Get Brakes Guide for Citroen C6 4 Door First Generation (2005-2012)

BRAKE SPECIFICATIONS

3.0i 24S

ES9A

2,7 24S

Engine plate

Master cylinder/diameter/travel

DT17BTED4

23,8 / 19,8/20,2/AFU (1)

254 / TEVES / AMCT / AFT (2)

Amplifier/supplier/type

Supplier/type/piston diameter

TRW / C II 40 + 45 WE - 30-12 PE / 40 et 45

FT

Disc diameter

Ventilated

330

Disc thickness/min. thickness

Brake pad grade

30/28

JURID-966 (with wear warning lamps)

TRW / C38 HR-PEX / 38

302

Caliper/supplier/type/piston diameter

Disc diameter

Ventilated

RR

Disc thickness/min. thickness

Brake pad grade

22/20

GALFER / G4555

(1) AFU = Emergency braking assistance.

(2) AFT = Automatic lighting of hazard lamps under emergency braking.

170

BRAKING SYSTEM: GENERAL SPECIFICATIONS

Braking circuit

Braking system

Braking circuit in the form of an X.

Disc brakes at the front and at the rear

(vehicles all types):

- The front brake discs are ventilated.

- The rear brake discs are ventilated.

Electric parking brake (FSE) acting via cables on the

rear wheels.

The compensator and main brake limiter functions are

assured by the ABS REF systems.

ESP is fitted as standard on the entire range.

NOTE: - REF (EBD) = Electronic Brakeforce

Distribution.

- ESP = Electronic Stability Programme.

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171

BRAKING SYSTEM: GENERAL SPECIFICATIONS

ABS/ESP hydraulic valve block

Components

Hydraulic valve block

ECU

Supplier

TRW

Reference

Observations

Located on the front LH chassis member:

4 regulation channels

ESP

VSC 440

25-way connector

Integral to the hydraulic valve block

2-way black connector

Front wheel sensor

Rear wheel sensor

The sensors, of inductive type, are fitted on the pivot

Air gap non-adjustable: 0.25 to 1.65 mm

2-way black connector

SIEMENS

VDO

The sensors, of inductive type, are fitted on the pivot

Air gap non-adjustable: 0.23 to 1.35 mm

The hub has a bearing with integral magnetic wheel

(48 pairs of poles)

Front pivot bearing

Rear hub bearing

NSK

The rear hub-bearing has a radial ABS target

(48 pairs of poles)

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172

BRAKING SYSTEM: GENERAL SPECIFICATIONS

Parking brake

(1) Electrically-controlled parking brake system (FSE)

(2) Parking brake cables

(3) Cable for manual unlocking of the electric parking brake (FSE).

WARNING: It is forbidden to open the electric parking brake system in After Sales. If a

malfunctioning of the electric parking brake is diagnosed, it is necessary to replace it.

Changing of the parking brake cables does not necessitate opening of the electric parking

brake system (see corresponding operation).

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(4) Handle for manual unlocking of the electric parking brake (FSE)

(5) Switch for the electric parking brake (FSE)

If it is impossible to release the electric parking brake, a handle (4) located in the front central

armrest will mechanically unlock the electric parking brake.

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173

TIGHTENING TORQUES: BRAKING SYSTEM

Front brakes

1

2

3

4

5

6

7

Front brake disc

1

0,1

0,2

0,5

Yoke on brake caliper

Unions on brake piping

Front brake caliper

3

4

11,5

1

Hydraulic valve block on intermediate support

Intermediate support on support

Front wheel sensor

0,8 0,2

0,8 0,1

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174

TIGHTENING TORQUES: BRAKING SYSTEM

Braking amplifier

Braking amplifier on support

8

9

Support on bulkhead

Master-cylinder

2,1 0,3

10

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175

TIGHTENING TORQUES: BRAKING SYSTEM

Rear brakes

11

12

13

14

Rear brake caliper

3,5 0,3

1,5 0,1

Unions on brake piping

Rear brake caliper support

Rear wheel sensor

10,8

1

0,8 0,1

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176

TIGHTENING TORQUES: BRAKING SYSTEM

Parking brake

15

16

17

18

Electric parking brake system (FSE)

