Content .. 65 66 67 68 ..

Jaguar X-Type Sedan and Estate (Wagon). Manual - part 67

1
2
3
4

5
6

Is the alignment within specification?
Yes

Vehicle is OK.

Adjust the alignment as necessary. For additional information, refer to
REFER to:

Underbody Misalignment Check

(502-00 Uni-Body, Subframe and Mounting System, General Procedures).

PINPOINT TEST D : THE PEDAL FEELS SPONGY

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

D1: CHECK FOR SPONGY PEDAL (IGNITION OFF)

Check for a firm brake pedal.

Is the brake pedal effort and brake pedal travel normal?
Yes

Vehicle is OK.

GO to D2

D2: CHECK BRAKE PEDAL RESERVE (IGNITION OFF)

Pump the brake pedal 10 times and hold on the final application.

Does the brake pedal feel firm on final application?
Yes

GO to D3

BLEED the brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation.

D3: CHECK BRAKE PEDAL RESERVE (ENGINE ON)

Engine is idle.
Apply the brake pedal lightly three or four times.
Wait 15 seconds for the vacuum to recover.
Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel
occurs.
Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
Release the accelerator pedal.

Does the brake pedal move downward as the engine speed returns to idle?
Yes

GO to D4

CHECK the vacuum to brake booster. For additional information, refer to
REFER to:

Brake Booster - RHD AWD/RHD FWD

(206-07 Power Brake Actuation, Removal and Installation).

D4: CHECK BRAKE FLUID LEVEL

Check the brake master cylinder reservoir fluid level.

Is the fluid level OK?
Yes

BLEED the brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation.

CHECK the brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder
Component Test in this section. ADD fluid and BLEED the brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation. REPEAT road test if necessary.

PINPOINT TEST E : THE PEDAL GOES DOWN FAST

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

E1: ROAD TEST VEHICLE

Road test and apply the brake pedal.

Is the brake pedal effort and brake pedal travel normal?
Yes

Vehicle is OK.

GO to E2

E2: CHECK BRAKE FLUID LEVEL

Check the brake master cylinder reservoir fluid level.

Is the fluid level within specification?
Yes

GO to E3

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation. REPEAT road test if necessary.

E3: CHECK BRAKE PEDAL TRAVEL-PRESSURIZE SYSTEM (IGNITION OFF)

Pump the brake pedal rapidly (five times).

Does the brake pedal travel build up and then hold?
Yes

BLEED the brake system. Refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

. TEST the system for normal operation. REPEAT road test. For additional information, refer to
REFER to:

Hydraulic Brake Actuation

(206-06 Hydraulic Brake Actuation, Diagnosis and Testing).

GO to E4

E4: CHECK FOR BRAKE SYSTEM LEAKS

1
2
3
4

1
2
3

Check for external brake system leaks. For additional information, refer to Master Cylinder in this section.

Are leaks found?
Yes

REPAIR as necessary, ADD fluid and BLEED brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation. REPEAT road test.

System is OK.

PINPOINT TEST F : THE PEDAL GOES DOWN SLOWLY

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

F1: ROAD TEST VEHICLE - CHECK BRAKE PEDAL OPERATION

Check if the condition occurs during actual stopping application by applying the brake pedal while the vehicle is
moving.

Does the condition occur when the vehicle is moving?
Yes

GO to F2

GO to F3

F2: CHECK FOR BRAKE SYSTEM LEAKS

Check for external brake system leaks. For additional information, refer to Master Cylinder in this section.

Are there any external brake system leaks?
Yes

REPAIR as necessary. ADD fluid and BLEED the brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation.

GO to F3

F3: CARRY OUT A BRAKE MASTER CYLINDER BYPASS TEST

Test for brake master cylinder bypass condition. Refer to Brake Master Cylinder Component Test in this section.

Are any concerns found?
Yes

INSTALL a new brake master cylinder, ADD fluid and BLEED the brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation.

System is OK.

PINPOINT TEST G : EXCESSIVE BRAKE PEDAL EFFORT

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

G1: CHECK BRAKE PADS

Check the brake pads for wear, contamination, correct installation, damage and type.

Are any concerns found?
Yes

INSTALL the front brake pads correctly or INSTALL new front brake pads if necessary. For additional information, refer
to
REFER to:

Brake Pads

(206-03 Front Disc Brake, Removal and Installation).

