check engine Citroen BERLINGO 2004 1.G Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Thread of oil then "dripdrip".
Refit the plug (3), Tighten to 2,4± 0,2 m.daN.
"Dripdrip" or nothing.
Refit the oil level plug (3).
Stop the engine.Add
0.5 litresextra oil into the gearbox.
Repeat the oil level procedure.
NOTE:The level is correct at the moment the thread of oil becomes “dripdrip”.
Refit the oil level plug
(3)(equipped with a new seal), tighten to2,4±0,2 m.daN.
Checking the oil level (continued).
Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.
An excessive level of oil can lead to the following consequences:
Oil heating up abnormally,
Oil leaks.
A level that is too low will result in the destruction of the gearbox.
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AZD

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SUSPENSION
STEERING
355
C2 AXLE GEOMETRY
Tyres inflated to correct pressures. Vehicle at reference height.
Steering rack locked at mid point (see corresponding operation).
Conditions for checking and adjusting
Vehicle heights at reference height
E1APOBZD
Front height Rear height
L1L2
H1 = R1 – L1 H2 = R2 + L2
H1
= Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear
subframe and the ground. sill and the ground.
R1= Front wheel radius under load.R2= Rear wheel radius under load.L1= Distance between the wheel axis and the measuring zoneL2= Distance between the wheel axis and the measuring zone
underneath the front subframe. underneath the rear sill.

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AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
Conditions for checking and adjusting
Vehicle heights at reference height
Rear height
Fr ont height
L2
L1
Tyres inflated to correct pressures. Vehicle at reference height.
Steering rack locked at mid point (see corresponding operation).
H1 = R1 L1
H1
= Measurement between the measuring zone underneath the front
subframe and the ground.
R1= Front wheel radius under load.L1= Distance between the wheel axis and the measuring zone
underneath the front subframe.
H2 = R2 + L2
H2
= Measurement between the measuring zone underneath the rear
sill and the ground.
R2=Rear wheel radius under load.L2= Distance between the wheel axis and the measuring zone
underneath the rear sill.
E1AP09MD
C3
C3

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AXLES
SUSPENSION
STEERING
C3 AXLE GEOMETRY
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool4003T or8006T (according to version).
Z1 = Measuring zone underneath the front subframe.Z2 = Measuring zone underneath the rear sill.
Measure the radius of the front wheel
R1 Calculate dimension H1 = R1 – L1Measure the radius of the rear wheel R2 Calculate dimension H2 = R2 + L2
Value at reference All types Except CRD (*) Vehicle CRD (*) Value at reference All types Except CRD (*) Vehicle CRD (*)
heightRaised suspensionRaised suspensionheightRaised suspensionRaised suspension
(+ 6 8 mm)Sports Sports
(+ 10 6 mm)Sports Sports
L1 = 142,5 mm L1 = 132,5 mm L2 = 52 mm L2 = 62 mm
(*) = CRD: Difficult road conditions.
Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads.
Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than
10 mm.
Checks at reference height

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AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
Conditions for checking and adjusting
Vehicle heights at reference height
Rear height
Fr ont height
L2
L1
Tyres inflated to correct pressures. Vehicle at reference height.
Steering rack locked at mid point (see corresponding operation).
H1 = R1 L1
H1= Measurement between the measuring zone underneath the front
subframe and the ground.
R1= Front wheel radius under load.L1= Distance between the wheel axis and the measuring zone
underneath the front subframe.
H2 = R2 + L2
H2= Measurement between the measuring zone underneath the rear
sill and the ground.
R2=Rear wheel radius under load.L2= Distance between the wheel axis and the measuring zone
underneath the rear sill.
E1AP0AUD
C3 PLURIEL
C3 Pluriel

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AXLES
SUSPENSION
STEERING
C3 PLURIEL
AXLE GEOMETR Y
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool 4003T
Z1
= Measuring zone underneath the front subframe.Z2 = Measuring zone underneath the rear sill.
Measure the radius of the front wheel
R1 Calculate dimension H1 = R1 – L1Measure the radius of the rear wheel R2 Calculate dimension H2 = R2 + L2
Value at referenceAll TypesValue at referenceAll Typesheight height
(+ 6 8 mm)L1 = 132,5 mm(+ 10 6 mm)L2 = 47 mm
(*) = CRD: Difficult road conditions.
Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads.
Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than
10 mm.
Checks at reference height

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AXLES
SUSPENSION
STEERING
ESSENTIAL: When checking the suspensions, the vehicle should be at reference height.
XSARA
AXLE GEOMETRY
Values of the front and rear suspensions, at reference height
Tools.
Compress the suspension, to obtain the values at reference height.
[1]Set of two suspension compressors: 9511T.A
[2] Set of four straps : 9511T.B
[3] Set of four shackles :9511T.C
A > B =
Negative figure: – = TOEOUT
A < B = Positive figure: + = TOEIN
WARNING
B3CP04LC

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AXLES
SUSPENSION
STEERING
H1 = R1 – L1 H1’ = R1 – L1’
H1
= From the front suspension arm linkage bolt axis to the ground.R1= Radius of the front wheel when laden.L1= From the centre of the wheel to the front suspension arm linkage
bolt axis.
H1’= From the front jacking point to the ground.L1’= From the front jacking point to the radius of the front wheel when
laden.
H2 = R2 L2
H2
= From the rear axle silentblock face to the ground.R2= Radius of the rear wheel when laden.L2= From the centre of the wheel to the rear axle silentblock face.
AXLE GEOMETRY
Checks at reference height
NOTE:
To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point.
WARNING: The values shown should only be used as guides. In case of doubt, check the settings at reference height
Rear heightFront height
B3CP05BCB3CP058DB3DP079C
XSARA PICASSO
Conditions for checking and adjusting:Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point(see corresponding operation).

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AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
Compress the suspension to obtain the calculated values.
NOTE:The difference in height between the two sides should be less than 10 mm. Measure the radius of the rear wheel:
R2.
Calculate dimension H2. Measure the radius of the front wheel:R1.
Calculate dimension H1or H1’.
Checks at reference height (the reference height of the vehicle is set as per the table below).
B3CP05BCB3CP05AC
XSARA PICASSO
Front axlesRear axle
Front axles
Rear axle Engines:NFV 6FZ RFN 9HZ 9HY RHY
H1 = R1 – L1 ou H1’ = R1 – L1’
NO CRD Vehicle (CRD = Difficult road conditions)
L1 = 90,5 mmL1’ = 124 mmL2 = 8,5 mm H2 = R2 + L2
B3DP079C
Value at reference height (8/+3 mm)Value at reference height (+10/3 mm)

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AXLES
SUSPENSION
STEERING
A > B =Negative figure: – = TOEOUT
A < B = Positive figure:+ =TOEIN
WARNING
AXLE GEOMETRY
Checks at reference height (the reference height of the vehicle is set as per the table below).
NO CRD Vehicle (CRD = Difficult road conditions)
Front axle Rear axle
Vehicle Tracking Castor Pivot angle Camber Tracking Camber
Adjustable Yes No
All types0 ± 1 mm4,8 ± 1,3 mm
0°09’ at + 0°09’3° ± 18’ 10°43’ ± 30’ 0° ± 30’
0°43’ ± 0°12’ 1°13’ ± 18’
XSARA PICASSO
B3CP02UC