2010 JAGUAR XFR brake fluid

Parking Brake Module
Parking Brake Switch
Parking Brake Release Actuator206-06: Hydraulic Brake ActuationSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingHydraulic Brake ActuationRemoval and InstallationBrake Fluid Reservoir (70.30.16)
Brake Master Cylinder (70.30.08)206-07: Power Brake ActuationSpecificationDescription and OperationComponent Location
OverviewDiagnosis and TestingPower Brake SystemRemoval and InstallationBrake Booster (70.50.17)
Brake Vacuum Pump - V8 5.0L Petrol/V8 S/C 5.0L Petrol206-09: Anti-Lock Control - Stability AssistSpecificationDescription and OperationComponent Location
Overview
System Operation and Component DescriptionDiagnosis and TestingAnti-Lock Control - Stability AssistRemoval and InstallationAnti-Lock Brake System (ABS) Module (70.60.02)
Front Wheel Speed Sensor
Hydraulic Control Unit (HCU) (70.60.18) (70.60.19)
Rear Wheel Speed Sensor (70.60.04)
Steering Wheel Rotation Sensor
Yaw Rate Sensor and Accelerometer211: Steering System
211-00: Steering System - General InformationSpecification

Published: 11-May-2011
General Information - Brake System Health and Safety Precautions
Description and Operation
WARNINGS:

EYE CONTACT: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes. Wash hands thoroughly
after handling. If brake fluid comes into contact with the eyes, flush the eyes with plenty of cold running water for 15 minutes.
Seek medical attention for any persistent eye irritation or abnormality.


SWALLOWED: Brake fluid contains polyglycol ethers and polyglycols. If swallowed, drink plenty of water. Seek immediate
medical attention.


INHALED: Dust from friction materials can be harmful if inhaled.
Only use new specified brake fluid from airtight containers.
CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

Always reduce the engine speed to idle before disconnecting the jump leads.

Before removing the jump leads, switch on the heater blower (high) or the heated rear screen, to reduce the voltage peak
when the leads are removed.

Always disconnect the jump leads in the reverse order to the connecting sequence and take great care not to short the ends of
the leads.

Do not rely on the generator to restore a discharged battery. For a generator to recharge a battery, it would take in excess of 8
hours continuous driving with no additional loads placed on the battery.

Component Cleaning

To prevent ingress of dirt, accumulations of loose dirt and greasy deposits should be removed before disconnecting or
dismantling components or assemblies.
Components should be thoroughly cleaned before inspection prior to reassembly.
Cleaning Methods:
Dry Cleaning
Removal of loose dirt with soft or wire brushes
Scraping dirt off with a piece of metal or wood
Wiping off with a rag

CAUTION: Compressed air is sometimes wet so use with caution, especially on hydraulic systems.
Blowing dirt off with compressed air (Eye protection should be worn when using this method)
Removal of dry dust using vacuum equipment. This method should always be used to remove friction lining material
dust (asbestos particles)
Steam Cleaning

Calibration of Essential Measuring Equipment


WARNING: Failure to comply may result in personal injury or damage to components.

It is of fundamental importance that certain essential equipment e.g. torque wrenches, multimeters, exhaust gas analysers,
rolling roads etc., are regularly calibrated in accordance with the manufacturers instructions.

Use of Control Modules

Control modules may only be used on the vehicle to which they were originally installed. Do not attempt to use or test a
control module on any other vehicle.

Functional Test

On completion of a maintenance procedure, a thorough test should be carried out, to ensure the relevant vehicle systems are
working correctly.

Preparation

Before disassembly, clean the surrounding area as thoroughly as possible. When components have been removed, blank off
any exposed openings using grease-proof paper and masking tape. Immediately seal fuel, oil and hydraulic lines when
separated, using plastic caps or plugs, to prevent loss of fluid and the entry of dirt. Close the open ends of oil ways, exposed
by component removal, with tapered hardwood plugs or readily visible plastic plugs. Immediately a component is removed,
place it in a suitable container; use a separate container for each component and its associated parts. Before dismantling a
component, clean it thoroughly with a recommended cleaning agent; check that the agent will not damage any of the materials
within the component. Clean the bench and obtain marking materials, labels, containers and locking wire before dismantling a
component.

