Ferodo DS4 User manual

INSTALLATION GUIDE
CITROËN
DS4
(MODEL B7)
REAR BRAKES
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 bolts
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
FBX100 1 lt
FBX500 5 lt
FBX2000 20 lt
Brake Pad FDB4224
Length (mm) 103.8
Width (mm) 56.1
Thickness (mm)* 17.2
Thickness min (mm)* 8.00
Brake Disc 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 BLEEDING
• Top up brake fluid reservoir to the max. level.
• Use a transparent pipe on brake caliper bleeding screw
respecting the following bleeding sequence:
1. Right hand rear wheel
2. Le hand rear wheel
3. Right hand front wheel
4. Le hand front wheel
• Press brake pedal slowly to pressurise the braking circuit.
• Keep brake pedal pressed.
• Open bleeding screw (brake pedal lowers and
system pressure decreases).
• Keep pedal pressed all the way down and close
bleeding screw.
• Let pedal move up.
• Wait for 2 seconds to make brake fluid reach brake
master cylinder.
• Repeat the operation until brake fluid is clean
and with no air bubbles.
FERODO PART NUMBERS
The Ferodo brand is a registered trademark of

BRAKE PADS
REMOVAL
WARNING
If brake fluid reservoir is at max.
level, remove filter and partially
empty it using a clean syringe.
• Disengage parking brake.
• Disconnect battery negative terminal.
• Position vehicle onto li.
• Loosen wheel nuts and remove rear wheels.
• Remove parking brake cable terminal (1)
from bracket (2).
• Remove parking brake cable terminal (4)
from brake caliper (3).
• Remove handbrake cable from caliper 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 brake pad wear evenness to detect any
caliper fault.
ASSEMBLY
• Visually check sealing around brake caliper piston
and the conditions of protective caps.
• Turn clockwise and press brake caliper piston
using a special tool to make it move back.
Remark: During this operation, visually check brake
fluid inside reservoir to prevent any leakage.
WARNING
When changing brake pads, also
change brake pad abutment shims.
• Fit new pad abutment shims and pads.
• Re-position brake caliper and tighten the (new)
fastening bolts to a torque of 35 Nm.
• Refit parking brake cable into original location.
• Fit rear wheels (and re-torque nuts) and remove
vehicle from li.
WARNING
Carry out the operations aer
battery re-connection.
• With engine running press brake pedal several times,
slowly and progressively until brake pedal feels firm.
• Check brake fluid level and top up, if necessary.
• Adjust parking brake.
• Fill up and bleed braking 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 fitting.
• Remove bolts from slide pins between brake
caliper and caliper mounting bracket.
• Remove the fastening bolts (6) between brake caliper
mounting bracket (7) and rear suspension.
• Visually check sealing around brake caliper 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 operation, visually check brake fluid
inside reservoir to prevent any leakage.
• Tighten brake caliper hydraulic pipe fitting 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 manufactures torque.
Brake caliper mounting bracket removal
WARNING
When changing brake 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 operations aer battery
re-connection
• With engine running press brake pedal several times,
slowly and progressively until brake pedal feels firm.
• Check brake fluid level and top up, if necessary.
• Adjust parking brake.
• Fill up and bleed braking system, if necessary.
ELECTRIC PARKING BRAKE
ADJUSTMENT
Remark: Electric parking brake can be adjusted only using a
diagnosis tester compatible with that of the manufacturer.
• Layout of parking brake cables.
• Calibrate parking brake (follow all the steps described
by the diagnosis tester).
• Read and delete any stored DTC.
• Operate parking brake control and check that rear
wheels are safely locked.
WARNING
It is strictly forbidden to open an electric
parking brake assembly aer sale. If an
electric parking brake fault is detected,
the whole unit must be replaced.
Remark: In case of total system failure, such as battery fault
or electric parking brake fault, system can be manually disen-
gaged using the special tool supplied with the vehicle tool kit.
Electric parking brake assembly
2
1
Parking brake cable removal 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