1994 JAGUAR XJ6 service

@ Steering
. Pack the annular gaps of the oil seal lips with grease.
. Bearing. Wash the hub assembly thoroughly and 'drift' the affected bearing cup(s) from the hub.
!&!$Q:
rn Hub. At this point the hub may be renewed if required.
Assembly
. Bearing. Assemble the inner bearing track to the hub using service tool 18G 134 and adaptor JD 550 - 5 / 1.
Ensure that the hub inner seal diameter is free of debris or damage and is lightly lubricated prior to assembly.
Only replace complete bearings, never cup or race in isolation.
Assemble the outer bearing cup to the hub using service tool
18G 134 and adaptor JD 550 - 5 / 2. Pack each race with approximately 4 ml of grease and position the inner race onto the stub axle.
Apply a smear of grease to hub inner surfaces and bearing cups. Assemble the hub to the stub axle followed by
outer race, bearing washer and hub nut.
It is not necessary to fill the hub cavity with grease, merely protect from corrosion with a coat of IubricanL'Seat'the bear-
ings by slightly tightening the hub nut whilst rotating the hub. Do not apply load without rotation. m:
. End float. Set a Dial Test Indicator (DTI) as shown in Fig. 1 and adjust the hub nut to achieve the correct end float.
As the adjustment is made, continually load the hub axial-
ly in both directions.
. Without disturbing the end float setting, fit the castellated
nut retainer so that it aligns with both hub nut and stub
axle drilling.
. Secure nut retainer using a new cotter pin.
9 Assembly and fitting is the reversal of this procedure not- ing that; all fixings MUST be tightened to specification
and operation of the braking system verified.
Fig. 1
Issue 1 August 1994 10 X300 VSM

1. SERVICE TOOLS & EQUIPMENT
Illustration
Not illustrated
Jaguar Number
JDID
JD 60
JDIOO
JD115
JD133
JD135
JD143
JD143-1
50143-2
JD143-3
Description
Hub Remover Rear Suspension
Nishbone Upper Bush Remover
1 Replacer
Remover Steering Arm and Swivel
Hub Ball Pins
Spring Compressor Front Suspension
Camber Tie Down Link (Front)
RemoverIRenewer Front Damper
Lower Bush
Remover
1 Renewer Suspension
Bushes (Main
Tool)
Adaptor Ring Front Sub Frame Rear
Bushes
Anvil adapter
Adaptor Remover
1 Renewer
Suspension Bushes
Issue 1 August 1994 ii X300 VSM

Suspension Systems
Not illustrated
1. SERVICE TOOLS & EQUIPMENT (continued)
JD199
0
Fixing
To be issued
Tightening Torque
(Nm)
JD199-1 Not i II ustrated
Description US98
LM Multi - purpose grease
Molib Alloy
PI907 No1
Molykote 11 1
Lower damper bolt
Wishbone to crossmember fulcrum shaft
Stabilizer mounting bushes
& rear damper top
guide bush
Caliper to carrier bolts
/ guide pins
Description
Notes
Adaptor Remover / Renewer
Suspension Bushes (Bottom Front
Wishbone Inner)
____~ ~ Spring
Compressor Rear Suspension
Damper Retaining Tie Rear
Suspension
Adaptor
Replacer Rear Hub Pivot
Bearing Cup
Driver Handle
Adaptor Remover
Main Shaft Pilot
Bearing Outer Track
Impulse Extractor (slide Hammer)
UNF. Basic Tool
Notes
Issue 1 August 1994 X300 VSM iii

Suspension Systems
11.4.3 Front End Inspection
Do not check and adjust front wheel alignment without carrying out the following inspection for front end damage and
wear:
. Check for specified air pressure in all four tires.
Raise front of vehicle off the floor; grasping upper and lower surface of the tire, shake each front wheel to check for
. Check front suspension lower arm ball joint and mounts for looseness, wear and damage.
Check steering gear mountings and all steering linkages for looseness.
. Renew parts if necessary.
. Grasp upper and lower surface of tire and shake each wheel to check wheel bearing end play.
. Check the action of the front dampers and the condition of their attachments, as sticking or binding front dampers
worn
bearings.
Check brake caliper mountings.
may not allow the vehicle to settle in to a normal level position, possibly affecting the front-wheel alignment.
m: Front wheel bearings are adjustable (0.001 to 0.003 in. endfloat).
11.4.4
. Check the wheel bearings.
. Inspect the front suspension upper joint and renew front suspension lower wishbone if needed.
Raise vehicle and position floor jacks beneath the front suspension lower wishbone.
Grasp the lower edge of the tire and move the wheel in and out.
While moving the wheel, observe the upper and lower wishbone.
. Movement between the vertical links and the wishbones indicates abnormal ball joint wear.
. Renew ball joints.
. Check the front wheel bearings.
. Check for excessive play and wear.
Upper / Lower Ball Joint Inspection
11.4.5 Damper Inspection
m: The gas-pressurized hydraulic front dampers are not serviceable, adjustable or refillable.
Verify that all attachments of the suspension components and the front dampers are tight. Renew any front damper
. Check front dampers for external damage.
. Check for oil leakage and vehicle sag.
that
has a damaged integral lower mounting bushing.
0 Oil Leak
Leakage is the condition in which the entire damper body is covered with oil and from where
it will drip on to
the pavement. Due to correct damper lubrication a light film of oil (weepage) can usually be seen on the upper
portion of the damper.
Should there be any leakage, ensure that the fluid does not originate from sources other than the front damper.
Renew worn or damaged dampers.
0 Vehicle Sag
Renewing front dampers will not correct the problem of vehicle sag, as basically this is controlled by the spring
units.
issue 1 August 1994 4 X300 VSM