Dismantling

Observe scrupulous cleanliness when dismantling components, particularly when parts of the brake, fuel or hydraulic systems
are being worked on. A particle of dirt or a fragment of cloth could cause a dangerous malfunction if trapped in these systems.
Clean all tapped holes, crevices, oil ways and fluid passages with compressed air.


WARNING: Do not permit compressed air to enter an open wound. Always use eye protection when using compressed air.

Make sure that any O-rings used for sealing are correctly reinstalled or renewed if disturbed. Mark mating parts to make sure
that they are replaced as dismantled. Whenever possible use marking materials which avoid the possibilities of causing
distortion or the initiation of cracks, which could occur if a center punch or scriber were used. Wire together mating parts where
necessary to prevent accidental interchange (e.g roller bearing components). Tie labels on to all parts to be renewed and to
parts requiring further inspection before being passed for reassembly. Place labelled parts and other parts for rebuild in
separate containers. Do not discard a part which is due for renewal until it has been compared with the new part, to make sure

Air Conditioning A/C Accelerator Pedal Position APP
Is a multitrack sensor which inputs the drivers demand into the engine
control module (ECM) After Bottom Dead Center ABDC Event occurring after bottom dead center After Top Dead Center ATDC Event occurring after top dead center Anti-lock Brake System ABS
System which prevents wheel lock-up under braking by sensing lack of
rotation of a wheel(s) and diverting fluid pressure away from it (them) Alternating Current ac Amplitude Modulation AM Automatic Temperature Control ATC Automatic Transmission Fluid ATF Ampere A SI unit of current Ampere hour Ah Barometric Pressure BARO Pressure of surrounding air at any given temperature and altitude Battery positive voltage B+ The positive voltage from a battery or any circuit connected directly to it Before Bottom Dead Center BBDC Event occurring before bottom dead center Before Top Dead Center BTDC Event occurring before top dead center Bottom Dead Center BDC Lowest point of piston travel in a reciprocating engine Battery Junction Box BJB Brake Pedal Position BPP Brake Horsepower BHP
Effective horsepower developed by an engine or motor, as measured by a
brake applied to its output shaft British Standard BS Standard specification issued by the British Standards Institution Brake Traction Control System BTCS

General Information - Standard Workshop Practices
Description and Operation

Protecting the Vehicle Published: 04-Jul-2014

Always install covers to protect the fenders before commencing work in the engine compartment. Always install the interior
protection kit, wear clean overalls and wash hands or wear gloves before working inside the vehicle. Avoid spilling hydraulic
fluid, antifreeze or battery acid on the paintwork. In the event of spillage, wash off with water immediately. Use polythene
sheets in the luggage compartment to protect carpets. Always use the recommended service tool, or a satisfactory equivalent,
where specified. Protect temporarily exposed screw threads by replacing nuts or installing caps.

Vehicle in Workshop

When working on a vehicle in the workshop always make sure that:

The parking brake is applied or the wheels are securely chocked to prevent the vehicle moving forwards or backwards
If the engine is to be run, there is adequate ventilation, or an extraction hose to remove exhaust fumes is installed
There is adequate room to jack up the vehicle and remove the wheels, if necessary
Fender covers are always installed if any work is to be carried out in the engine compartment
The battery is disconnected if working on the engine, underneath the vehicle, or if the vehicle is jacked up


CAUTION: When electric arc welding on a vehicle, always disconnect the generator wiring to prevent the possibility of a
surge of current causing damage to the internal components of the generator.
If using welding equipment on the vehicle, ensure a suitable fire extinguisher is readily available.

Screw Threads

Damaged nuts, bolts and screws must always be discarded. Attempting to recut or repair damaged threads with a tap
or die impairs the strength and fit of the threads and is not recommended.
NOTES:

During certain repair operations, it may be necessary to remove traces of thread locking agents using a tap. Where this
is necessary, the instruction to do so will appear in the relevant operation and it is essential that a tap of the correct size and
thread is used.


New Taptite bolts when used cut their own threads on the first application.

