Citroen BERLINGO 2004 1.G Workshop Manual

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AXLES
SUSPENSION
STEERING
FEATURES OF ELECTRIC POWER STEERING
Engines: HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Steering mechanism
Tightening torques m.daN.
(4)
Balljoint fixing on pivot: 3,5 ± 0,3
(5)
Steering rod locknut: 5 ± 0,5
(8)
Threaded washer
(9) Stud: 0,8 ± 0,1
(10)
Flat washers
(11)Fixing of mechanism on subframe:8 ±0,8
Connectors.
(6)
Supply of electric assistance motor
(7) Torque sensor signals
HFX KFV 8HX 8HWKFV (BVA)
NFU 8HY 8HV
Electric motor 60 A 65 A
Steering rack travel2x72 2x64
Steering ratio45,6/1
Number of rotations
3,22,8
of steering wheel
Inner angle of lock 38° 32°30’
Outer angle of lock 32°24’ 28°42’
B3EP13JD
C3 C3 PLURIEL

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AXLES
SUSPENSION
STEERING
FEATURES OF ELECTRIC POWER STEERING
Engines: HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Steering assistance
Supplier:KOYO.
The steering assistance is rpovided by the assistance motor
(12), controlled
by the ECU.
Power delivered to the assistance motor
(12)depends on:
Speed of the vehicle.
Torque applied on the steering wheel.
Electric powerassisted steering ECU.
Only one ECU version, whatever the enginetype.
The electric power steering ECU is linked to the following connectors:

(6)Assistance motor supply.
(13)Electric power steering ECU supply.
(14) Control signals.
After changing the electric power steering ECU, it is necessary to
perform a configuration
(see corresponding operation).
B3EP13KCB3EP13LC
C3 C3 PLURIEL

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AXLES
SUSPENSION
STEERING
SPECIAL FEATURES: STEERING
Engines: HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Centring the steering rack
Preliminary operation.
Raise and support the vehicle on a twocolumn lift.
Remove, on the RH side of the steering rack:
Clip
(1).
Clip (2).
Release the steering rack rpotection gaiter.
Setting.
Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension
Y.
Calculate the dimension:
L = (Y – X): 2.
Refit:
The steering rack rpotection gaiter
New clips
(1)and (2).
B3EP13UC
B3EP13VD
C3 C3 PLURIEL

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AXLES
SUSPENSION
STEERING
XSARA AXLE GEOMETRY
Front and rear measuring points
XSARA ALL TYPES N°RPO 8667 #
Front heightRear height
H1= Dimension between the centre of the front suspension arm mounting and the ground.H2= Dimension between the contact face of the rear mounting and the ground.R1= Front wheel radius under load.R2= Rear wheel radius under load.L1= Distance between the centre of the wheel and the centre of the front suspension arm mounting.L2= Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell.
B3CP06ZD

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AXLES
SUSPENSION
STEERING
Front axle Rear axle
AXLE GEOMETRY
Reference heights
: 4300T N°RPO 9429
# Tools. [1] Gauge for measuring the radius of wheels with 4 bolts
Setting the reference height.
Front
Fr ont
Measure the dimension «R1».
Calculate the dim.
H1 = R1 L1.Measure the dimension
«R2».
Calculate the dim.
H2 = R2 + L2.
Compress the suspension until the values
(H1)and (H2)are obtained.
NOTE:The difference in height between the two sides should be less than10 mm.
XSARA
Reference heights
(in mm)115,5
90,575,5 73
8388 103 Engines2.0i 16V
(RFS)All engines (except
2.0 i 16V and CRD)All CRD
engines 2.0i 16V
(RFS)All Saloon (except
2.0i 16V and CRD)EstateAll CRD
engines
B3CP04AD

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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
AXLE GEOMETRYXSARA
Values of the front and rear suspensions, at reference height
Front axle
Adjustable
YES
NO
Pivot angle
Camber CastorTracking
Camber
(*) CRD
= Difficult road conditions.
Tracking
Tolerances
± 30’ ± 30’ ±18’ ± 1 mm 1,5 ± 1 mm
0°15’ ± 10’
(toe-out)
3° 2°55’ 3° ± 07’ 2°55’
10°22’ 11° ± 07’ 10°26’
0°12’ 0° ± 07’ 0°07’ 10°40’
0°
Saloon or
entreprise KFWSaloon all engine
typesexcept KFW
Estate
all engine types
except CRD (*)
Rear axle
NO YES
Saloon CRD (*)
KFW2.0i 16V (RFS)Saloon CRD (*)
all engine types
except KFW
Estate CRD (*)
all engine types
Adjustable TolerancesSaloon all engine types
Saloon entreprise2.0i 16V (RFS)Estate
all engine typesSaloon CRD (*)
all engine types
Estate CRD (*)
all engine types
10°44’
± 1,3 mm
± 15’4,54 ± 1,3 mm 5,1 ± 1,3 mm 4,27 ± 1,3 mm 3,45 ± 1,3 mm
0°41’ ± 11’ 0°46’ ± 11’ 0°39’ ± 11’ 0°31’ ± 10’
0°57’ 0°58’ 0°59’

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AXLES
SUSPENSION
STEERING
XSARA
AXLE GEOMETRY
a= Angle which defines the tracking between the front and rear axles.
Its value must not exceed
12'.
B3CP04UC

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AXLES
SUSPENSION
STEERING
XSARA
FR ONT AXLE
Tightening torques (m.daN).
(1)
Damper nut: 4,5 ± 0,4
(2)Cup screw : 2,5 ± 0,3
(3)Suspension leg(4)Antiroll bar link rod upper balljoint: 3,7 ± 0,3
(5)Suspension leg pivot (hollow pivot): 4,5 ± 0,5
(5) Suspension leg pivot (pivot «H»): 5,5 ± 0,5
(6)Antiroll bars(7)Antiroll bar link rod lower balljoint:3,7 ± 0,3
(8)Pivot lower balljoint:4 ± 0,4
(9)Driveshaft nut: 32,5 ± 2,5
(10) Wheel bolt:9 ±1
(11)Lower arm front mounting: 7,6 ± 0,7
(12) Lower arm rear mounting
and antiroll bar bearing: 6,8 ± 0,6
(13)Screw under rear mounting: 3,1 ± 0,3
(14) Balljoint fixing on lower arm:5 ±0,5Subframe to bodyshell fixing screw: 8,5 ± 0,8
B3CP040PB3CP041D
VehiclesRPO 8667#are all equipped
as standard with ventilated discs.

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AXLES
SUSPENSION
STEERING
FRONT AXLE
Evolution: Suspension arm balljoint
XSARA
Application from RPO: 7968.
New components:
Suspension arm balljoint.
Pivot.
Old fitting
ØA = 16 mm.
New fittingØA = 18 mm.
Repair requirements.
ESSENTIAL:Swapping of old and new components is forbidden.
It is permitted to fit a new pivot/balljoint assembly on one side of an old
vehicle.
Replacement Parts.
The old components are still available from Replacement Parts.
B3CP054D