2005 Citroen BERLINGO brake

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BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
Front brakes
1Front brake disc1 ± 0,1
2Yoke on caliper3 ± 0,3
3Unions on brake piping1,5 ± 0,1
4Caliper on pivot10,5 ± 1
5ABS/ESP hydraulic block support on the chassis member0,2 ± 0,1
6Wheel sensor0,8 ± 0,1
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BRAKESTIGHTENING TORQUES: BRAKING SYSTEM
Front brakes
7Braking amplifier2,2 ± 0,3
8Master cylinder on braking amplifier2 ± 0,5
Parking brake
9Parking brake lever1,5 ± 0,2
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BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
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Rear brakes
10Unions on brake piping1,5 ± 0,1
11Rear brake caliper support 5,3 ± 0,5
12Rear brake caliper3 ± 0,3
13Wheel sensor0,8 ± 0,1
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BRAKES
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ABS/ESP HYDRAULIC BLOCK
Components Supplier Type Observations
Hydraulic blockBOSCHABS REF 8.0
Installed under the front LH
ESP 8.0chassis member. 4 regulation channels.
The emergency braking control is incorporated in the primary piston at «a».
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BRAKES
PARKING BRAKE ADJUSTMENT
Adjustment.
IMPERATIVE: Respect the safety and cleanliness requirements.
Raise and support the vehicle.
Remove the central console.
WARNING: Check the routing of the brake cables under the vehicle.
Release the handbrake lever.
Press gently on the brake pedal
(then repeat the operation 3 times).
Action the handbrake lever with a force of 40 daN.
Use a feeler gauge at «J»to measure the movement of the lever in relation to its stop.
NOTE:The movement should be less than 1,5 mmand more than 0,05 mm.
(1)Nut for adjusting the tension of the handbrake cables
Move the nut (1)to obtain a movement «J»less than or equal to 1,5 mm.
Action the handbrake lever 8 timeswith a force of 40 daN.
With the handbrake released, check the movement «j»with a feeler gauge.
NOTE:The movement should be less than 1,5 mmand more than 0,05 mm.
Refit the central console
(see corresponding operation).
Check the efficiency of the handbrake.
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BRAKES
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BLEEDING AND FILLING THE BRAKING SYSTEM
Tools.
[1]Bleeding apparatus: «LURO» or similar
[2]LEXIA diagnostic tool: 4171-T
[3]PROXIA diagnostic tool: 4165-T
NOTE:Bleeding of the secondary braking circuit is done with the aid of diagnostic tools [2]and [3].
Draining of the brake fluid reservoir.
Remove the screws (3)and the battery tray (2).
Remove the filter of the brake fluid reservoir (4).
Drain the brake fluid reservoir (4)to the maximum extent
(if necessary, use a clean syringe).
Remove the screws (1).
Uncouple the clickfit union at «a».
Remove the brake fluid reservoir (4).
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BRAKES
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BLEEDING AND FILLING THE BRAKING SYSTEM
Disconnect the connector «b».
Uncouple the pipe (5).
Remove the reservoir (6), moving aside the tabs «c»of the pins (7).
Clean the brake fluid reservoir (4) and the brake fluid reservoir (6).
Refit the brake fluid reservoir (6).
Couple the pipe (5).
Reconnect the connector «b».
Couple the clickfit union, at «a».
Refit:
- The brake fluid reservoir (4).
- The screws (1).
- The filter of the brake fluid reservoir.
- The battery tray.
- The screws (3).
- The battery.
Reconnect the battery.
IMPERATIVE: Carry out the operations that are necessary following a reconnection of the
battery
(see corresponding operation).
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BRAKES
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BLEEDING AND FILLING 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.
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 : Bleed screw (8).
Rear brake caliper : Bleed screw (9).
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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