Ferodo DS4 Installation Manual

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Page 1

INSTALLATION GUIDE

CITROËN DS4

(MODEL B7)

REAR BRAKES

TRW BRAKING SYSTEM WITH ELECTRIC PARKING BRAKE



REAR BRAKE ASSEMBLY

1. Rear brake disc

2. Rear brake pads

3. Disc guard cover

4. Rear brake caliper

5. Brake caliper mounting bracket

6. Brake caliper slide pins

7. Bleeding screw

8. Caliper bleed screw cover

9. Caliper bracket mounting b olts

10. Bearing hub nut

11. Bearing hub cap

BRAKE FLUID

Product DOT 4

Capacity 1.0 litre

Maintenance intervals

Replacement and bleeding every 2 years

BRAKE FLUID DOT4

FBX050 500 ml

FBX10 0 1 lt

FBX500 5 lt

FBX2000 20 lt

Brake Pa d FDB4224

Length (mm) 103.8 Width (mm) 56.1 Thickness (mm)* 17.2 Thickness min (mm)* 8.00

Brake Di sc DDF1735

Diameter (mm) 268.00 Thickness (mm) 12.00 Min. thickness (mm) 10.00 Note: with bearing and ABS ring

* Backplate included

BRAKE FLUID

TOPPING UP AND BLEED ING

• Top up brake ﬂ uid reservoir to the max. level.

• Use a transparent pipe on brake caliper bleedin g screw respecting the following ble eding sequence:

1. Right hand rear wh eel

2. Le hand rear whee l

3. Right hand front wheel

4. Le hand front wheel

• Press brake pedal slowly to pressurise the brak ing circuit.

• Keep brake pedal pressed.

• Open blee ding screw (brake pedal lowers and system press ure decreases).

• Keep pedal presse d all the way down and close bleeding screw.

• Let pedal move up.

• Wait for 2 seconds to make brake ﬂ uid reach brake master cylinder.

• Repeat the op eration until brake ﬂ uid is clean and with no air bubbles.

FERODO PART NUMBERS

The Ferodo brand is a registered trademark of

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BRAKE PADS

REMOVAL

WARNING

If brake ﬂ uid rese rvoir is at max. level, remove ﬁ lter an d partially empty it using a clean syringe.

• Disengage parking brake.

• Disconnect battery negative terminal.

• Position vehicle onto li .

• Loosen wheel nuts and remove rear whe els.

• Remove parking brake cable terminal

(1)

from bracket

(2).

• Remove parking brake cable terminal

(4)

from brake caliper

(3).

• Remove handbrake cable from calip er body

(a).

• Loosen lower screw

(5) with a wrench in point (b).

• Turn brake caliper

(3) up.

• Remove brake pads

(7) and pad abutment shims (6 ).

• Check bra ke pad wear evenness to detect any caliper fault.

ASSEMBLY

• Visually ch eck sealing around brake caliper piston and the conditions of protective caps.

• Turn clockwise and press b rake caliper piston using a special tool to make it move back.

Remark: During this ope ration, visually check brake ﬂ uid inside rese rvoir to prevent any leakage.

WARNING

When changing bra ke pads, also change brake pad abutment shims.

• Fit new pad abutment shims an d pads.

• Re-position br ake caliper and tighten the (new) fastening bolts to a torque of 35 Nm.

• Reﬁ t parking brake cable into original location.

• Fit rear wheels (and re-torque nuts) and remove vehicle from li .

WARNING

Carry out the ope rations a er battery re-connection.

• With engine r unning press brake pedal several times, slowly and progressively until brake ped al feels ﬁ rm.

• Check brake ﬂ u id level and top up, if necessary.

• Adjust parking brake.

• Fill up and bleed braki ng system, if necessary.

BRAKE DISCS

REMOVAL

• Disengage parking brake.

• Disconnect battery negative terminal.

• Position vehicle onto li .

• Loosen fastening nuts and remove rear wheels.

• Remove brake pads (see dedicated procedure above).

• Remove fastening screw from brake caliper hydraulic pipe ﬁ tting.

• Remove bolts from slide pins between brake caliper and caliper m ounting bracket.

• Remove the fastening bolts (6) between brake caliper mounting bracket (7) and rear suspension .

• Visually check sealing around brake calipe r piston and the conditions of protective caps.

• Turn clockwise to retract the caliper piston into the caliper body using a special tool. Remark: During this ope ration, visually check brake ﬂ uid inside reservoir to prevent any leakage.

• Tighten brake caliper hydraulic pipe ﬁ tting screw to manufactures torque.

ASSEMBLY

• Position brake disc with bearing onto rear bearing spindle and tighten hub/bearing nut to the manufacturer’s torque.

• Position caliper mounting bracket onto rear suspension and tighten the mounting bolts to manuf actures torque.

Brake caliper mounti ng bracket removal

WARNING

When changing bra ke pads, also change pad abutment shims.

• Fit new brake pad abutment shims to the caliper bracket.

• Re-position brake caliper and tighten the (new) fastening screw to a torque of 35 Nm.

• Re-attach parking brake cable.

• Fit rear wheels (and re-torque), remove vehicle from li .

WARNING

Carry out the ope rations a er battery re-connection

• With engine running press brake pedal several tim es, slowly and progressively until brake ped al feels ﬁ rm.

• Check brake ﬂ uid level and top up, if necessar y.

• Adjust parking brake.

• Fill up and bleed braking system, if neces sary.

ELECTRIC PARKING BRAKE

ADJUSTMENT

Remark: Electric par king brake can be adjusted only using a diagnosis tester compatible with that of the ma nufacturer.

• Layout of parking brake cables.

• Calibrate parking brake (follow all the steps described by the diagnosis tester).

• Read and delete any stored DTC.

• Operate park ing brake control and check that rear wheels are safely locked.

WARNING

It is strictly forbid den to open an electric parking brake assemb ly a er sale. If an electric parki ng brake fault is detected, the whole unit mus t be replaced.

Remark: In case of total system failure, such a s battery fault or electric parking brake fault, system can be manually disengaged using the special tool supp lied with the vehicle tool kit.

Electric parking brake assembly

Parking brake cable remova l from bracket

Brake pad removal

Brake caliper cable removal

1. Primary cable

2. Electric parking brake unit

3. Electric parking brake secondary cables

Remove lower screw