Some bolts are coated with a thread locking agent and unless stated otherwise, they must not be reused. New bolts
having the same part number as the original must always be installed. When nuts or bolts are to be discarded, the
repair operation and relevant torque chart will include an instruction to that effect. Do not use proprietary thread
locking agents as they may not meet the specification required. See also Encapsulated ('Patched') Bolts and Screws.
Always make sure that replacement nuts and bolts are at least equal in strength to those that they are replacing.
Castellated nuts must not be loosened to accept a split pin except in recommended cases when this forms part of an
adjustment.
Do not allow oil or grease to enter blind holes, the hydraulic action resulting from tightening the bolt or stud can split
the housing and also give a false torque reading.
Always tighten a nut, bolt or screw to the specified torque figure, damaged or corroded threads can give a false torque
reading.
Nut and bolt loosening and tightening sequences, where given, must ALWAYS be followed. Distortion of components or
faulty sealing of joints will result if the sequences are not followed. Where an instruction is given to tighten in stages,
these stages must be adhered to; do not attempt to combine stages particularly where certain stages involve
tightening by degrees.
To check or re-tighten a fixing to a specified torque, first loosen a quarter of a turn, then retighten to the specified
torque figure.
Unless instructed otherwise, do not lubricate bolt or nut threads prior to installing.
Where it is stated that bolts and screws may be reused, the following procedures must be carried out:
Check that threads are undamaged.
Remove all traces of locking agent from the threads.

CAUTION: DO NOT use a wire brush; take care that threads are not damaged.
Make sure that threads are clean and free from oil or grease.
Apply the specified locking agent to the bolt threads.

General Information - Road/Roller Testing
Description and Operation Published: 11-May-2011

Road or roller testing may be carried out for various reasons and a procedure detailing pre-test checks, through engine starting
and stopping, pre-driving checks, on-test checks to final checks on completion of the test is given in this section.

Unless complete vehicle performance is being checked, the full road test procedure need not be carried out. Instead, those
items particularly relevant to the system/s being checked can be extracted.

Pre - Test Checks


WARNING: If the brake system hydraulic fluid level is low, pedal travel is excessive or a hydraulic leak is found, do not
attempt to road test the vehicle until the reason for the low fluid level, excessive pedal travel or hydraulic leak is found and
rectified.

It is suggested that pre-test checks, and functional tests of those systems/circuits which affect the safe and legal operations
of the vehicle, such as brakes, lights and steering, should always be carried out before the road or roller test.

Engine oil level
Engine coolant level
Tires, for correct pressure, compatible types and tread patterns, and wear within limits
There is sufficient fuel in the tank to complete the test
All around the engine, transmission and under the vehicle for oil, coolant, hydraulic and fuel leaks. Make a note of any
apparent leaks and wipe off the surrounding areas to make it easier to identify the extent of the leak on completion of
the test
Starting the Engine


CAUTION: On initial drive away from cold and within the first 1.5 km (1 mile), do not depress accelerator pedal beyond
half travel until the vehicle has attained a minimum speed of 25 km/h (15 miles/h). Never operate at high engine speed or
with the accelerator pedal at full travel whilst the engine is cold.
With the ignition switched off, check:
The parking brake is applied
The transmission selector lever is in Park
All instrument gauges (except fuel gauge) read zero

With the ignition switched on, check:

Ignition controlled warning lamps come on
Engine coolant temperature gauge registers a reading compatible with the engine coolant temperature
Fuel gauge registers a reading appropriate to the fuel level in the tank
The operation of the parking brake and brake fluid level warning lamps

On Road or Roller Test Check:


CAUTION: If road testing, check the brake operation while still travelling at low speed before continuing with the test. If
the brakes pull to one side, or appear to be otherwise faulty, do not continue with the road test until the fault has been found
and rectified.
Initial gear engagement is smooth
Parking brake control operates smoothly and the parking brake releases quickly and completely
Transmission takes up the drive smoothly, without judder
The engine power output is satisfactory, full power is achieved, acceleration is smooth and pedal operation not stiff or
heavy, and engine speed returns to idle correctly
There is no excessive or abnormally colored smoke from the engine under normal driving, heavy load or overrun
conditions
Steering operation, including power steering, is smooth, accurate, not excessively heavy or with excessive free play or
vibration. Does not pull to one side and self centres smoothly after cornering
Speedometer, oil pressure warning lamp, coolant temperature gauge and tachometer register the correct readings or
operate correctly
Switches and controls operate smoothly and positively, warning lamps operate correctly and the direction indicator
control self cancels when the steering is returned to the straight ahead position
Heating and ventilation systems work correctly and effectively
Brake operation and efficiency

