Ati Citroen C2 2004 1.G Workshop Manual

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BRAKESBRAKE SPECIFICATIONS
Brake pedal gear 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:2,7 ± 0,5
Tightening torques (m.daN).
B3FP166DB3FP164CB3FP165C
C3 C3 PLURIEL

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BRAKES
BRAKE SPECIFICATIONS
Evolution: rear wheel cylinder (applies from RPO 9667)
C3 C3 Pluriel
Evolution.
New wheel cylinders at the rear, with cutoff pressure 27 bars instead of 35 bars.
Assembly.
(1)
Rear wheel cylinder.
Repair.
IMPERATIVE:The mixing of the old and new components is STRICTLY FORBIDDEN.
WARNING:
Identify the type of assembly prior to starting a repair.
ESSENTIAL: Systematically replace the wheel cylinders on both sides on the same axle.
Replacement parts.
Replacement Parts will market only the components for the new assembly.
C3 C3 PLURIEL

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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 operation3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C3 C3 PLURIEL

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BRAKES
B3FP16ED
HANDBRAKE (Adjustment)
Adjustment (continued).
(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 (accor
ding 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 mm and more
than 0,05 mm.
Refit: The brake drums.
The wheels.
The central console.Check the operation of the handbrake.
C3 C3 PLURIEL

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BRAKES
B3FP15XC
BLEEDING AND FILLING THE BRAKING SYSTEM
Tools.
[1]
Generic bleeding apparatus: «LURO» or similar.
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 reser
voir and to top it up, using only brake fluid that is clean and clear.
C3 C3 PLURIEL

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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
C3 C3 PLURIEL

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BRAKES
Without ABS 23,8 (expansion holes)Ftec 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
203/205 203/205
247 247
8/68/6
BENDIX JURID TEXTRR BENDIX JURID
D 8259 519 428 D 8259 E 558 519
BOSCH/Loadsensitive compensator
32
0,3 White
BRAKE SPECIFICATIONS
Saloons
XSARA
1.4i1.6i 16V
2.0i 16V
KFW NFU RFN RFS WJY 8HZ RHY RHZ1.9 D 1.4 HDi2.0 HDi
FTØ
mmMaster cylinder
Master vac
Caliper/piston makes
Disc
Disc thickness/min.thickness Ventilated
Brake pad grade
Thickness/min. thickness
RRØ
mmDrum Ø min./max.
Disc nonventilated
Make
Brake lining grade
Make/Type
Cutoff pressure in Bars
Ramp/Paint reference
Disc thickness/min.thickness
Engine type

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BRAKES
Without ABS 23,8 (expansion holes)Ftec 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
247247
8 / 68 / 6
JURID
E 558519 E 558 519
BOSCH/Loadsensitive compensator
32
0,3 White
BRAKE SPECIFICATIONS
Estates
1.4i 1.6i 16V 2.0i 16V 1.9 D 1.4 HDi 2.0 HDi
Engine type KFW NFU RFN WJY 8HZ RHY RHZ
FTØ
mmMaster cylinder
Master vac
Caliper/piston makes
Disc
Disc thickness/min. thicknessVentilated
Brake pad grade
thickness/min. thickness
RRØ
mmDrum Ø min./max.
Disc nonventilated
Make
Brake lining grade
Make/Type
Cutoff pressure in Bars
Ramp/Paint reference
Disc thickness/min.thickness
XSARA

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BRAKES
BRAKE SPECIFICATIONS
XSARA
Tighten the nuts (1)to 2.3 m.daN.
The clevis pin
(2)is held in place by a plastic clip.
B3FP10YD

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BRAKES
BRAKE SPECIFICATIONS 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).
B3FP09HCB3FP09JC
2
1