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

12.2 FAULT DIAGNOSIS AND TESTING
rrouble
-ong brake pedal
dibration during braking
'oor braking performance
3rakes pull to one side
3rakes do not release
ixcessive pedal travel
Cause
Brake caliper piston or caliper guide
pins sticking
Worn
I damaged brake pads
Worn
1 damaged brake pads
Loose caliper mounting bolts
Insufficient grease on sliding parts
Foreign material
or scratches on
brake rotor contact surface
Damaged brake rotor contact surface
Leak
in hydraulic system
Air
in system
Worn
I damaged brake pads
Foreign material on brake pads
Brake caliper piston malfunction
Tandem master cylinder malfunction
Vacuum booster fault
Disconnected
or damaged vacuum
hose
Low brake
fluid level
Worn
I damaged brake pads
Foreign material on brake pad
Failing valves
in ABS valve block
Abnormal wear or distortion on front
brake rotor
Incorrect wheel alignment
Incorrect tire pressure
No brake pedal free play
Vacuum booster
binding
Tandem master cylinder return port faulty
Faulty valve
in ABS valve block
Leak
in hydraulic system
Air
in system
Remedy
Service or renew caliper or caliper
guide pins
Renew brake pads
Renew brake pads
Tighten caliper mounting bolts
Apply grease where necessary
Clean brake rotor contact surface
Renew brake
rotor
Repair leak. Check all pipework con-
nections. Refill and bleed the system
Check the system
for leaks and bleed
brakes
Renew brake pads
Examine brake pads and clean
or
renew as necessary
Renew faulty brake caliper piston
Service
or renew tandem master cyl- inder
Renew vacuum booster
Renew vacuum hose
Check for leaks, refill and bleed the
system
Renew brake pads
Examine brake pads and clean
or renew as necessary
Renew valve block
Examine front brake
rotor and service
or renew as necessary
Carry out wheel alignment. Refer to
Section
11, iv Service Data
Inflate tire
to correct pressure
Adjust brake pedal free play
Renew vacuum booster
Clean return
port on tandem master cy I i nder
Renew valve block
Repair leak. Check all pipework con
- nections. Refill and bleed the system
Check the system
for leaks and bleed
brakes
0
0
0
Issue 1 August 1994 16 X300 VSM

Brakes
12.4 BRAKE SYSTEM BLEEDING
WAR-: GREAT CARE MUST BE EXERCISED WHEN SERVICING OR REPAIRING THE SYSTEM. AVOID SKIN/ EYE
CONTACT OR INGESTION OF BRAKE FLUID. IF SKIN OR EYES ARE ACCIDENTALLY SPLASHED WITH
BRAKE FLUID,
RINSETHE AFFECTED AREA IMMEDIATELY WITH PLENTY OF WATER AND SEEK MEDICAL
ATTENTION. IF BRAKE FLUID IS INGESTED, SEEK MEDICAL ATTENTION IMMEDIATELY.
CAUm: Fluid must not be allowed to contact the vehicle paintwork. Remove any spilt fluid from the paintwork
by rinsing away with running water. Methylated spirit (denatured alcohol) must not be used to clean the
contaminated area.
CAUTION: Never use methylated spirit (denatured alcohol) for component cleaning purposes. Use only a proprietary
brake cleaning fluid.
WARNING : THROUGHOUT THE FOLLOWING MAINTENANCE / SERVICE OPERATIONS, ABSOLUTE CLEANLINESS
MUST BE OBSERVED TO PREVENT FOREIGN MATTER CONTAMINATING THE BRAKE SYSTEM.
12.4.1 System Bleeding - General Instructions
Use a brake bleeder bottle with a clear bleeder tube. Also recommended is a filler unit with a fill pressure of 1.0 bar. If a filler unit is not used, ensure that their is sufficient brake fluid in the reservoir throughout the bleeding procedure.
m: Always bleed the caliper furthest away from the actuation unit first. On right hand drive vehicles, bleed in the
following order: front
left (FL),front right (FR), rear left (RL) and rear right (RR). On left hand drive vehicles bleed in the following order: FR, FL, RR and RL.
12.4.2
. Ensure that the vehicle is standing level. Switch the igni-
tion off.
Check that the fluid level in the reservoir is between the min and max marks.
. Connect the bleeder bottle tube to the relevant front cali- per (see'note' above) bleeder screw (1 Fig. 1) and open the
screw.
rn Bleed until new, clear, bubble free fluid is observed in the
tube and then close the bleeder screw.
. Repeat this procedure at each remaining caliper.
With the motorrunning check brake pedal travel.
If excess- ive, check for leaks and repeat the bleed procedure.
Fill the reservoir to the max level.
System Bleeding After Brake Fluid Renewal
12.4.3 System Bleeding After Tandem Master Cylinder
Renewal
Ensure that the vehicle is standing level. Switch the igni- tion off.
rn Check that the fluid level in the reservoir is between the min and max marks.
Connect the bleeder bottle tube to the relevant front cali- per (see'note'above) bleederscrew(1 Fig. 1) and open the
screw.
Ficr. 1
X300 VSM 19 Issue 1 August 1994

