Citroen BERLINGO 2004 1.G Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS C3 PLURIEL
Engine types KFV NFU 8HX
Tyresrolling
Circumference
Gearbox type
MA/5N MA/5S MA/50
Gearbox ident.plate20 CP 60 (m)(1)20 CP 63 (mp)(2)20 CP 71 (m)(1)
Reduction box torque
13x59 16x65 14x60
Speedometer ratio21x18
1.4i
1.6i 16V1.4 HDi Petrol
Diesel
(1)m = Manual geearbox.(2)mp = Piloted manual gearbox.

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS
Petrol
XSARA
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque1.4i1.6i 16V
AUTOMATIC AUTOMATIC
2.0i 16V
KFW NFU RFN RFS
195/55 R15 1,815 m
MA/5 AL4 BE4/5 AL4 BE3/5
20 CP 13
(1)20 CP 51 (2)20 TP 49
20 DL 40
20 TP 4720 TE 47
16x65 21x73 19x72 23x73 14x62
21x18 24x21 22x19 24x21 22x19
Diesel
1.9 D
1.4 HDi2.0 Hdi
WJY 8HZ RHY (3) RHZAUTOMATIC
195/55 R15 – 1,815 m
BE4/5
AL4
20 DL 41
19x75
22x19 20 DM 54 20 DL 42
19x7020 DM 10
17x6120 TP 48
14x62
22x19
NOTE:(RHY engine BE4/5 gearbox) (1) Estate = 20 CP 44 (16x65) (21x18) (2) DAIC = 20 CP 52 (14x60) (21x18) (3)XSARA DAIC RHD = 20 DM 08Right hand drive: 6FZRFN= 20 DM 03 WJY= 20 DM 05 8HZ= 20 DM 53 RHY = 20 DM 07 RHZ= 20 DM 11

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO
Engine typeNFV 6FZ RFN
Tyresrolling
185/65 R15
Circumference1,895 m
Gearbox type BE4/5 AL4
Gearbox ident. plate20 DL 67 20 DL 69 20 TS 02
Reduction box torque15x6419x77 21x73
Speedometer ratio22x1824x20
Diesel
1.6 16V HDi 2.0 HDi
Engine type 9HZ 9HY RHYTyresrolling
185/65 R15
Circumference1,895 m
Gearbox typeBE4/5
Gearbox ident. plate20 DM 62 20 DL 65
Reduction box torque19x70 19x72
Speedometer ratio22x18 22x18
Right hand drive:NFV = 20 DL 676FZ = 20 DL 69RHY = 20 DL 65.
1.6i
1.8i 16V2.0i 16V PetrolAUTOMATIC

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
«a»Identification label.
«b»Location for engraving of serial and gearbox nos.
B2CP3SQC
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
(1)Retaining clip.(2)Secondary shaft.(3)Drive pinion (5th gear).(4) Bearing retaining clip screw.(5)Gearbox casing.(6)Intermediate plate.(7)Gearbox casing fixing screw.(8)Clutch bearing guide screw.(9) Clutch housing.(10)Bearing guide.(11)Primary shaft.(12)Differential housing.(13)Speedometer screw.(14)Counter drive.(15)Planet pinions.(16) Satellite pinions.(17)Differential gearwheel.(18)Driven pinion (1st gear).(19)1st / 2nd gear synchroniser and reverse gear driven pinion.(20)Driven pinion (2nd gear).(21) Driven pinion (3rd gear).(22) 3rd / 4th gear synchroniser.B2CP3SRP
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
(23)Driven pinion (4th gear).(24)Driven pinion (5th gear).(25)5th gear synchroniser.
Tightening torques (m.daN).
(4)
Bearing retaining clip screw(x4):1,8 ± 0,2
(6)
Intermediate plate (11 fixing screws): 5 ± 0,5
(7)
Gearbox casing(15 fixing screws):1,9 ± 0,216 fixing screws RPO 9784
17 fixing screws RPO 9786

(8)Clutch bearing guide screw(3 fixing screws):0,6 ±0,15
B2CP3SRP
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
«a»Identification label.
«b»Location for engraving of serial and gearbox nos.
B2CP3HTC
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(1)Primary shaft.(2)Clutch bearing guide.(3)Clutch housing.(4) Gearbox casing.(5) Intermediate plate.(6)Bearing retaining clip.(7) Drive pinion (5th gear).(8) Secondary shaft.(9)5th gear synchroniser.(10)Driven pinion (5th gear).(11)Driven pinion (4th gear).(12)3rd / 4th gear synchroniser.(13)Driven pinion (3rd gear).(14)Driven pinion (2nd gear).(15) 1st / 2nd gear synchroniser and reverse gear driven pinion.(16) Driven pinions (1st gear).(17)Differential gearwheel.(18)Satellite pinions.(19)Planet pinions.(20)Counter drive.(21)Speedometer screw.(22) Differential housing.B2CP167P
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
Tightening torques (m.daN).
(23)
Clutch bearing guide (3 fixing screws): 0,6 ± 0,15.
(24)
Intermediate plate (11 fixing screws): 5 ± 0,5.
(25)
Rear cover (3 fixing screws):2,2 ±0,2.
(26)
Bearing retaining clip (4 fixing screws): 1,8 ± 0,2.
(27)
Secondary shaft nut (1 nut):14 ± 1.
(28)
Gearbox casing (15 fixing screws):1,8 ±0,2.
B2CP167P
XSARA