument panel, is
lit when the brake fluid falls below the minimum
mark on the brake fluid reservoir.
ABS / Traction Control - Inhibit / Disable
Faults conditions are detected by the ABS/TC CM which disables the ABS and traction control until the fault is rectified.
The ABS and traction control warning lights on the instrument pack remains lit whilst a fault exists. The system will
be disabled when the following conditions occur:
0
0 Valve failure
0 Sensor failure
0 Main driver failure (internal ABS /TC CM fault)
0 Redundancy error (internal ABS JTC CM fault)
0 Overvoltage J undervoltage
0 Pump motor failure.
0 Throttle valve actuator motor failure (traction control vehicles only).
0 Throttle valve actuator potentiometer failure (traction control warning light only).
X300 VSM 1 Issue 1 August 1994

Brakes (a)
12.1.2. Anti-lock Braking / Traction Control Operation
The rear wheels are controlled collectively on a 'select-low' principle during ABS operation. During traction control,
separate circuits allow individual control of the rear wheels. To facilitate this the valve block has four outlet ports.
The
ABS/TC CM is integrated with the valve block. The pump, motor, valve block and control module are supplied as
a unit and are non-sewiceable. Faulty units must be renewed as a whole.
Both front and rear brakes on
all vehicles are fitted with single piston caliper assemblies. Ventilated brake rotors, with
provision for parking brake shoes at the rear, are fitted all round.
0
Issue 1 August 1994 X300 VSM 3
1. Vacuum booster 9. Pressure conscious reduction valve 2. Vacuum hose 10. Ventilated brake rotor 3. Tandem master cylinder 11. Single piston caliper 4. Primary brake circuit 12. %way brake pipe connector
5. Secondary brake circuit 13. Wheel speed sensor
6. Hydraulic pump / motor unit 14. ABS warning lamp 7. Valve block 15. Brake fluid level warning lamp
8. ABS/TCCM
Fig. 1 ABS / Traction Control System
The vacuum booster (see Fig.
1) is mounted on the brake pedal box and secured by three bolts. Brake pedal force is
increased by the vacuum booster which activates the Tandem Master Cylinder (TMC) intermediate piston. Brake fluid
is supplied to the pump inlet ports on two separate circuits. The primary circuit supplies the front brakes whilst the
secondary circuit supplies the rear brakes.

Pressure conscious reduction valves (PCRVs) are fitted between the outlet of the valve block and the rear brake circuit
to optimize. The valves are fitted to prevent over braking due to the increased size of the rear brake calipers which are
required for traction control. Up to a threshold of 15 bar, brake pressure to the front and rear brakes is equal. Above
15 bar the PCRVs reduce pressure to the rear brakes to provide a closer balance between front and rear brakes and
optimize road adhesion.
Wheel speed sensors are fitted to all wheels to transmit wheel speed information to the control module. The module
uses this information to modulate brake pressure during anti
-lock braking or traction control.
12.1.3. Anti-lock Braking Operation
170 287
1. Vacuum booster 9. Pressure conscious reduction valve
2. Vacuum hose 10. Ventilated brake rotor
3. Tandem master cylinder 11. Single piston caliper
4. Primary brake circuit 12.
%way brake pipe connector
5. Secondary brake circuit 13. Wheel speed sensor
6. Hydraulic pump I motor unit 14. ABS warning lamp 7. Valve block 15. Brake fluid level warning lamp
8. ABSICM
Fig. 1 Brake System (non-Traction Control)
The rear brakes (see Fig. 1) are controlled collectively on a
'select-low' principle. Under ABS braking conditions, equal
brake pressure is applied to both rear calipers, although only one wheel may have a tendency to lock.
The valve block has three outlet
ports, Brake fluid volume is supplied equally to the rear brakes via the %way brake
pipe connector.
Issue 1 August 1994 4 X300 VSM

12.1.5. ABS Components
Hydraulic Module
The hydraulic module is located under the bonnet adjacent
to the engine compartment firewall. It is secured within a steel mounting bracket at three securing points. All elec- tronic and power connections are made through one cable
loom connect ion.
The hydraulic pump
(1 Fig. 1) is a reciprocating two-circuit pump in which one brake circuit is assigned to each pump
circuit. The pump supplies adequate pressure and volume
supply to the brake circuits under anti
-lock braking condi- tions. The pump is driven by and electric motor (2 Fig. 1). The
pump housing incorporates two low pressure accumulators
and damping chambers for each brake circuit.
A modulator valve block
(3 Fig. 1) incorporates the ABS CM or ABS / TC CM (4 Fig. 1). Vehicles with traction control are
fitted with a throttle position actuator (5 Fig. I), which is an
electrical device controlled by the ABS 1 TC CM.
Valve blocks on vehicles without traction control comprise
six solenoid valves, three normally open (NO) inlet valves
and three normally closed
(NC) outlet valves. These valve
blocks have three outlet ports. Valve blocks on vehicles with
traction control comprise nine solenoid valves, four
NO inlet valves,four NC outlet valves and one special isolating valve.
Fig. 2 shows a hydraulic module for vehicles with traction
control. The valve block (2 Fig. 2) has four outlet ports (Indi- vidual control of the driven wheels).
A BS CM, A BS / TC CM
The ABS CM or ABS TCI CM locates beneath the modulator
valve block and is secured by
two screws. The CM houses
the solenoids which operate the inlet and outletvalves of the
modulator valve block. When fitted, the valve stems locate
in the
CM mounted solenoids. There is no electrical connec- tion between the CM and the modulator valve block. Fig. 3 shows an ABS TC 1 CM having nine solenoids.
The
CM functions include the following:
0 Providing control signals for the operation of ABS
and traction control solenoid valves
0 Calculating wheel speed from voltage signals trans- mitted by the wheel speed sensors
0 Monitoring of all electrical components
0 On Board Diagnostics (OBD): storage of possible fail- ures in a non-volatile memory.
The signals from the four wheel speed sensors are indepen
- dently processed by the ABS CM or ABSITC CM, calculating
numerical values which correspond directly to the wheel
speed. These values are converted into control signals for
pressure modulation during ABS control.
The ABS and traction control
are continuously monitored,
whilst the ignition is on,for possiblefaults and interruptions.
If a fault is detected, the module deactivates the ABS and
indicates this by lighting the ABS warning lamp. In a fault
condition, conventional braking is unaffected. The module
stores fault codes in a non
-volatile memory which can be
read via the OBD link.
U: For electrical diagnostic information on the ABS I traction control systems, refer to EDM, Section 12. Fia.
1
Fia. 2
Fin. 3 I
J70286
Issue 1 August 1994 X300 VSM