Brake Testing


WARNING: When brake testing, avoid breathing the smoke or fumes from hot brakes, this may contain asbestos dust
which is hazardous to health, see Health and Safety Precautions.

DTC Description Possible Causes Action Battery voltage at electric
steering column lock control
module too low
Electric steering column lock
control module, instrument
cluster, central junction box
fault with the road wheel against a curb. If the
column lock is failing to disengage, the customer
may be able to rectify this by rotating the
steering wheel while pressing the engine start
button
If fault persists, complete a CAN network
integrity test using the manufacturers approved
diagnostic system. Alternatively, refer to the
electrical circuit diagrams and check CAN circuits
between the central junction box, the instrument
cluster and the electronic steering column lock.
Refer to the electrical circuit diagrams and check
the central junction box, the instrument cluster
and the electronic steering column lock power
and ground supply circuits for short circuit to
ground, short circuit to power, open circuit, high
resistance. Repair circuit(s) as required. Clear
DTC, perform an on demand self-test and retest
If fault persists, check that the vehicle battery
supply voltage is between 9-16 volts. Rectify as
required B100D-96
Column Lock
Authorisation -
Component internal
failure
Battery voltage at electric
steering column lock control
module too low
Torque load on steering
column
CAN fault
Electric steering column lock
control module - Internal
failure
Clear DTC, repeatedly lock and unlock car using
the key fob and retest
If fault persists, check that the vehicle battery
supply voltage is between 9-16 volts. Rectify as
required
Ensure the column lock bolt movement is not
obstructed or restricted (the parked position of
the road wheels may be exerting a turning force
through the steering column, preventing the lock
from releasing. The steering wheel may need to
be held against the force to allow the column
lock to release). Clear DTC, repeatedly lock and
unlock car using the key fob and retest
If fault persists, complete a CAN network
integrity test using the manufacturers approved
diagnostic system. Alternatively, refer to the
electrical circuit diagrams and check CAN circuits
between the central junction box, the instrument
cluster and the electronic steering column lock.
Refer to the electrical circuit diagrams and check
the central junction box, the instrument cluster
and the electronic steering column lock power
and ground supply circuits for short circuit to
ground, short circuit to power, open circuit, high
resistance. Repair circuit(s) as required. Clear
DTC, perform an on demand self-test and retest
If fault persists, check and install a new electric
steering column lock control module as required B1024-87
Start Control Unit -
Missing message
Smart card docking station
failure - slave node not
responding
Carry out any pinpoint tests associated with this
DTC using the manufacturer approved diagnostic
system. Refer to the electrical circuit diagrams
and check the smart card docking station LIN
circuit for short, open circuit. Suspect the smart
card docking station, check and install a new
docking station as required, refer to the new
module/component installation note at the top
of the DTC Index B1046-11
Front Fog Lamp Control
Switch - Circuit short to
ground
Fog lamp switch circuit -
short to ground
Refer to the electrical circuit diagrams and check
fog lamp switch circuit for short to ground B1046-15
Front Fog Lamp Control
Switch - Circuit short to
battery or open
Fog lamp switch circuit -
short to power, open circuit
Refer to the electrical circuit diagrams and check
fog lamp switch circuit for short to power, open
circuit B1048-11 Brake Fluid Level Switch
- Circuit short to ground
Brake fluid level switch
circuit - short to ground
Refer to the electrical circuit diagrams and check
brake fluid level switch circuit for short to ground

it may turn out to be the most important.