.INSTALL the rear brake pads correctly or INSTALL new rear brake pads if necessary. For additional information, refer
to
REFER to:

Brake Pads

(206-04 Rear Disc Brake, Removal and Installation).

.REPEAT road test.

GO to G2

G2: CHECK VACUUM

Disconnect the vacuum booster hose from the booster.
Connect a vacuum/pressure tester to the vacuum hose.
Run the engine at normal operating temperature.
Record the vacuum reading.

Is the reading 40.5kPa (12 in-Hg) or greater?
Yes

GO to G3

LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.

G3: INSPECT SYSTEM

Switch the engine off.
Reconnect the vacuum hose.
Inspect the brake booster, rubber grommet and all vacuum plumbing for cracks, holes, damaged connections or
missing clamps.
Pump the brake pedal several times to release the vacuum. Push down on the brake pedal and hold.

Does the brake pedal move down when the engine is started?
Yes

Vacuum system is OK.

GO to G4

G4: CHECK POWER BRAKE BOOSTER VALVE

Check the brake booster and vacuum pump valves. For additional information, refer to Brake Booster in this section.

Is the power brake booster and vacuum pump valve OK?
Yes

CHECK the brake booster. For additional information, refer to Brake Booster in this section. INSTALL a new brake
booster if necessary. TEST the system for normal operation.

INSTALL a new brake booster valve and vacuum pump valve. TEST the system for normal operation.

PINPOINT TEST H : BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE

1
2

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

H1: TEST BRAKE LOCKUP

Road test the vehicle and apply the brake pedal lightly.

Do the brakes lockup?
Yes

GO to H2

Vehicle is OK.

H2: INSPECT BRAKE PADS

Inspect brake pads for contamination, correct installation, damage and type.

Are any concerns found?
Yes

CHECK the front brake pads. For additional information, refer to
REFER to:

Front Disc Brake

(206-03 Front Disc Brake, Description and Operation).

.CHECK the rear brake pads. For additional information, refer to
REFER to:

Rear Disc Brake

(206-04 Rear Disc Brake, Description and Operation).

.INSTALL new brake pads as necessary.REPEAT road test.

GO to H3

H3: INSPECT BRAKE CALIPERS

Inspect brake calipers for binding, leaking or sticking.

Are any concerns found?
Yes

CHECK the front brake calipers. For additional information, refer to
REFER to:

Front Disc Brake

(206-03 Front Disc Brake, Diagnosis and Testing).

.CHECK the rear brake calipers. For additional information, refer to
REFER to:

Rear Disc Brake

(206-04 Rear Disc Brake, Diagnosis and Testing).

.INSTALL the brake calipers correctly or INSTALL new brake calipers as necessary. TEST the system for normal
operation. REPEAT road test if necessary.

Vehicle is OK.

PINPOINT TEST I : BRAKES DRAG

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

I1: ROAD TEST VEHICLE

Road test the vehicle and apply the brakes.

Are the brakes functioning correctly?
Yes

Vehicle is OK.

GO to I2

I2: CHECK CALIPERS

Check the front caliper pistons for binding, leaking or sticking. For additional information, refer to
REFER to:

Front Disc Brake

(206-03 Front Disc Brake, Diagnosis and Testing).

. Check the rear caliper pistons for binding, leaking or sticking. For additional information, refer to
REFER to:

Rear Disc Brake

(206-04 Rear Disc Brake, Diagnosis and Testing).

Do the disc brake caliper pistons and pins bind, leak or stick?
Yes

INSPECT the brake calipers and parking brake cables. INSTALL new components as necessary. Road test vehicle.

GO to I3

I3: CHECK BRAKE BOOSTER

Check the brake booster connecting rod alignment and travel. For additional information, refer to
REFER to:

Power Brake System

(206-07 Power Brake Actuation, Diagnosis and Testing).

Is the connecting rod OK?
Yes

Vehicle is OK.

INSTALL a new brake booster. For additional information, refer to
REFER to:

Brake Booster - RHD AW D/RHD FWD

(206-07 Power Brake Actuation, Removal and Installation).

. TEST the system for normal operation.

PINPOINT TEST J : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

J1: TEST ON ROUGH ROAD

Road test the vehicle on rough road conditions.
Apply the brakes slowly.

Is the brake pedal effort and brake pedal travel normal?
Yes

Vehicle is OK.

GO to J2

J2: CHECK BRAKE FLUID LEVEL

Check the brake master cylinder reservoir fluid level.