Nut for parking brake cables

0,4 0,06

0,6

6

Gyrometer/accelerometer sensor on support

Sensor support on body

0,9 0,1

0,4 0,06

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Gyrometer/accelerometer sensor

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177

VALUES FOR CHECKING AND ADJUSTING THE BRAKING SYSTEM

Front brakes

Rear brakes

Engines

ES9A - DT17BTED4

Engines

ES9A - DT17BTED4

Type

Ventilated brake discs

Type

Ventilated brake discs

Diameter (mm)

Nominal thickness (mm)

Minimum thickness (mm)

330

30

Diameter (mm)

Nominal thickness (mm)

Minimum thickness (mm)

302

22

28

20

Difference in maximum thickness

on same circumference (mm)

Difference in maximum thickness

on same circumference (mm)

0,01

0,05

0,01

0,05

Maximum run-out (mm)

Front brake pads (engines all types)

Rear brake pads (engines all types)

Nominal thickness (mm)

Minimum thickness (mm)

13

3

Nominal thickness (mm)

Minimum thickness (mm)

11,15

2

178

GENERAL FEATURES OF ELECTRIC PARKING BRAKE

Presentation.

(6) Electric parking brake control

"a" Parking brake warning lamp

Functioning of the electric parking brake.

To apply the parking brake:

Prior conditions:

- Vehicle stationary or not.

- Ignition switched on.

- Engine running or not.

Pull and release the control (6).

NOTE: The parking brake can be activated when the vehicle is moving, at whatever speed, but

only if the control (6) is kept pulled, the parking brake being deactivated as soon as the control (6)

is released.

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NOTE: The electric parking brake has an "anti-lock" system for limiting the locking of the wheels

and guaranteeing vehicle stability if the parking brake is actioned while the vehicle is moving.

To release the parking brake:

Prior conditions:

- Vehicle stationary.

- Gear lever in position P.

- Ignition switched on.

- Engine running.

Press on the brake pedal.

Pull and release the control (6).

Parking brake warning lamp:

Condition for the warning lamp "a" coming on:

- Electric parking brake activated or incorrectly deactivated.

- Malfunctioning of the electric parking brake.

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179

GENERAL FEATURES OF ELECTRIC PARKING BRAKE

Presentation.

(1) Handle for manual unlocking of the electric parking brake (FSE)

(2) Cable for manual unlocking of the electric parking brake

(3) Rear RH cable of the electric parking brake

(4) Electric parking brake system (FSE)

(5) Rear LH cable of the electric parking brake

(6) Electric parking brake control

"a" Parking brake warning lamp

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Normal functioning of the electric parking brake.

Applying the parking brake.

Prior conditions:

- Vehicle stationary or not.

- Ignition switched on.

- Engine running or not.

Pull and release the control (6).

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180

GENERAL FEATURES OF ELECTRIC PARKING BRAKE

NOTE: The parking brake can be activated when the vehicle is moving, at whatever speed, but only if

the control (6) is kept pulled, the parking brake being deactivated as soon as the control (6) is released.

NOTE: The electric parking brake has an "anti-lock" system for limiting the locking of the wheels and

guaranteeing vehicle stability if the parking brake is actioned while the vehicle is moving.

Releasing the parking brake.

Prior conditions:

- Vehicle stationary.

- Gear lever in position P.

- Ignition switched on.

- Engine running.

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Press on the brake pedal.

Pull and release the control (6).

Parking brake warning lamp.

Condition for the warning lamp "a" coming on:

- Electric parking brake activated or incorrectly deactivated.

- Malfunctioning of the electric parking brake.

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181

GENERAL FEATURES OF ELECTRIC PARKING BRAKE

Releasing of the electric parking brake (with a fault).

NOTE: Impossible to release the parking brake with the method "Normal functioning".

The fault may be caused by the following components:

- Battery voltage.

- Malfunctioning of the electric parking brake system.

Open the central armrest.

