Citroen BERLINGO 2004 1.G Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: KFW NFU NFV 6FZ RFN RFS 8HZ 9HZ 9HY WJY RHY RHZ
NOTE:All the clutches are «push»type with hydraulic control.
Description.The declutch control has a declutch fork mounted on a balljoint.(1)The balljoint is screwed into the clutch casing.(2) Declutch fork.(3) Clutch casing.(4) Bearing.(5) Clutch plate.
The clutch control slave cylinder
(7) is fixed by two screws (6)onto the exterior of the clutch casing.
Tightening torques (m.daN).
Fixing of clutch plate / engine flywheel: 2 ± 0,2 Fixing of clutch control slave cylinder / clutch housing:2 ±0,25 Fixing of engine flywheel / crankshaft
Pretightening:1,75 ± 0,1Angular tightening:75° ± 5°: 6,3 ± 2,2
B2BP047CB2BP05SC
XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Clutch cable.
Removing.
Uncouple the cable from the lever (1).
Unclip the cable from the gearbox by actioning
the side tabs
(2).
Detach the cable from the bulkhead.
Remove the clip
(3).
Uncouple the cable from the clutch pedal.
B2BP001CB2BP002C
XSARA XSARA PICASSO
B2BP02VC
B2BP02WC
«PUSH» clutch
«PULL» clutch
B2BP03BCB2BP002C

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Refitting.
Place the pedal in the high position (contact at “a”).
Attach the cable yoke on the hook of the clutch pedal.
Fit a new clip
(3).
Fit the endpiece (4)to the bulkhead (fit with G6grease).
Clip the endpiece (5)on the gearbox.
Couple the cable to the lever (1).
Depress the clutch cable several times to lodge the cable in place.
Check that the endpiece (4) is correctly lodged on the bulkhead.
Check the operation of the automatic adjusting system.
After fitting the cable, pull the clutch lever in the inverse direction
(direction F), the lever should
move back when pulled by hand.
Press the clutch pedal very lightly and repeat the same operation. The lever should not move
back.
WARNING:If a system blockage is detected when checking, or if the pedal has been removed,
the pedal position must be adjusted. The correct positioning of the pedal is obtained by the
angular displacement of the stop supports
"a"and "b".
B2BP03CD
XSARA XSARA PICASSO
«PUSH» clutch
«PULL» clutch
B2BP03DD

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Adjusting the pedal height.
Loosen the nut (6)and the screw (7).
Using a lever, raise the stop support (8)to its highest position. In this position, there should be a substantial free
play in the pedal.
Lower the support until there is a free play of
2 ± 1 mm.
Tighten the nut (6) and the screw (7).
Check that the clutch cable sleeve can move freely.
At rest, the clutch cable sleeve should be free and able to lengthen and shorten.
Clutch pedal travel.
The automatic clutch wear adjustment system has no manual adjustment.
Pedal travel is identical on all models:154 ± 5 mm.
The adjustment is achieved by reducing the length of the cable sleeve.
WARNING:Automatic adjustment of the pedal travel is accompanied by a modification of the curvature of the
cable sleeve. Do not add any supplementary fixing points or alter the routing in any way.
«c»Routing of new cable.«b»Routing after adjustment of play.«x» Clutch wear.
B2BP03ECB2BP03FD
XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
B2BP04XC
Bleeding the hydraulic clutch control
IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any
ingress of impurities into the hydraulic circuit.
IMPERATIVE: Do not use automatic bleeding equipment
(risk of the brake fluid
emulsifying in the hydraulic circuit).
Couple a transparent tube (5) on the bleed screw, at «c».
Submerge the end of the tube
(5)in the recipient containing the brake fluid, located
below the level of the clutch slave cylinder.
Use the transparent tube
(5)to act as a siphon, at «b».
WARNING:the end of the tube (5)must be submerged in the brake fluid.
Open the bleed screw, at
«c».
