Note. Read the warning about the danger of brake fluid given at the beginning of the operation before starting work paragraph 2, and the warning about the danger of asbestos dust given at the beginning of paragraph 4.
Note. Installation will require new guide pin bolts.
Removing
1. Apply the parking brake. Raise the front of the vehicle and securely jack stands under it (see «Lifting and placing the car on supports»). Remove the corresponding wheel.
2. To minimize brake fluid leakage, first loosen the brake fluid reservoir cap and then tighten it again with a piece of polyethylene underneath to ensure a tight seal. Alternatively, if necessary, the hoses can be sealed off with a suitable brake hose clamp or clamp.
3. Clean the area around the caliper brake line union, and then loosen the flare nut half a turn.
4. Turn out bolts of fastening of the top and bottom directing fingers of supports (see paragraph 4). When working with a Lucas caliper, use a second open-end wrench to hold the guide pin from turning. Discard the guide pin bolts; when installing, use new ones. After unscrewing the bolts of the guide pins, move the caliper away from the brake disc, then disconnect the caliper from the end of the brake hose. Keep in mind that it is not necessary to touch the brake pads and they can be left in the caliper support bracket.
Repair
5. The caliper can be repaired after purchasing the appropriate repair kit from a Peugeot/Citroen dealer. Make sure the repair kit matches the caliper you are working on. Mark the location of the relevant parts to ensure correct installation and lubricate the new seals with clean brake fluid. Follow the assembly instructions included with the repair kit.
Installation
6. Connect the caliper to the brake hose, and then make sure the brake pads are still properly seated in the caliper support bracket.
7. Install the caliper on the brake pads. Apply an appropriate thread locking compound to the threads of the new guide pin bolts if the bolts have not already been coated with it. Install a new lower valve guide bolt, then reinstall the caliper and install a new upper guide pin bolt. When working with a Bosch caliper, position the guide pins so that the flat on the pin is horizontal and properly mates with the machined surface on the caliper bearing tabs. Tighten both guide pin bolts to the specified torque while holding the pins with an open end wrench (if it is needed).
8. Securely tighten the brake hose fitting, and then remove the clamp that pinches the brake hose, or polyethylene from the tank (whichever is applicable) and bleed the hydraulic circuit as described in paragraph 2. Subject to the above precautions, only the brake circuit of the affected front wheel will need to be bled to minimize brake fluid leakage.
9. Depress the brake pedal several times until the pads come into firm contact with the brake disc and normal operation is restored (without vacuum enhancement effect) pedal pressure.
10. Install the wheel, lower the vehicle and tighten the wheel bolts to the specified torque.