Pull on the handle (7) located on the plastic part of the central armrest in order to release the parking

brake mechanically.

WARNING: This control does not permit application of the parking brake.

WARNING: It is forbidden to open up the electric parking brake system.

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182

ELECTRIC PARKING BRAKE SYSTEM

Removing-refitting the electric parking brake system.

IMPERATIVE: Respect the safety and cleanliness requirements.

WARNING: Before disconnecting the battery, partially open the door windows.

Removing.

IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables.

IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in

the central armrest, before operating on the parking brake cables.

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Disconnect the battery.

Raise and support the vehicle, wheels hanging.

Remove the central console (1) (see corresponding operation).

Uncouple the handle (2) from the manual unlocking cable of the electric parking brake.

Remove:

- The exhaust line (4) (ES9A engine).

- The protection (5).

- The protection (3).

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183

ELECTRIC PARKING BRAKE SYSTEM

Uncouple the parking brake cable (6) from the brake caliper (on each side).

Unclip the parking brake cable at "a" (on each side).

Detach the brake cables from their attachments on the bodywork.

Extract the manual unlocking cable of the electric parking brake from its location at "b".

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184

ELECTRIC PARKING BRAKE SYSTEM

Slacken the nuts (7).

Remove the electric parking brake system assembly.

Refitting.

Refit the electric parking brake system assembly.

Tighten the nuts (7)

: 0,4 0,1 m.daN.

Attach the brake cables on their attachments on the bodywork.

Clip the parking brake cable, at "a" (on each side).

Couple the parking brake cable (6) on the brake caliper (on each side).

IMPERATIVE: Position the shim (8) (thickness 3 mm) at "c" (on each side).

Engage the manual unlocking cable of the electric parking brake in its location at "b".

Couple the handle (2) to the parking brake cable.

Refit the central console (1) (see corresponding operation).

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Refit:

- The protections (5) and (3).

- The exhaust line (4) (ES9A engine).

Reconnect the battery.

Apply and release the electric parking brake.

Check the functioning of the electric parking brake.

NOTE: Remove the shim (8) from the brake calipers.

IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery

(see corresponding operation).

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185

ELECTRIC PARKING BRAKE CABLES

Removing-refitting the parking brake cables.

IMPERATIVE: Respect the safety and cleanliness requirements.

WARNING: Before disconnecting the battery, partially open the door windows.

Removing.

IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables.

IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in

the central armrest, before operating on the parking brake cables.

Disconnect the battery.

Raise and support the vehicle, wheels hanging.

IMPERATIVE: Do not introduce any foreign body into the electric parking brake system.

Remove the electric parking brake system (see corresponding operation).

"a" connector

(1) electric parking brake system (FSE)

(2) manual unlocking cable

Undo the nuts (3).

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186

ELECTRIC PARKING BRAKE CABLES

Connector end.

Unclip and push back the ring (4).

Uncouple the parking brake cable (5).

Manual unlocking cable end.

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Do up at «b».

Uncouple the parking brake cable.

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187

ELECTRIC PARKING BRAKE CABLES

Refitting.

Connector end.

Clip the parking brake cable (5) at «c».

Clip the ring (4).

NOTE: Align the pin «d» with the notch «e».

Do up the nut (3).

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Tighten the nut (3) to

: 0,6 0,1 m.daN.

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188

ELECTRIC PARKING BRAKE CABLES

Manual unlocking cable end.

NOTE: Grease the cable worm (6).

Engage the parking brake cable (6) into the electric parking brake system.

Do up 3 turns anti-clockwise at "b".

NOTE: Align the pin "g" with the notch "f".

Do up the nut (3).

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Tighten the nut (3) to

: 0,6 0,1 m.daN.

Refit the electric parking brake system (see corresponding operation).

Reconnect the battery.

Apply and release the electric parking brake.

Check the functioning of the electric parking brake.

IMPERATIVE: Perform the operations that are necessary following a reconnection of the

battery (see corresponding operation).

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189

BRAKE FLUID CHECKS

IMPERATIVE: Respect the safety and cleanliness requirements.