C3 PLURIEL XSARA
C2C3XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
Bleeding the hydraulic clutch control
Action the clutch pedal manually through its full travel:7 times rapidlydown and up.
Allow the clutch pedal to come back up to its high position.
Fill the brake fluid reservoir to the maximum of its capacity.
Open the bleed screw, at
«c».
Action the clutch pedal manually through its entire travel:7 timesrapidly down and up.
The last time, keep the clutch pedal fully down.
Reclose the bleed screw, at
«c».
If necessary, repeat the operation.
Top up the brake fluid to the MAX. level of the brake fluid reservoir.
Work the clutch vigorously
40 times.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension
(X)greater than or equal to 45 mm(the dimension (X)is
given as a guide).
Repeat the bleed operations if necessary.
C5FP0FQCB2BP04YC
C2 C3 C3 PLURIEL
XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
Engine types HFX KFV 8HX
Tyresrolling
165/70 R14 165/70 R14 185/55 R14 165/70 R14 185/55 R15
Circumference1,804 m1,804 m 1,781 m 1,804 m 1,781 m
Gearbox typeMA 5/S MA 5/N MA 5/L MA 5/0
Gearbox ident. plate20 CP 2020 CP 21 20 CP 16 20 CP 55 20 CP 67
PRO 9919 PRO 9919 PRO 9919 PRO 9919 PRO 9919
Reduction box torque16x65 14X60 17X61
Speedometer ratio21x18
GEARBOX AND TYRE SPECIFICATIONS
1.1i
1.4i1.4 HDi Petrol
C2
Diesel
Manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
Engine types KFV NFU 8HX
Tyresrolling
165/70 R14 185/55 R15 185/55 R14 195/45 R16 185/70 R15 165/70 R14
Circumference1,804 m 1,781 m 1,781 m 1,772 m 1,804 m 1,804 m
Gearbox typeMA 5/N MA 5/S MA 5/L MA 5/0
Gearbox ident. plate20 CP 21 20 CP 64 20 CP 66 20 CP 65
PRO 9786
PRO 9786 PRO 9786 PRO 9786
Reduction box torque16x6516x6314x6016X63
Speedometer ratio21x1821x18
GEARBOX AND TYRE SPECIFICATIONS
1.4i
1.6i 16V1.4 HDi Petrol
C2
Diesel
Piloted manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
Engine type Trim level
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident.plate
Reduction box torque
Engine type Trim level
Tyresrolling Circumference
Speedometer ratio
(1) Export et DAIC
= 20 CP 16 (14X60) (21X18) (2) EXPORT et DAIC= 20 CP 55 20 CP 72 (16X65) (21X18).
Gearbox type
Gearbox ident. plate
Reduction box torque
GEARBOX AND TYRE SPECIFICATIONS
1.6i 16V
AUTOMATIC 1.4i 1.1iPetrol
HFXX SX Exclusive
Exclusive Exclusive X SX Exclusive
X SX X SX
NFU
KFV
Diesel
165/70 R 14 1,804 m185/60 R15 1,828 m 165/70 R 14 1,804 m185/60 R15 1,828 m
MA/5 AL4 MA/5
20 CP 14 20 CP 15 ou
(*)20 TP 75 20 CP 58
14x6016x63 21x7317x64
21x18
u
1.4 HDi
X SX Exclusive
8HX 8HW 8HV 8HY
165/70 R14 1,804 185/60 R15 1,828 m
MA/5BE4/5
20 CP 54
(2)20 DM 25 20 DM 26
17x61 19x72 19x7721x1822x19
1.4 HDi 16V
C3
Manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS
C3
Trim level
Engine type KFU NFU 8HX
Tyresrolling
185/60 R15 165/70 R14Circumference1,828 m 1,804 m
Gearbox typeMA/5
Gearbox ident. plate20 CP 56 20 CP 65
Reduction box torque17x64 16x63
Speedometer ratio21x18
1.4i 16V
1.6i 16V1.4 HDi Petrol
Diesel
Piloted manual gearbox