Get Brakes Guide for Citroen C3 SUV First Generation (2002-2009)

BRAKE SPECIFICATIONS (WITHOUT ABS)

1.4i

1.4 HDi

1.1i

KFV

8HX

8HW

HFX

Engine type

Master cylinder

20.6

Master vac

203.2

Caliper/piston

makes

Ø

LUCAS/TRW

266

C48/13 48

mm

FR

Plain

Disc

Ventilated

13/11

Disc thickness/min. thickness

Brake pad grade

TEXTAR T 4144

Drum

Ø

203

205

mm

Max. thickness

RR

DON

8259

Make

Brake lining grade

194

BRAKE SPECIFICATIONS (WITH ABS)

1.4 HDi 16V

1.6i 16V

8HV

8HY

NFU

Engine type

Master cylinder

22.2

Master vac

228.6

Caliper/piston

makes

Ø

LUCAS/TRW

C54/22 54

mm

FR

Plain

Disc

Ventilated

266

Disc thickness/min. thickness

22/20

Brake pad grade

TEXTAR T 4144

Cylinder or caliper

Disc Ventilated

LUCAS C38 HR 9/13

Ø

mm

247

9/7

RR Disc thickness/min. thickness

Make

GALFER

G 4554

Brake lining grade

195

BRAKE SPECIFICATIONS

Braking system specifications

Braking circuit without ABS - REF (drum brakes at the rear)

- 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

B3FP161D

196

BRAKE SPECIFICATIONS

Braking circuit with ABS - REF (drum brakes at the rear)

B3FP162D

197

BRAKE SPECIFICATIONS

Braking circuit with ABS - REF (disc brakes at the rear)

B3FP163D

198

BRAKE SPECIFICATIONS

Braking circuit with ABS - REF

(a) Hydraulic circuit.

(b) Electrical circuit.

(1) Master cylinder in tandem.

(2) Braking servo.

(3) Brake caliper (or drum at the rear).

(4) Hub equipped with a bearing with an integral magnetic wheel (48

pairs of poles).

(5) Wheel sensor.

(6) Brake fluid level sensor.

(7) Hydraulic block plus ECU.

(8) Stoplamp switch.

(9) Instrument panel.

(10) Diagnostic socket.

(11) Built-in systems interface (BSI).

B3GP02RP

199

BRAKE SPECIFICATIONS

(7) Hydraulic block

Part No.

Elements

Ref.

Supplier

Observations

47 way connector.

Alone on the hydraulic block..

Changing only the ECU is prohibited.

ABS MK 60

Electronic

ECU

7

ESP ABS

MK 60

2 way blue connector.

The sensors are inductive-type.

Mounted on the pivot.

Non-adjustable airgap: 0,16 to 1,6 mm.

Tightening torque: 0,8 ± 0,2 m.daN

Front wheel

sensor.

96 387 201 80

96 385 307 80

TEVES

5

2 way blue connector.

The sensors are inductive-type.

Mounted on the suspension arm.

Non-adjustable airgap: 0,35 to 1,6 mm.

Tightening torque: 0,8 ± 0,2 m.daN

Rear wheel

sensor.

Hub

bearing.

Hub equipped with a bearing with an integral

magnetic wheel (48 pairs of poles).

4

7

SNR

ABS MK.60

96 394 937 80

Hydraulic

block.

Installed on the front LH chassis member

4 adjustment channels

TEVES

200

ESP ABS MK 60

96 418 772 80

B3FP12XC

BRAKE SPECIFICATIONS

Brake pedal gear

Front brake

Rear brake

B3FP166D

B3FP164C

B3FP165C

Tightening torques (m.daN).

(12) Yoke fixing on caliper

(16) Servo fixing

2.2 ± 0.3

2 ± 0.5

10.5± 1

3± 0.3

(14) Rear caliper fixing on arm

(15) Yoke fixing on caliper

5.3±0.5

3.8±0.3

(17) Fixing on master cylinder

(13) Yoke fixing on caliper

201

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

operation 3 times).

Pull vigorously on the handbrake lever 4 or 5 times.

C5FP0ELD

202

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 mm at «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 mm and more

than 0,05 mm.

Refit:

- The brake drums.

- The wheels.

- The central console.

Check the operation of the handbrake.

B3FP16ED

203

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 reservoir

and to top it up, using only brake fluid that is clean and clear.

B3FP15XC

204

BLEEDING AND FILLING THE BRAKING SYSTEM

Bleeding, filling (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 caliper

B : 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

B3FP15YC

B3FP15ZD

205

BLEEDING AND FILLING THE BRAKING SYSTEM

Purge. remplissage (Suite).

With the bleeding apparatus

- Raccorder l’appareil à purger [1] sur le réservoir de liquide de frein (1).

- Régler la pression de l’appareil à 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.

B3FP160C

206

Brakes for Your Citroen C3 SUV First Generation (2002-2009)

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