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Chapter 9 Braking System

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Chapter 9 Braking System 9•1 Chapter 9 Braking system Contents Anti-lock Braking System (ABS) - general information 22 Master cylinder - removal, overhaul and refitting 13 Anti-lock Braking System (ABS) components - removal and Rear brake caliper - removal, overhaul and refitting 11 refitting 23 Rear brake disc - inspection, removal and refitting 8 Brake pedal - removal and refitting 14 Rear brake drum - removal, inspection and refitting 9 Front brake caliper - removal, overhaul and refitting 10 Rear brake pad wear check See Chapter 1 Front brake disc - inspection, removal and refitting 7 Rear brake pads - renewal 5 Front brake pad wear check See Chapter 1 Rear brake pressure-regulating valves (models Front brake pads - renewal 4 with rear disc brakes) - removal and refitting 20 General information 1 Rear brake shoe wear check See Chapter 1 Handbrake - adjustment 17 Rear brake shoes - renewal 6 Handbrake cables - removal and refitting 19 Rear wheel cylinder - removal and refitting 12 Handbrake lever - removal and refitting 18 Stop-light switch - removal, refitting and adjustment 21 Hydraulic fluid level check See Chapter 1 Vacuum pump (16-valve models) - removal and refitting 24 Hydraulic fluid renewal See Chapter 1 Vacuum pump (16-valve models) - testing and overhaul 25 Hydraulic pipes and hoses - renewal 3 Vacuum servo unit - testing, removal and refitting 15 Hydraulic system - bleeding 2 Vacuum servo unit check valve - removal, testing and refitting .... 16 Degrees of difficulty Easy, suitable for Fairly easy, suitable Fairly difficult, suitable Difficult, suitable for Very difficult, novice with little for beginner with for competent DIY experienced DIY suitable for expert DIY experience some experience mechanic mechanic or professional Specifications Front brakes Type Disc, with single-piston sliding caliper Disc diameter: 16-valve models 266 mm All other models 247 mm Disc thickness: New: Solid disc 10 mm Ventilated disc 20.4 mm Minimum thickness: Solid disc 8.0 mm Ventilated disc 18.4 mm Maximum disc run-out 0.2 mm Brake pad minimum thickness 2.0 mm Rear brakes Type: Larger-engined models, and all models with ABS Disc, with single-piston sliding caliper All other non-ABS models Single leading shoe drum Drum brakes: Drum diameter: New 180 mm Maximum diameter after machining 182 mm Brake shoe thickness: New 4.85 mm Minimum 1.5 mm Disc brakes: Disc diameter 247 mm Disc thickness: New 8.0 mm Minimum thickness 6.0 mm Maximum disc run-out 0.2 mm Brake pad minimum thickness 2.0 mm 9•2 Braking system ABS system Wheel sensor-to-reluctor ring air gap 0.3 to 1.2 mm Torque wrench settings Nm Ibfft Front brake caliper: Guide pin bolts (Girling caliper) 35 26 Mounting bracket-to-swivel hub bolts 120 89 Rear brake caliper mounting bolts 120 89 Rear hub nut: Models with rear drum brakes 200 148 Models with rear disc brakes 180 133 Master cylinder-to-servo unit nuts 10 7 Brake pedal pivot bolt 25 18 Pedal bracket retaining nuts 5 4 Vacuum servo unit mounting nuts 20 15 ABS wheel sensor retaining bolts 9 7 Roadwheel bolts 90 66 each rear caliper. The regulating valve is When topping-up or renewing the fluid, similar to that fitted to the rear wheel cylinders always use the recommended type, and 1 General information on drum brake models, and helps to prevent ensure that it comes from a freshly-opened rear wheel lock-up during emergency braking. sealed container. The braking system is of the servo- On all models, the handbrake provides an assisted, dual-circuit hydraulic type. The independent mechanical means of rear brake Hydraulic fluid is an effective arrangement of the hydraulic system is such application. paint stripper, and will attack that each circuit operates one front and one On 16-valve models, due to the ACAV plastics; if any is spilt, it rear brake from a tandem master cylinder. intake system, there is insufficient vacuum in should be washed off Under normal circumstances, both circuits the inlet manifold to operate the braking immediately, using copious quantities operate in unison. However, in the event of system servo effectively at all times. To of fresh water hydraulic failure in one circuit, full braking overcome this problem, a vacuum pump is force will still be available at two wheels. fitted to the engine, to supplement the inlet Most large-capacity engine models have manifold vacuum and ensure that sufficient General disc brakes all round as standard; all other vacuum is always present in the servo unit. 1 The correct operation of any hydraulic models not equipped with the Anti-lock The vacuum pump is mounted on the end of system is only possible after removing all air Braking System (ABS) are fitted with front disc the cylinder head, and driven directly off the from the components and circuit; -this is brakes and