2004 Citroen BERLINGO 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
B3FP160C
BLEEDING AND FILLING THE BRAKING SYSTEM (Continued)
With the bleeding apparatus.
Connect the bleeding apparatus [1]on the brake fluid reservoir (1).
Adjust the apparatus pressure to
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.
C3 C3 PLURIEL

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ELECTRICAL
SYSTEM
Vehicles/models Gearboxes Class Climate
1C
1.4iT
2F
MMAP 3 GF
1C
1.4i Réfri T
3F
C3 PlurielGF
C
1.6i 16V MMAPA 3 T
F
GF
4C
1.4 HDiMT
5F
GF
STARTER MOTORS
C3 PLURIEL

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ELECTRICAL
SYSTEM
ALTERNATORS
Allocation of alternator classes
C3 C3 PLURIEL
Meaning of abbreviations, see page:472.
Without aircon With aircon
Without cold pack With cold pack Without cold pack With cold pack
RT3
RT3RT3
RT3RT3
RT3RT3
RT3
Engine Gearbox Climate Base N1 or
N3Base N1 or
N3Base N1 or
N3Base N1 or
N3
N2 N2 N2 N2
C
81.1iT7BVM F7GF898 9C881.4i T77
77
7BVMF
GF8C789
891.4i T788
8BVAF87GF9C81.4i 16VT7BVMP F7GF898 9