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Home >> Jaguar >> 2003 >> XJ8 Base >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brake System - General Information (2003.5-09) >> General Procedures >> Brake System Bleeding - VIN Range: G45704->H99999 (70.25.03)

Brake System Bleeding - VIN Range: G45704->H99999 (70.25.03)

WARNING: 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: Make sure that the vehicle is standing on a level surface or supported on a wheel free lift.
CAUTION: If brake fluid comes into contact with the paintwork, the affected area must be immediately washed down with cold water.
NOTE: The system consists of separate circuits for each front and diagonally opposite rear wheel. Each front to rear circuit and each wheel circuit can be bled individually of each other.
NOTE: The service anti-lock braking system (ABS) hydraulic control unit is supplied pre-filled with brake fluid. Therefore, a conventional bleed procedure should be adequate to remove all the air from the brake system.
    CAUTION: Make sure that the brake master cylinder reservoir filler cap does not become contaminated.
    Fig 1: Locating Brake Master Cylinder Reservoir Filler Cap
    G06387398Courtesy of JAGUAR CARS, INC.
  1. Remove the brake master cylinder reservoir filler cap.
    2. NOTE: Always use fluid from a sealed container and dispose of used fluid safely.
    Fig 2: Locating MAX Mark On Brake Master Cylinder Reservoir
    G06387399Courtesy of JAGUAR CARS, INC.
  2. Fill up the brake master cylinder reservoir to the MAX mark as necessary.
  3. Install a bleed tube to the rear right-hand brake caliper bleed nipple.
  4. Bleed the circuit.
    • Make sure the bleed tube is firmly attached to the bleed nipple.
    • Submerge the end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
    • Position the bleed jar base at least 300 mm (12 in) above the bleed nipple to maintain fluid pressure and prevent air leaking past the bleed nipple threads.
    • Open the bleed nipple half a turn.
    • Slowly apply the brake pedal to its maximum travel (this forces brake fluid into the bleed jar).
    • Close the bleed nipple.
    • Return the brake pedal to the rest position.
    • Wait 2 seconds to allow the brake fluid to replenish the system.
    • Fill up the brake master cylinder reservoir to the MAX mark as necessary.
    • Continue to bleed the circuit until air-free brake fluid is pumped into the jar.
    • Fully tighten the bleed nipple.
  5. Repeat the procedure for the rear left, front right and front left-hand brake circuits.
  6. Fill up the brake master cylinder reservoir to the MAX mark.
    Fig 3: Locating MAX Mark On Brake Master Cylinder Reservoir
    G06387399Courtesy of JAGUAR CARS, INC.
    NOTE: Due to the complexity of the fluid path within the integral park brake calipers, it may be difficult to achieve a satisfactory result using the procedure above when new calipers have been installed. Therefore carry out the following steps to make sure that the system is properly bled.
  7. Remove both rear wheels and tires. Refer to WHEEL AND TIRE (74.20.05) .
    8. NOTE: Left-hand shown, right-hand similar.
    Fig 4: Locating Logo Badge
    G06387415Courtesy of JAGUAR CARS, INC.
  8. Remove the logo badge.
    9. NOTE: Left-hand shown, right-hand similar.
    Fig 5: Locating Anti-Rattle Spring
    G06387416Courtesy of JAGUAR CARS, INC.
  9. Remove the anti-rattle spring.
    10. NOTE: Left-hand shown, right-hand similar.
    Fig 6: Locating Brake Caliper Retaining Bolt Dust Covers
    G06387417Courtesy of JAGUAR CARS, INC.
  10. Remove the brake caliper retaining bolt dust covers.
    11. NOTE: Left-hand shown, right-hand similar.
    Fig 7: Locating Brake Caliper Retaining Bolt Dust Covers
    G06387417Courtesy of JAGUAR CARS, INC.
  11. Detach the brake caliper.
    12. NOTE: The inner brake pad must have at least 7mm of friction material. If there is less then 7mm a new pad must be used.
    NOTE: Left-hand shown, right-hand similar.
    Fig 8: Locating Outer Brake Pad
    G06387419Courtesy of JAGUAR CARS, INC.
  12. Remove the outer brake pad.
    13. NOTE: Left-hand shown, right-hand similar.
    Fig 9: Locating Brake Caliper Retaining Bolt Dust Covers
    G06387417Courtesy of JAGUAR CARS, INC.
  13. Attach the brake caliper with a protective cloth placed between the caliper fingers and the disc.
  14. Slowly apply the brake pedal until the piston is extended to the brake disc.
    15. NOTE: Left-hand shown, right-hand similar.
    Fig 10: Locating Brake Caliper Retaining Bolt Dust Covers
    G06387417Courtesy of JAGUAR CARS, INC.
  15. Detach the brake caliper.
  16. Bleed the caliper.
    • Make sure the bleed tube is firmly attached to the bleed nipple.
    • Submerge the end of the bleed tube in a bleed jar containing a small quantity of approved brake fluid.
    • Position the bleed jar base at least 300 mm (12 in) above the bleed nipple to maintain fluid pressure and prevent air leaking past the bleed nipple threads.
    • Position the brake caliper with the piston facing down and the bleed nipple at the top.
    • Open the bleed nipple half a turn.
    • Using a suitable tool, fully retract the caliper piston.
    • Close the bleed nipple.
    • Repeat the above procedure twice.
    • Fill up the brake master cylinder reservoir to the MAX mark as necessary.
    • Continue to bleed the caliper using the above procedure until air-free brake fluid is pumped into the jar.
    • Fully tighten the bleed nipple.
    17. NOTE: Left-hand shown, right-hand similar.
    Fig 11: Locating Outer Brake Pad
    G06387419Courtesy of JAGUAR CARS, INC.
  17. Install the outer brake pad.
    18. NOTE: Left-hand shown, right-hand similar.
  18. Install the brake caliper.
    • Tighten to 28 Nm.
      Fig 12: Locating Brake Caliper Retaining Bolt Dust Covers
      G06387417Courtesy of JAGUAR CARS, INC.
    19. NOTE: Left-hand shown, right-hand similar.
    Fig 13: Locating Brake Caliper Retaining Bolt Dust Covers
    G06387417Courtesy of JAGUAR CARS, INC.
  19. Install the brake caliper retaining bolt dust covers.
    20. NOTE: Left-hand shown, right-hand similar.
    Fig 14: Locating Anti-Rattle Spring
    G06387416Courtesy of JAGUAR CARS, INC.
  20. Install the anti-rattle spring.
    21. NOTE: Left-hand shown, right-hand similar.
  21. Install the logo badge.
    • Tighten to 5 Nm.
      Fig 15: Locating Logo Badge
      G06387415Courtesy of JAGUAR CARS, INC.
  22. Install the wheels and tires. Refer to WHEEL AND TIRE (74.20.05) .
    23. NOTE: Always use fluid from a sealed container and dispose of used fluid safely.
    Fig 16: Locating MAX Mark On Brake Master Cylinder Reservoir
    G06387399Courtesy of JAGUAR CARS, INC.
  23. Fill up the brake master cylinder reservoir to the MAX mark as necessary.
    24. CAUTION: Make sure that the brake master cylinder reservoir filler cap does not become contaminated.
    Fig 17: Locating Brake Master Cylinder Reservoir Filler Cap
    G06387398Courtesy of JAGUAR CARS, INC.
  24. Install the brake master cylinder reservoir filler cap.
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