Citroen BERLINGO 2005 1.G Workshop Manual

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BRAKES
PARKING BRAKE ADJUSTMENT
Adjustment.
IMPERATIVE: Respect the safety and cleanliness requirements.
Raise and support the vehicle.
Remove the central console.
WARNING: Check the routing of the brake cables under the vehicle.
Release the handbrake lever.
Press gently on the brake pedal
(then repeat the operation 3 times).
Action the handbrake lever with a force of 40 daN.
Use a feeler gauge at «J»to measure the movement of the lever in relation to its stop.
NOTE:The movement should be less than 1,5 mmand more than 0,05 mm.
(1)Nut for adjusting the tension of the handbrake cables
Move the nut (1)to obtain a movement «J»less than or equal to 1,5 mm.
Action the handbrake lever 8 timeswith a force of 40 daN.
With the handbrake released, check the movement «j»with a feeler gauge.
NOTE:The movement should be less than 1,5 mmand more than 0,05 mm.
Refit the central console
(see corresponding operation).
Check the efficiency of the handbrake.
B3FP7F1C
B3FP7F2D
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BRAKES
B3FP7EQC
BLEEDING AND FILLING THE BRAKING SYSTEM
Tools.
[1]Bleeding apparatus: «LURO» or similar
[2]LEXIA diagnostic tool: 4171-T
[3]PROXIA diagnostic tool: 4165-T
NOTE:Bleeding of the secondary braking circuit is done with the aid of diagnostic tools [2]and [3].
Draining of the brake fluid reservoir.
Remove the screws (3)and the battery tray (2).
Remove the filter of the brake fluid reservoir (4).
Drain the brake fluid reservoir (4)to the maximum extent
(if necessary, use a clean syringe).
Remove the screws (1).
Uncouple the clickfit union at «a».
Remove the brake fluid reservoir (4).
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BRAKES
B3FP7ESD
BLEEDING AND FILLING THE BRAKING SYSTEM
Disconnect the connector «b».
Uncouple the pipe (5).
Remove the reservoir (6), moving aside the tabs «c»of the pins (7).
Clean the brake fluid reservoir (4) and the brake fluid reservoir (6).
Refit the brake fluid reservoir (6).
Couple the pipe (5).
Reconnect the connector «b».
Couple the clickfit union, at «a».
Refit:
- The brake fluid reservoir (4).
- The screws (1).
- The filter of the brake fluid reservoir.
- The battery tray.
- The screws (3).
- The battery.
Reconnect the battery.
IMPERATIVE: Carry out the operations that are necessary following a reconnection of the
battery
(see corresponding operation).
B3FP7ERC
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BRAKES
B3FP7EUC
BLEEDING AND FILLING THE BRAKING SYSTEM
Filling the braking circuit.
WARNING: Use only the approved and recommended hydraulic fluids.
IMPERATIVE: Only use new brake fluid that has not emulsified; avoid any introduction of
impurities into the hydraulic circuit.
Fill the brake fluid reservoir (4).
Bleeding the primary braking circuit.
WARNING: During the bleed operations: take care to maintain the level of the brake fluid
in the reservoir, keep it topped up.
WARNING: The ABS system must not be in action during the bleed operation.
WARNING: Respect the sequence for the opening of the bleed screws.
Front brake caliper : Bleed screw (8).
Rear brake caliper : Bleed screw (9).
Bleed each brake caliper, proceeding in the following sequence:
- Front LH wheel.
- Front RH wheel.
- Rear LH wheel.
- Rear RH wheel.
B3FP7ETC
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BRAKES
BLEEDING AND FILLING THE BRAKING SYSTEM
Bleeding the braking circuit with the bleed apparatus.
Connect the bleed apparatus [1]on the brake fluid reservoir (4).
Adjust the apparatus pressure to 2 bars.
For each brake circuit:
- Couple a transparent tube on the bleed screw.
- Submerge the other end of the tube in a clean container.
- Open the bleed screw.