Brakes
a 12.5 GENERAL FI77lNG lNSTRUCTlONS
12.5.1 Brake Fluid
WARNING: BRAKE FLUID IS CORROSIVE. EXTREME CARE MUST BE TAKEN WHEN HANDLING. AVOID SKIN OR EYE
CONTACT. AVOID INGESTION. IF SKIN OR EYES ARE ACCIDENTALLY SPLASHED WITH BRAKE FLUID,
RINSE THE AFFECTED AREA IMMEDIATELY WITH PLENTY OF WATER AND SEEK MEDICAL ATTENTION.
IF BRAKE FLUID
IS INGESTED, SEEK MEDICAL ATTENTION IMMEDIATELY.
CAUTION:
Fluid must not be allowed to contact the vehicle paintwork. Remove any spilt fluid from the paintwork
by rinsing away with running water. Methylated spirit (denatured alcohol) must not be used to clean the
contaminated area.
Cleaning Solvents
CAUTION: Never use methylated spirit (denatured alcohol) for cleaning purposes. Use only a proprietary brake
cleaning fluid.
m: THROUGHOUT THE FOLLOWING MAINTENANCE / SERVICE OPERATIONS, ABSOLUTE CLEANLINESS
MUST BE OBSERVED TO PREVENT GRIT OR OTHER FOREIGN MATTER CONTAMINATING THE BRAKE
TION. TO CLEAN BRAKE SYSTEM COMPONENTS, WASH
IN A PROPRIETARY BRAKE CLEANING FLUID.
REMOVE ALL TRACES OF CLEANING FLUID BEFORE REASSEMBLY. ALL BRAKE SYSTEM RUBBER COh PONENTS MUST BE DIPPED IN CLEAN BRAKE FLUID AND ASSEMBLED USING THE FINGERS ONLY.
SYSTEM.
IFTHE SYSTEM IS TO
BE FLUSHED, USE CLEAN BRAKE FLUID TO MINIMUM DOT 4 SPECIFICA-
12.5.2 Hoses
Fully release the unions (1 Fig. 1) securing each end of the
hose to the fluid pipes. Withdraw the pipe unions (1 Fig. 1) from the hose ends.
Plug the ends of the pipes (2 Fig. 1) to prevent the loss of
fluid and the ingress of dirt.
Remove the mounting bracket locknut (3 Fig. 1) and re- move the hose (4 Fig. 1).
Thoroughly clean the hose and examine for any signs of
wear or damage. Renew the hose if there is any doubt
about its condition. Thoroughly clean the bore of the hose
using compressed air.
. Remove all blanking plugs and fit the new hose to the cali- per / connector. Secure the hose to the mounting bracket.
. Before fully tightening the locknut, ensure that the hose is
neither kinked nor twisted.
. Bleed the brakes.
12.5.3 Pipes
. Fully release the pipe unions (1 Fig. 1).
. Withdraw the pipe (5 Fig. 1) from the vehicle. Plug the
pipes (2 Fig. 1) to prevent the loss of fluid or the ingress of dirt. Thoroughly clean and examine the pipe for signs of damage or deterioration. Renew the pipe if there is any
doubt about its condition.
Thoroughly clean the bore of the pipe using compressed
air.
. Remove all blanking plugs and fit the new pipe to the ve- hicle. Secure the pipe to the body.
. Bleed the brakes.
17
Fig. 1
X300 VSM 21 Issue 1 August 1994