rear drum brakes. ABS is fitted as end of the inlet camshaft. achieved by bleeding the system. standard to the 16-valve model, and was Note: When servicing any part of the 2 During the bleeding procedure, add only offered as an option on most other models; on system, work carefully and methodically; also clean, unused hydraulic fluid of the models equipped with ABS, disc brakes are observe scrupulous cleanliness when recommended type; never re-use fluid that fitted at both the front and rear (refer to overhauling any part of the hydraulic system. has already been bled from the system. Section 22 for further information on ABS Always renew components (in axle sets, where Ensure that sufficient fluid is available before operation). applicable) if in doubt about their condition, starting work. The front disc brakes are actuated by and use only genuine Citroen replacement 3 If there is any possibility of incorrect fluid single-piston sliding type calipers, which parts, or at least those of known good quality. being already in the system, the brake ensure that equal pressure is applied to each Note the warnings given in "Safety first" and at components and circuit must be flushed disc pad. relevant points in this Chapter concerning the completely with uncontaminated, correct On models with rear drum brakes, the rear dangers of asbestos dust and hydraulic fluid. fluid, and new seals should be fitted to the brakes incorporate leading and trailing shoes, various components. which are actuated by twin-piston wheel 4 If hydraulic fluid has been lost from the cylinders. The wheel cylinders incorporate 2 Hydraulic system - bleeding system, or air has entered because of a leak, integral pressure-regulating valves, which ensure that the fault is cured before control the hydraulic pressure applied to the proceeding further. rear brakes. The regulating valves help to Warning: Hydraulic fluid is 5 Park the vehicle on level ground, switch off prevent rear wheel lock-up during emergency poisonous; wash off immediately the engine and select first or reverse gear, then braking. A self-adjust mechanism is and thoroughly in the case of skin chock the wheels and release the handbrake. incorporated, to automatically compensate for contact, and seek immediate 6 Check that all pipes and hoses are secure, brake shoe wear. As the brake shoe linings medical advice if any fluid is swallowed or unions tight and bleed screws closed. 'Clean wear, the footbrake operation automatically gets into the eyes. Certain types of hydraulic any dirt from around the bleed screws. operates the adjuster mechanism, which fluid are inflammable, and may ignite when 7 Unscrew the master cylinder reservoir cap, effectively lengthens the shoe strut and allowed into contact with hot components; and top the master cylinder reservoir up to the repositions the brake shoes, to remove the when servicing any hydraulic system, it is "MAX" level line; refit the cap loosely, and lining-to-drum clearance. safest to assume that the fluid is remember to maintain the fluid level at least On models with rear disc brakes, the inflammable, and to take precautions against above the "MIN" level line throughout the brakes are actuated by single-piston sliding the risk of fire as though it is petrol that is procedure, or there is a risk of further air calipers which incorporate mechanical being handled.. Finally, it is hygroscopic (it entering the system. handbrake mechanisms. A pressure- absorbs moisture from the air) - old fluid may 8 There are a number of one-man, do-it- regulating valve is situated in the brake line to be contaminated and unfit for further use. yourself brake bleeding kits currently available Braking system 9•3 from motor accessory shops. It is instructed to do so. When the flow stops, recommended that one of these kits is used tighten the bleed screw again, have the whenever possible, as they greatly simplify assistant release the pedal slowly, and the bleeding operation, and also reduce the recheck the reservoir fluid level. risk of expelled air and fluid being drawn back 18 Repeat the steps given in paragraphs 16 into the system. If such a kit is not available, and 17 until the fluid emerging from the bleed the basic (two-man) method must be used, screw is free from air bubbles. If the master which is described in detail below. cylinder has been drained and refilled, and air 9 If a kit is to be used, prepare the vehicle as is being bled from the first screw in the described previously, and follow the kit sequence, allow approximately five seconds manufacturer's instructions, as the procedure between cycles for the master cylinder may vary slightly according to the type being passages to refill. used; generally, they are as outlined below in 19 When no more air bubbles appear, tighten 2.22 Bleeding a rear brake caliper using a the relevant sub-section.
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