Engine Citroen C3 2004 1.G Workshop Manual

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C2
BRAKE SPECIFICA TIONS
(7) Hydraulic blockBRAKESRef. Components Supplier Part no. Observations
ABS MK 70 Mounted on the front LH chassis
Hydraulic block 96 514 120 80 member.
ESP ABS MK.60 4 adjustment channels.
7 96 490 288 80
ABS MK.70
ECU ESP ABS 26way connector.
MK 60 Integral to the hydraulic block.
2way blue connector.
The sensors are inductivetype.
Front wheel sensor TEVES Mounted on the pivot
Nonadjustable airgap:
0.16 to 1.6 mm.
596 387 201 80Tightening torque:0.8 ±0.2 m.daN.
2way blue connector.
The sensors are inductivetype
Rear wheel sensor Mounted on the suspension arm.
Nonadjustable airgap
: 0,35 à 1,6 mm.
Tightening torque:0,8 ± 0,2 m.daN.
Hub equipped with a bearing with
4 Hub bearing SNR an integral magnetic wheel
(48 pairs of poles).B3FP7BVC

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BRAKESBRAKE SPECIFICATIONS
Brake pedal
Front brakes Rear brakes
(16)
Servo fixing:2,2 ±0,3
(17)Fixing on master cylinder:2 ±0,5(12)Yoke fixing on caliper: 10,5 ± 1
(13)Yoke fixing on caliper: 3 ± 0,3(14)
Rear caliper fixing on arm: 5,3 ± 0,5
(15) Yoke fixing on caliper: 3,8 ± 0,3
Tightening torques (m.daN).
B3FP166DB3FP164CB3FP165C
C2

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BRAKES
C5FP0ELD
HANDBRAKE (Adjustment)
Adjustment.
Lift and chock the vehicle.
Remove:
The rear cover
(8).
The nut (9).
The handbrake trim (6).
The gear lever gaiter (5).
The front cover (3).
The screws (1).
Disconnect the connectors of the following components:
The cigar lighter
(2).
The electric window buttons (4).
Remove the central console
(7).
WARNING:Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal
(Then repeat the ope
ration 3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C2

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BRAKES
B3FP16ED
HANDBRAKE (Adjustment)
Adjustment (continued).
A
: Drum brakes.B:Disc brakes.(10)Nut for adjusting cable tensions.
Remove:
The rear wheels.
The drums
(according to version).
Release the handbrake.Use a gauge set to measure at
«a»the travel of the lever
from its stop.
Adjust the nut
(10)to obtain a travel of less than or equal
to 1 mmat «a».
Refit the brake drums without tightening them (according
to version).
Action the handbrake lever 8 times with an effort of 40 m.daN.
With the handbrake released, check the travel of the
lever at
«a», using a gauge set.NOTE:The travel should be less than 1 mmand more
than 0,05 mm.
Refit:
The brake drums. The wheels.
The central console.
Check the operation of the handbrake.
C2

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BRAKES
B3FP15XC
BLEEDING AND FILLING THE BRAKING SYSTEM
Tools.
[1]
Generic bleeding apparatus :«LURO»Bleeding, refilling.
Draining.
Drain the brake fluid reservoir (1)to the maximum(if necessary, use a clean syringe).
Disconnect the connector (4).
Uncouple the pipe (2).
Unscrew the shaft (3).
Remove the reservoir (1).
Empty the brake fluid reservoir (1).
Clean the brake fluid reservoir (1).
Refit:
The brake fluid reservoir
(1).
The shaft (3).
Couple the pipe (2).
Reconnect the connector (4).
Filling the braking system.WARNING:Use only those hydraulic fluids that are approved and recommended.
Fill the brake fluid reservoir (1).
Bleeding the braking system.WARNING:During the bleeding operation, take care to maintain the level of brake fluid in the reservoir
and to top it up, using only brake fluid that is clean and clear.
C2

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BRAKES
B3FP15YCB3FP15ZD
BLEEDING AND FILLING THE BRAKING SYSTEM (Continued)
Bleeding the primary braking circuit.
WARNING:The ABS should not be active during the
bleeding operation.
Front brake caliper, Bleed screw
(5).A: Rear brake caliperB: Rear brake drum
Bleed screw
(6).
Bleed each wheel cylinder, proceeding in the following
order:
Front LH wheel.
Front RH wheel.Rear LH wheel.
Rear RH wheel.
C2

