Note: Before you begin, read the brake fluid hazard warning at the beginning of this manual paragraph 2, and the warning about the dangers of asbestos dust given at the beginning of paragraph 4.
Note: New guide pin bolts will be required during installation.
Removal
1. Apply the parking brake. Raise the front of the vehicle and support it securely (see "Lifting and installing 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, placing a piece of plastic underneath to ensure a tight seal. Alternatively, if necessary, the hoses can be sealed tightly using a suitable brake hose clamp or clamp.
3. Clean the area around the brake line union nut on the caliper, then loosen the union nut half a turn.
4. Unscrew the bolts securing the upper and lower guide pins of the calipers (see paragraph 4). When working with the Lucas caliper, use a second open-end wrench to hold the guide pin from turning. Discard the guide pin bolts; when installing, new ones should be used. After removing the guide pin bolts, move the caliper away from the brake disc, then disconnect the caliper from the end of the brake hose. Keep in mind that there is no need to touch the brake pads and they can be left in the caliper support bracket.
Repair
5. The caliper can be repaired by 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 corresponding components 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, then check that the brake pads are still properly seated in the caliper support bracket.
7. Install the caliper onto the brake pads. Apply a suitable thread locking compound to the threads of the new guide pin mounting bolts if the bolts were not coated previously. Install the new lower valve guide bolt, then reinstall the caliper and install the new upper valve guide pin bolt. When working with a Bosch caliper, position the guide pins so that the flat on the pin is horizontal and mates correctly with the machined surface on the caliper's bearing lugs. Tighten both guide pin bolts to the specified torque while holding the pins with an open-end wrench (if necessary).
8. Tighten the brake hose nipple securely, then remove the clamp holding the brake hose or the plastic bag from the reservoir (whichever is applicable) and bleed the hydraulic system as described in paragraph 2. Provided that the above precautions are taken to minimize brake fluid leakage, it will only be necessary to bleed the brake circuit of the corresponding front wheel.
9. Press the brake pedal several times until the pads come into firm contact with the brake disc and normal operation is restored (without vacuum amplification effect) pedal pressure.
10. Install the wheel, lower the vehicle and tighten the wheel bolts to the specified torque.