Bleed Citroen BERLINGO 2005 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine CLUTCH - GEARBOX - TRANSMISSION (continued)
Gearbox specifications312 - 314
Clutch specifications315 - 316
Checking and adjusting the hydraulic
clutch control317 - 318
Tightening torques: manual gearbox
319 - 330
Manual gearbox controls
331 - 343
Recommendations - precautions:
automatic gearbox344 - 346
Tightening torques: manual gearbox
347 - 349
Automatic gearbox controls
350 - 359
Driveshafts360
AXLES - SUSPENSION - STEERING
Axle geometry: C4361 - 364
Tightening torques: front axle365 - 366
Tightening torques: rear axle367
Tightening torques: power steering368 - 369
Setting the steering rack mid-point370
Checking the power steering pressure371 - 374
Axle geometry: Xsara375 - 379Adjusting the handbrake 426
Filling, bleeding the brakes427
AIR CONDITIONING
R134.a: quantities428
Checking the compressor lubricant429 - 430
Pollen filter: all types431 - 433
Filtering and drying cartridge434 - 436
Checking the efficiency of the circuit437 - 446
C4447 - 451
Xsara452
Xsara picasso453 - 456
CONTENTS
Tightening torques: front axle380
Tightening torques: rear axle382
Tightening torques: steering 383 - 384
Tightening torques: power steering385 - 387
Axle geometry: Xsara Picasso388 - 392
Tightening torques: front axle393
Tightening torques: rear axle394
Tightening torques: power steering395 - 397
BRAKES
Brake specifications: C4398 - 399
Tightening torques: Brakes401 - 403
Adjusting the handbrake 405
Filling, bleeding the brakes406 - 410
Brake specifications: Xsara411
Tightening torques 414
Brake specifications415 - 418
Adjusting the handbrake 419
Filling, bleeding the brakes420
Brake specifications: Xsara Picasso421 - 422
Brake specifications423 - 424
Aircon circuit
Angl-t2-Index-2005 9/01/06 10:05 Page IV

Downloaded from www.Manualslib.com manuals search engine 317
CLUTCH
GEARBOX
TRANSMISSION
HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS
B2BP04XC
IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any
ingress of impurities into the hydraulic circuit.
IMPERATIVE: Do not use automatic bleeding equipment
(risk of the brake fluid
emulsifying in the hydraulic circuit).
Couple a transparent tube (5)on the bleed screw, at «c».
Submerge the end of the tube (5)in the recipient containing the brake fluid, located
below the level of the clutch slave cylinder.
Use the transparent tube (5) to act as a siphon, at «b».
WARNING: the end of the tube (5) must be submerged in the brake fluid.
Open the bleed screw at «c».
XSARA PICASSO
Bleeding the hydraulic clutch control
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 317

Downloaded from www.Manualslib.com manuals search engine 318
CLUTCH
GEARBOX
TRANSMISSION
HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS
Bleeding the hydraulic clutch control
Action the clutch pedal manually through its full travel: 7 timesrapidly down and up.
Allow the clutch pedal to come back up to its high position.
Fill the brake fluid reservoir to the maximum of its capacity.
Open the bleed screw at «c».
Action the clutch pedal manually through its entire travel: 7 times
rapidly down and up.
The last time, keep the clutch pedal fully down.
Reclose the bleed screw, at «c».
If necessary, repeat the operation.
Top up the brake fluid to the MAX.level of the brake fluid reservoir.
Work the clutch vigorously 40 times
.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension (X)greater than or equal to 45 mm
(the dimension (X)is
given as a guide).
Repeat the bleed operations if necessary.
C5FP0FQC
XSARA PICASSO
B2BP04YC
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 318

Downloaded from www.Manualslib.com manuals search engine AXLES
SUSPENSION
STEERING
CHECKING THE POWER STEERING ASSISTANCE PRESSURE
Fill the power steering reservoir to the max.mark «a»on the cap (4).
Engine stopped, move the steering slowly from lock to lock, in both directions approx. ten times.
Top up the fluid to the max. mark «a»on the cap (4).
Run the engine at idle for 3 minutes, without any action on the steering wheel.
Move the steering from lock to lock, until there is no longer any tight spot.
Top up the level if it again goes down.
Bleed the circuit by moving the steering several timesin each direction.
Top up the level if it again goes down.
IMPERATIVE: Use new power steering fluid for both filling and topping-up the circuit.
B3EP16HC
374
C4
Angl.-t2-page361-397-2005 9/01/06 10:22 Page 374

Downloaded from www.Manualslib.com manuals search engine 406
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).
C4
Angl.-t2-PAGE398-427-2005 9/01/06 10:24 Page 406

Downloaded from www.Manualslib.com manuals search engine 407
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
C4
Angl.-t2-PAGE398-427-2005 9/01/06 10:24 Page 407

Downloaded from www.Manualslib.com manuals search engine 408
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
C4
Angl.-t2-PAGE398-427-2005 9/01/06 10:24 Page 408

Downloaded from www.Manualslib.com manuals search engine 409
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.
C4
Angl.-t2-PAGE398-427-2005 9/01/06 10:24 Page 409

Downloaded from www.Manualslib.com manuals search engine 410
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.
C4
Angl.-t2-PAGE398-427-2005 9/01/06 10:24 Page 410

Downloaded from www.Manualslib.com manuals search engine 420
BRAKESBLEEDING THE BRAKING SYSTEM XSARA
Bleeding: The brakes can be bled either:
- using brake bleeding equipment, in which case the pressure of the equipment should be set to2 bars.
- or in the conventional way.
IMPERATIVE order of bleeding
Wheels:
- Rear Right.
- Front Left.
- Rear Left.
- Front Right.
Top up using brake fluid supplied by CITROËN Replacement Parts.
Angl.-t2-PAGE398-427-2005 9/01/06 10:24 Page 420