WARNING: Brake fluid is toxic to health. Avoid any contact with your skin or with your eyes. If there is contact with your eyes, rinse immedia-

tely with copious amounts of water for several minutes.

WARNING: Brake fluid is highly corrosive to paintwork. If there is spillage onto the bodywork, clean the surface immediately.

Tools:

Brake fluid tester (*):

Reference

TLF

Supplier

Type

SURETEST

DOW AUTOMOTIVE

FACOM OUTILLAGE

EBT

BETATEST

DF.16

Measures the boiling point of brake fluid

Measures the rate of hydrometry of brake fluid

06.1

(*) The list not exhaustive, refer to the catalogue "Tools and Equipment".

Checks.

Remove the filter of the brake fluid reservoir.

IMPERATIVE: Any pollution of the brake fluid is forbidden. The brake fluid should be limpid and free of suspended matter or sediments.

Check the brake fluid, following the method recommended by the supplier of the testing equipment.

Test values:

Brake fluid

DOT 3

DOT 4

Minimum boiling point «Humid»

140°C

155°C

SUPER DOT 4

DOT 5

180°C

NOTE: If the tested value is lower than the minimum "humid" boiling point or within a tolerance of +10 % of this value, replace the brake fluid

(see corresponding operation).

IMPERATIVE: Use exclusively the hydraulic fluids that are approved and recommended.

190

DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM

Tools.

[1] Generic bleeding apparatus

[2] LEXIA station

[3] PROXIA station

: «LURO» or similar

: 4171-T

: 4165-T

NOTE: Bleeding of the secondary braking circuit is done with the help of diagnostic tools [2] or [3].

Draining the brake fluid reservoir.

Disconnect the battery.

Remove the engine cover (1) and the lid (2).

Disconnect the connector «a».

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Take out the filter of the brake fluid reservoir (4).

Drain the brake fluid reservoir (1) to the maximum extent (if necessary, use a clean syringe).

Remove the pin (3) and the brake fluid reservoir (4).

Clean the brake fluid reservoir (4).

Refit the brake fluid reservoir (4), the pin (3) and the filter of the brake fluid reservoir.

Reconnect the connector.

Reconnect the battery.

IMPERATIVE: Perform the operations that are necessary following a reconnection of the

battery (see corresponding operation).

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191

DRAINING, FILLING AND BLEEDING 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.

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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

Rear brake caliper

: Bleed screw (5).

: Bleed screw (6).

Bleed each brake caliper, proceeding in the following sequence:

- Front LH wheel.

- Front RH wheel.

- Rear LH wheel.

- Rear RH wheel.

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192

DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM

Using the bleeding apparatus.

Connect the bleeding apparatus [1] on the brake fluid reservoir (4).

Adjust the apparatus pressure to 2 bars.

For each brake 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.

- Check the brake fluid level (should be between «DANGER» level and «MAXI» level).

- Fill if necessary with the approved and recommended synthetic brake fluid.

Without bleeding apparatus.

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NOTE: Two operators are necessary.

For each brake 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.

NOTE: Recommence the process a second time if that is necessary.

- Check the brake fluid level (should be between «DANGER» level and «MAXI» level).

- Fill if necessary with the approved and recommended synthetic brake fluid.

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193

DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM

Bleeding the secondary braking system.

WARNING: During the bleeding operation, take care to maintain the level of brake fluid in

the reservoir and to top it up.

NOTE: Connect the bleeding apparatus [1] on the brake fluid reservoir (4).

Use the diagnostic tools [2] or [3].

Select the menu ESP VSC 440.

Bleed sequence: Menu ESP.

- Front LH wheel.

- Front RH wheel.

- Rear LH wheel.

- Rear RH wheel.

Follow the instructions given by the diagnostic tool.

At the end of the bleeding programme, check the brake fluid level and top up, if necessary.

Check the brake pedal travel (no lengthening), if not satisfactory repeat the bleeding procedure.

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Brakes for Your Citroen C6 4 Door First Generation (2005-2012)

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