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BRAKES
B3FP160C
BLEEDING AND FILLING THE BRAKING SYSTEM (Continued)
With the bleeding apparatus.
Connect the bleeding apparatus [1]on the brake fluid reservoir (1).
Adjust the apparatus pressure to
2 Bars.
For each circuit:
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles. Close the bleed screw.
Remove the bleeding apparatus
[1].
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE:Two operators are necessary.
For each circuit:
Apply the brake pedal to place the circuit under pressure.
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles.
Close the bleed screw. Remove the tool
[1].
NOTE:Recommence the process a second time if that is necessary.
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
C2

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BRAKESBRAKE SPECIFICATIONS (WHITHOUT ABS REF)
Engine typeHFX KFV KFU 8HX 8HW
Master cylinder
20,6
Ø Master vac203,2
mm Caliper/piston makesLUCAS/TRW C48/13 48
FT Disc Plain266 266
Disc thickness/minimum thickness13/1113/11
Ø
mm Disc Ventilated266
Disc thickness/minimum thickness22/20
Brake pad gradeTEXTRR T 4144
ØDrum / Max. thickness
mm Width203/205/38
RRMakeDON
Brake lining grade8259
Braking compensator (Vehicle without ABS) (CICR= Compensator integral to the wheel cylinder). REF= Electronic brakeforce distribution.
Supplier/Type/Cutoff pressure (Bar)RPO 9666 LUCAS LUCAS/CICR/35Supplier/Type/Cutoff pressure (Bar)RPO 9667 LUCAS LUCAS/CICR/27 1.1i
1.4i1.4i 16V 1.4 HDi
C3

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BRAKES
BRAKE SPECIFICATIONS (WITH ABS REF)
Engine type HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Master cylinder
22,2(*)
Ø Master vac
228,6
mm Caliper /piston LUCAS/TRW LUCAS/TRW LUCAS/TRW LUCAS/TRWmakesC 48/13 48 C 54/22 54 C 48/13 48 C 54/22 54
Disc Plain266 266
FT Disc thickness/minimum thickness13/11 13/11
Ø
mm Disc Ventilated266 266
Disc thickness/minimum thickness22/20 22/20
Brake pad gradeTEXTRR T 4144
Ø Cylinder or caliperLUCAS C38 HR 9/13
mm Disc Plain247 247
RR Disc thickness/minimum thickness9/7 9/7
Ø Drum / Max. thickness /
mm Width203/205/38 203/205/38
MakeDONGALFER DON GALFER
Brake lining grade8259 G 4554 8259 G 4554
(*)= With emergency braking system.REF= Electronic brakeforce distribution.NOTE:Braking compensators = The compensator and limiter functions for the main brakes are assured by the ABS REF system. 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi 1.4 HDi 16V
C3

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BRAKESBRAKE SPECIFICATIONS (WITH & WITHOUT ABS REF)
Engine typeKFV 8HX KFV NFU 8HX
Master cylinder
20,6 22,2(*)
ØMaster vac
203,2228,6
FT mm Makes /piston makesLUCAS/TRW C38 HR 9/13
Disc Ventilated266
Disc thickness/minimum thickness22/20
Brake pad gradeTEXTRR T 4144
ØCylinder or caliperLUCAS/TRW C 38/13 38
mmDiscPlain247
RR Disc thickness/minimum thickness9/7
ØDrum / Max. thickness /
mmWidth203/205/38203/205/38
MakeDONGALFERDON
Brake lining grade8259/1 G 4554 8259/1
(*)= With emergency braking system.(CICR = Compensator integral to the wheel cylinder)Braking compensator (Vehicle without ABS)REF= Electronic brakeforce distribution.
Supplier/Type/Cutoff pressure (Bar) :LUCAS/CICR/27
Braking compensator (Vehicle with ABS)NOTE:Braking compensators = The compensator and limiter functions for the main brakes are assured by the ABS REF system.
C3 PLURIEL
Sans ABS REF Ftec ABS REF
1.4i 1.4 HDi 1.4i 1.6i 16V 1.4 HDi