Is the fluid level OK?
Yes

GO to J3

CHECK brake master cylinder reservoir sealing points. For additional information, refer to Brake Master Cylinder in
this section. ADD brake fluid and BLEED the brake system. For additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

.TEST the system for normal operation. REPEAT road test if necessary.

J3: CHECK BRAKE PEDAL RESERVE

Engine is idle.

2
3
4

5
6

1
2
3
4
5

Apply the brake pedal lightly three or four times.
Wait 15 seconds for the vacuum to replenish.
Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel
occurs.
Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min.
Release the accelerator pedal.

Does the brake pedal move downward as the engine speed returns to idle?
Yes

GO to J4

CHECK the vacuum to the brake booster. For additional information, refer to
REFER to:

Power Brake System

(206-07 Power Brake Actuation, Diagnosis and Testing).

J4: CHECK THE FRONT HUB AND BEARING ASSEMBLY

Check the front hub and bearing assembly. For additional information, refer to
REFER to:

Front Suspension

(204-01 Front Suspension, Diagnosis and Testing).

Are the front wheel bearings loose?
Yes

INSTALL a new front wheel bearing if damaged. For additional information, refer to
REFER to:

Front Wheel Bearing and W heel Hub

(204-01 Front Suspension, Removal and Installation).

. TEST the system for normal operation.

CHECK the front brake discs for thickness variances. For additional information, refer to
REFER to:

Brake Disc Runout Check

(206-00 Brake System - General Information, General Procedures).

PINPOINT TEST K : SLOW OR INCOMPLETE BRAKE PEDAL RETURN

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

K1: CHECK FOR BRAKE PEDAL RETURN

Run the engine at fast idle while making several brake applications.
Pull the brake pedal rearward with approximately 44 N force.
Release the brake pedal and measure the distance to the toe board.
Make a hard brake application.
Release the brake pedal and measure the brake pedal to toe board distance. The brake pedal should return to its
original position.

Does the brake pedal return to its original position?
Yes

Vehicle is OK.

GO to K2

K2: CHECK FOR BRAKE PEDAL BINDING

Check the brake pedal to make sure it is operating OK.

Is the brake pedal operating OK?
Yes

INSTALL a new brake booster. For additional information, refer to
REFER to:

Brake Booster - RHD AWD/RHD FWD

(206-07 Power Brake Actuation, Removal and Installation).

.TEST the system for normal operation.

REPAIR or INSTALL new brake pedal. TEST the system for normal operation.

Component Tests

Brake Booster

1. Check all hoses and connections. All unused vacuum connectors should be capped. Hoses and their connections should be correctly

secured and in good condition with no holes and no collapsed areas. Inspect the valve on the brake booster for damage.

2. Check the hydraulic brake system for leaks or low fluid.

3. With the transmission in PARK (automatic transmissions) or in NEUTRAL (manual transmissions), stop the engine and apply the

parking brake. Pump the brake pedal several times to exhaust all vacuum in the system.

4. With the engine switched off and all vacuum in the system exhausted, apply the brake pedal and hold it down. Start the engine.

If the vacuum system is operating, the brake pedal will tend to move downward under constant foot pressure. If no motion is felt,
the vacuum booster system is not functioning.

5. Remove the vacuum hose from the brake booster. Manifold vacuum should be available at the brake booster end of the hose with

the engine at idle speed and the transmission in PARK or NEUTRAL. Make sure that all unused vacuum outlets are correctly
capped, hose connectors are correctly secured and vacuum hoses are in good condition. W hen it is established that manifold
vacuum is available to the brake booster, connect the vacuum hose to the brake booster and repeat Step 3. If no downward
movement of the brake pedal is felt, install a new brake booster.

6. Operate the engine for a minimum of 10 seconds at a fast idle. Stop the engine and allow the vehicle to stand for 10 minutes.

Then, apply the brake pedal with approximately 89 N of force. The pedal feel (brake application) should be the same as that noted
with the engine running. If the brake pedal feels hard (no power assist), install a new valve and then repeat the test. If the brake
pedal still feels hard, install a new brake booster. If the brake pedal movement feels spongy, bleed the brake system. For
additional information, refer to
REFER to:

Brake System Bleeding

(206-00 Brake System - General Information, General Procedures).

in this section.

Brake Master Cylinder

Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through the brake pedal. In diagnosing the
condition of the brake master cylinder, check pedal feel as evidence of a brake concern. Check for brake warning lamp illumination and the
brake fluid level in the brake master cylinder reservoir.

Normal Conditions

Content .. 65 66 67 68 ..