Clutch Citroen BERLINGO 2004 1.G User Guide

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines 8HX 8HW 8HZ
Cylinder head
Camshaft bearing covers
Pretightening0,5 ±
Tightening1 ±
Fixings of camshaft subassemblies on cylinder head
Pretightening0,5
Tightening1
Exhaust manifold2,5 ± 0,2
Valve cover2,5 ± 0,2
Camshaft pulley4,3 ±0,4
Flywheel
Flywheel
Pretightening1,7 1,7
Tightening70°±5° 75° ± 5°
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump assembly
Pretightening0,5 ± 0,06
Tightening0,9 ± 0,1
Coolant/oil heat exchanger1 ± 0,1
C3 C3 PLURIEL XSARA

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ENGINESPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines8HV 8HY
Flywheel Clutch
Flywheel 1,7 ± 0,2
Clutch mechanism 2 ± 0,2
Lubrication circuit
Oil pump assembly0,9 ± 0,1
Oil/coolant heat exchanger 1 ± 0,1
Turbocharger lubrication pipe2,2 ± 0,2
Injection circuit
Injector fixing flange nut
Tightening0,4 ±0,1
Angular tightening65° ± 5°
Fuel high pressure pump
Union on diesel injector
Fuel high pressure pump pinion 5 ± 0,5
Union on fuel high pressure pump2,3 ± 0,2
Cooling circuit
Coolant pump1 ± 0,2±
C3

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ENGINE
SPECIAL FEATURES TIGHTENING TORQUES (m.daN )
Engines9HZ 9HY
Cylinder head
Camshaft bearing covers
Pretightening0,5 ± 0,1
Tightening1 ± 0,1
Exhaust manifold 3 ± 0,3
Camshaft pulley
Pretightening2 ± 0,2
Angular tightening50 ±5°
Cylinder head
Pretightening2 ± 0,2
Tightening4 ± 0,5
Angular tightening260 ± 5°
EGR valve1 ±0,1
Flywheel Clutch
Flywheel
Pretightening3 ± 0,3
Angular tightening90 ±5°
Clutch mechanism2 ± 0,2
XSARA PICASSO

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Remove:
The fixings of the pipe linking the power steering pump with the rotary valve.
The clutch lower closing plate.
Lock the engine flywheel, using tool
[6].
Remove the screw (8).
Refit the screw (8)without its thrust washer.
Remove:
The accessories pulley
(9), using tool[8].
Tool [6].
The lower torque reaction rod.
Support the engine by means of a workshop hoist.
Remove:
The bearing shell fitting
(10).
The nut (12).
Screws (11).
The bracket (13).
NOTE:Lift then lower the engine with the workshop hoist, to have access to the
timing cover fixing screws.
Remove:
The intermediate timing cover.
The lower timing cover.
B1CP04BCB1BP2R3CB1BP2R4C
XSARA XSARA PICASSO

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SPEEDOMETERALL TYPES
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates:
The speed indicated by a speedometer must never be lower than the actual vehicle speed.
Between the speed displayed «SD»and the speed travelled «ST», there must always be the following relationship:
ST < SD < 1.10 ST + 4 Kph
Example: For an actual speed of 100 Kphthe speed displayed by the speedometer may be between 100and 114 Kph.
The speed indicated by the speedometer may be influenced by:
The speedometer.
The tyres fitted to the vehicle.
The final drive ratio.
The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle
(see information note N° 78-85 TT of 19 October 1978).NOTE:Before replacing the speedometer, check the conformity of the following points:
The tyres fitted to the vehicle.
The gearbox final drive ratio.
The speedometer drive ratio.
CLUTCH
GEARBOX
TRANSMISSION

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GEARBOX
TRANSMISSION
281
CLUTCH SPECIFICATIONS C2
Engine type HFX KFV NFU 8HX
Gearbox type Supplier
BVM BVM/BVMP (*)BVM/BVMP (*)BVM/BVMP (*)
MA 5/S MA 5 N/L MA 5 S/L MA 5/0
Mechanism / typeVALEO LUK
Engine type180 CP0 3400 200 P 3900
Bearing supplier / heightSKF 17 mm
Clutch disc11 R 10??
Ø of lining.Ext/Int180/127200/134
Quality of lining408
1.1i 1.4i 1.6i 16V1.4 HDi
(*): BVM = Manual gearbox.
: BVMP = Piloted manual gearbox.

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
C3 C3 PLURIEL
Engine type HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Gearbox type Supplier
MA/5 BE4/5
Mechanism / typeVALEO ? LUK
Engine type180 CPO 3400200 MF
200 P 3900 230 P 4700
3850
Clutch disc11 R 10 X 200 VTB
Ø Garniture.Ext/Int180/127 ? 200/134 228/155
Quality of liningF408
1.1i 1.4i 16V 1.4 HDi1.4 HDi 16V1.4i 1.6i 16V

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA
Engine type KFW NFU RFN RFS
Gearbox type Supplier
MA/5 MA/5 BE4/5
Mechanism / typeVALEO
Engine type180CPO 3400 200 CPR 3800 230 DNG 4700 215 DT 5250
Clutch disc180 XJF 73 C 200X(D95) 11A12X 230 DNG 4700 215 FD 95
Ø Garniture.Ext/Int180/127 200/137 228/155 215/147
Quality of liningF 408 F 808
1.4i 1.6i 16V2.0i 16V

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
XSARA
Engine type 8HZ WJY RHY RHZ
Gearbox type Supplier
BE4/5
Mechanism / typeLUK
Engine type200 P 4200 200 P 3700 230 P 4700 235 T 5700
Clutch disc215 F (D 93) 22 BX 228 228D
Ø Garniture.Ext/Int200/134 200/134 230/155 235/155
Quality of liningF 408F202
1.4 HDi 1.9 D2.0 HDi

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA PICASSO
Engine type NFV 6FZ RFN 9HZ 9HY RHY
Gearbox type Supplier
BE4/5
Mechanism / typeVALEO LUK
Engine type200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700
Clutch disc200X(D95) 230 DNG 4700 215 FD 95 228
11A12X
Ø Garniture.Ext/Int200/137 228/155 215/147 225/150 230/155
Quality of liningF410 F 808 F 810 DS F408
1.6i 1.4 HDi 16V2.0 HDi1.8i 16V 2.0i 16V