2. Do not touch anything until a road test and a thorough visual inspection of the vehicle have been carried out. Leave the
tire pressures and vehicle load just where they were when the condition was first observed. Adjusting tire pressures,
vehicle load or making other adjustments may reduce the conditions intensity to a point where it cannot be identified
clearly. It may also inject something new into the system, preventing correct diagnosis.

3. Make a visual inspection as part of the preliminary diagnosis routine, writing down anything that does not look right.
Note tire pressures, but do not adjust them yet. Note leaking fluids, loose nuts and bolts, or bright spots where
components may be rubbing against each other. Check the luggage compartment for unusual loads.
4. Road test the vehicle and define the condition by reproducing it several times during the road test.

5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This will identify the correct diagnostic
procedure. Carry out the Road Test Quick Checks more than once to verify they are providing a valid result. Remember,
the Road Test Quick Checks may not tell where the concern is, but they will tell where it is not.

Road Test Quick Checks

1. 24-80 km/h (15-50 miles/h): With light acceleration, a moaning noise is heard and possibly a vibration is felt in the
front floor pan. It is usually worse at a particular engine speed and at a particular throttle setting during acceleration at
that speed. It may also produce a moaning sound, depending on what component is causing it. Refer to Tip-In Moan in
the Symptom Chart.

2. Acceleration/deceleration: With slow acceleration and deceleration, a shake is sometimes noticed in the steering
wheel/column, seats, front floor pan, front door trim panel or front end sheet metal. It is a low frequency vibration
(around 9-15 cycles per second). It may or may not be increased by applying brakes lightly. Refer to Idle Boom/Shake
/Vibration in the Symptom Chart.

3. High speed: A vibration is felt in the front floor pan or seats with no visible shake, but with an accompanying sound or
rumble, buzz, hum, drone or booming noise. Coast with the clutch pedal depressed or shift control selector lever in
neutral and engine idling. If vibration is still evident, it may be related to wheels, tires, front brake discs, wheel hubs
or front wheel bearings. Refer to High Speed Shake in the Symptom Chart.

4. Engine rpm sensitive: A vibration is felt whenever the engine reaches a particular rpm. It will disappear in neutral
coasts. The vibration can be duplicated by operating the engine at the problem rpm while the vehicle is stationary. It
can be caused by any component, from the accessory drive belt to the torque converter which turns at engine speed
when the vehicle is stopped. Refer to High Speed Shake in the Symptom Chart.

5. Noise/vibration while turning: Clicking, popping, or grinding noises may be due to a worn, damaged, or incorrectly
installed front wheel bearing, rear drive half shaft or CV joint.

6. Noise/vibration that is road speed relative: This noise/vibration can be diagnosed independent of engine speed or gear
selected (engine speed varies but torque and road speed remain constant). The cause may be a rear drive
axle/differential whine.
Road Conditions

An experienced technician will always establish a route that will be used for all NVH diagnosis road tests. The road selected
should be reasonably smooth, level and free of undulations (unless a particular condition needs to be identified). A smooth
asphalt road that allows driving over a range of speeds is best. Gravel or bumpy roads are unsuitable because of the additional
road noise produced. Once the route is established and consistently used, the road noise variable is eliminated from the test
results.


NOTE: Some concerns may be apparent only on smooth asphalt roads.

If a customer complains of a noise or vibration on a particular road and only on a particular road, the source of the concern
may be the road surface. If possible, try to test the vehicle on the same type of road.

Vehicle Preparation

Carry out a thorough visual inspection of the vehicle before carrying out the road test. Note anything which is unusual. Do not
repair or adjust any condition until the road test is carried out, unless the vehicle is inoperative or the condition could pose a
hazard to the technician.
After verifying the condition has been corrected, make sure all components removed have been installed.

Lift Test

After a road test, it is sometimes useful to do a similar test on a lift.

When carrying out the high-speed shake diagnosis or engine accessory vibration diagnosis on a lift, observe the following
precautions:


WARNING: If only one drive wheel is allowed to rotate, speed must be limited to 55 km/h (35 miles/h) indicated on the
speedometer since actual wheel speed will be twice that indicated on the speedometer. Speed exceeding 55 km/h (35 miles/h)
or allowing the drive wheel to hang unsupported could result in tire disintegration, differential failure, constant velocity joint