- Wait until the brake fluid flows out without air bubbles.
- Close the bleed screw.
- Remove the bleed apparatus [1].
Check the level of the brake fluid
(between the «DANGER»level and the «MAXI»level).
Fill if necessary with the the approved and recommended synthetic brake fluid.
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BRAKESBLEEDING AND FILLING THE BRAKING SYSTEM
Bleeding the braking circuit without the bleed apparatus.
NOTE:Two operators are necessary.
For each brake circuit:
- Apply the brake pedal to place the circuit under pressure.
- Couple a transparent tube on the bleed screw.
- Submerge the other end of the tube in a clean container.
- Open the bleed screw.
- Wait until the fluid flows out without air bubbles.
- Close the bleed screw.
NOTE:Recommence the process a second timeif that is necessary.
Check the level of the brake fluid
(between the «DANGER»level and
the «MAXI»level).
Fill if necessary with the the approved and recommended synthetic
brake fluid.Bleeding the secondary braking circuit.
WARNING: During the bleed operations: take care to maintain the
level of the brake fluid in the reservoir, keep it topped up.
NOTE:The bleed apparatus [1]is still connected on the brake fluid
reservoir (4).
Use the diagnostic tools [2]or [3].
Select the menu corresponding to the vehicle:
- ABSmenu
(according to equipment).- ESPmenu (according to equipment).
Follow the instructions of the diagnostic tool.
At the end of the bleed programme, check the level of the brake fluid,
top up if necessary.
Check the travel of the brake pedal: it must not be excessive. If it is,
restart the bleed procedure.
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BRAKES
Without ABS 23,8 (expansion holes)With ABS 23,8 (valve)
228,6
BOSCH 54 LUCAS 57 BOSCH 54
266 283 266
22 / 20
FERF 769 ASFM 380 FERF 769
13 / 2
228 / 230 228 / 230
247 247
8 / 6 8 / 6
JURID
E 558 519 E 558 519
BOSCH/Load-sensitive compensator
32
0,3 - White
BRAKE SPECIFICATIONS
Estates
TU3JP TU5JP4 EW10J4 DW8 DV4TD DW10TDDW10
ATED
FTØ
mmMaster cylinder
Amplifier
Caliper makes/pistons
Disc
Disc thickness/min. thicknessVentilated
Brake pad grade
Thickness/min. thickness
RRØ
mmDrum - Ø min./max.
Disc non-ventilated
Make
Brake lining grade
Make/type
Cut-off pressure in bars
Ramp/paint reference
Disc thickness/min. thickness
XSARA
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BRAKES
ABS/ESP HYDRAULIC BLOCK XSARA
Braking system specifications
- 'X'braking circuit.
- Front: disc brakes, ventilated
(according to model).
- Rear: drum brakes with automatic adjustment.
- Cable operated handbrake acting on the rear wheels.
(1)Hydraulic valve block «ABS Bosch 5.3»or
(1)Hydraulic valve block «ABS Bosch 5.3 REF»or
(1)Hydraulic valve block «ABS with ESP Bosch 5.7».
(2)Load sensitive braking compensator
(according to model).
B3FP09HC
B3FP09JC
2
1
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BRAKES
BRAKE SPECIFICATIONS
Gyrometer sensor (7) Hydraulic block
C4AP17YCB3HP002C
Observations Part no. Supplier Components
XSARA
ESP hydraulic
blockBOSCH 5.7 ESPLocated on the front
LH wheelarch:
4 adjustmentchannels.IMPERATIVE: Respect the direction of fitting of the gyrometer/
accelerometer sensor
(connector towards the rear of the vehicle).WARNING: The gyrometer/accelerometer sensor should not be
subjected to any impact. Any gyrometer/accelerometer sensor
having suffered an impact must be replaced.
Tightening torque (15): 0,6 ± 0,1 m.daN.
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BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
XSARA
Tighten the nuts (1)to 2.3 m.daN.
The shaft (2)is held in place by a plastic clip.
B3FP10YD
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