brake disc Citroen XSARA 2004 1.G Workshop Manual

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RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Safety requirements.
ESSENTIAL:Given the special features of the MA type piloted
manual gearbox, observe the requirements detailed below.
IMPERATIVE: Always disconnect the battery negative terminal
before operating on the actuators.
NOTE:
After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position
(rod pushed in).
IMPERATIVE:After Sales checks done with the engine running must be
performed with «Neutral»engaged and the handbrake on (unless there
is a clear mention otherwise in the repair procedures).
IMPERATIVE:The areas of movement of the clutch fork and of the gear
engagement lever must always be kept free during the actuatoroperating phases.
CLUTCH
GEARBOX
TRANSMISSION
IMPERATIVE:When initialising the clutch actuator and/or gearbox
actuator, do not allow any person to walk or stand in front of the vehicle.
WARNING:When the engine is running, it is forbidden to perform
repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
WARNING:Each time the driver’s door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators
(there is movement of the clutch fork and
of the gear lever).
WARNING:Whether the ignition is switched on or not, an action on the
gear selector causes the clutch fork and the gear engagement lever to
move on the gearbox.
Engines: HFX KFV NFU 8HX
C2

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BRAKES
20,6
203,2
LUCAS.TRW/C 48/13/48
266
13/11
0,05
0,01
TEXTRR/T 4144
13/3
203/205
38
DON/8259/1
BRAKE SPECIFICATIONS (WITHOUT ABS)
Master cylinder
ØMaster vac
mm Caliper/piston makes
Disc Plain
FTDisc thickness/minimum thickness
Maximum runout (mm)
Difference in max. thickness
on same circumference (mm)
Supplier / Brake pad grade
Original thickness/minimum thickness
ØOriginal drum/maximum
RR mm Width
Supplier / grade1.1i1.4 HDi
HFXKFV 8HX
Engine type
C2
1.4i

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BRAKESBRAKE SPECIFICATIONS (WITH ABS)
Engine type
Master cylinder
Master vac
ØCaliper/piston makes
FT
mm
DiscPlain
Ventilated
Disc thickness/minimum thickness
Supplier / Brake pad grade
Ø mm Disc Plain
Disc thickness/minimum thickness
RRSupplier / Brake pad grade
ØmmOriginal drum/
maximum/Width
Supplier / Lining grade
(*)
= With emergency braking assistance (AFU).
1.1i
HFX KFV NFU 8HX1.4i1.6i 16V 1.4 HDi
C2
22,2 (*)
228,6
LUCAS.TRW/C 48/13/48LUCAS.TRW LUCAS.TRW/C
C 54/22/54 48/13/48
266
266
13/1122/2013/11
TEXTRR/T 4144
247
9/7
LUCAS.TRW C 38 HR 9/13
203/205/38203/205/38
DON 8259/1 GALFER G 4554 DON 8259/1

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BRAKES
B3FP7BSD
BRAKE SPECIFICATIONS
Braking circuit without ABS REF (drum brakes at the rear)
Braking system specifications
Braking circuit at «X».
Front brakes with ventilated discs
(*).
Rear brakes with eitther drums or discs
(*).
Handbrake lever controlling cables acting on the
rear wheels.
The compensator and main brake limiter functions
are assured by the
ABS EBD system.
NOTE: REF= Electronic Brakeforce Distribution.
(*)= according to version.
C2

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BRAKES
BRAKE SPECIFICATIONS
Braking circuit with ABS REF (disc brakes at the rear)
B3FP7BUD
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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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