elect Citroen BERLINGO 2004 1.G Repair Manual

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AXLES
SUSPENSION
STEERING
FEATURES OF ELECTRIC POWER STEERING
Engines: HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Steering column
Tightening torques m.daN.
(1)
Steering wheel fixing:2 ±0,3
(2)
Steering column fixing on support:2,2 ± 0,5
(3)
Steering cardan fixing: 2,2 ± 0,2Identification.
Identified by the colour of the ring at «a».
Left hand drive
:BLUE ring.
Right hand drive
: WHITE ring.
B3EP13GDB3EP13HC
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 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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BRAKES
B3FP7BSD
BRAKE SPECIFICATIONS
Braking circuit without ABS REF (drum brakes at the rear)
Braking system specifications
Braking circuit at «X».
Front brakes with ventilated discs
(*).
Rear brakes with eitther drums or discs
(*).
Handbrake lever controlling cables acting on the
rear wheels.
The compensator and main brake limiter functions
are assured by the
ABS EBD system.
NOTE: REF= Electronic Brakeforce Distribution.
(*)= according to version.
C2

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BRAKES
BRAKE SPECIFICATIONS
Braking circuit with ABS REF
(a) Hydraulic circuit(b)Electrical circuit
(1)Master cylinder in tandem(2)Braking servo(3)Brake caliper (or drum at the rear)(4)Hub equipped with a bearing with an integral magnetic wheel(48 pairs of poles)(5)Wheel sensor(6)Brake fluid level sensor(7)Hydraulic block plus ECU(8)Stoplamp switch(9)Instrument panel(10)Diagnostic socket(11)Builtin systems interface (BSI)
B3GP02RP
C2

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BRAKES
C5FP0ELD
HANDBRAKE (Adjustment)
Adjustment.
Lift and chock the vehicle.
Remove:
The rear cover
(8).
The nut (9).
The handbrake trim (6).
The gear lever gaiter (5).
The front cover (3).
The screws (1).
Disconnect the connectors of the following components:
The cigar lighter
(2).
The electric window buttons (4).
Remove the central console
(7).
WARNING:Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal
(Then repeat the ope
ration 3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C2

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BRAKESBRAKE SPECIFICATIONS (WHITHOUT ABS REF)
Engine typeHFX KFV KFU 8HX 8HW
Master cylinder
20,6
Ø Master vac203,2
mm Caliper/piston makesLUCAS/TRW C48/13 48
FT Disc Plain266 266
Disc thickness/minimum thickness13/1113/11
Ø
mm Disc Ventilated266
Disc thickness/minimum thickness22/20
Brake pad gradeTEXTRR T 4144
ØDrum / Max. thickness
mm Width203/205/38
RRMakeDON
Brake lining grade8259
Braking compensator (Vehicle without ABS) (CICR= Compensator integral to the wheel cylinder). REF= Electronic brakeforce distribution.
Supplier/Type/Cutoff pressure (Bar)RPO 9666 LUCAS LUCAS/CICR/35Supplier/Type/Cutoff pressure (Bar)RPO 9667 LUCAS LUCAS/CICR/27 1.1i
1.4i1.4i 16V 1.4 HDi
C3

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BRAKES
BRAKE SPECIFICATIONS (WITH ABS REF)
Engine type HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Master cylinder
22,2(*)
Ø Master vac
228,6
mm Caliper /piston LUCAS/TRW LUCAS/TRW LUCAS/TRW LUCAS/TRWmakesC 48/13 48 C 54/22 54 C 48/13 48 C 54/22 54
Disc Plain266 266
FT Disc thickness/minimum thickness13/11 13/11
Ø
mm Disc Ventilated266 266
Disc thickness/minimum thickness22/20 22/20
Brake pad gradeTEXTRR T 4144
Ø Cylinder or caliperLUCAS C38 HR 9/13
mm Disc Plain247 247
RR Disc thickness/minimum thickness9/7 9/7
Ø Drum / Max. thickness /
mm Width203/205/38 203/205/38
MakeDONGALFER DON GALFER
Brake lining grade8259 G 4554 8259 G 4554
(*)= With emergency braking system.REF= Electronic brakeforce distribution.NOTE:Braking compensators = The compensator and limiter functions for the main brakes are assured by the ABS REF system. 1.1i 1.4i 1.4i 16V 1.6i 16V 1.4 HDi 1.4 HDi 16V
C3

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BRAKESBRAKE SPECIFICATIONS (WITH & WITHOUT ABS REF)
Engine typeKFV 8HX KFV NFU 8HX
Master cylinder
20,6 22,2(*)
ØMaster vac
203,2228,6
FT mm Makes /piston makesLUCAS/TRW C38 HR 9/13
Disc Ventilated266
Disc thickness/minimum thickness22/20
Brake pad gradeTEXTRR T 4144
ØCylinder or caliperLUCAS/TRW C 38/13 38
mmDiscPlain247
RR Disc thickness/minimum thickness9/7
ØDrum / Max. thickness /
mmWidth203/205/38203/205/38
MakeDONGALFERDON
Brake lining grade8259/1 G 4554 8259/1
(*)= With emergency braking system.(CICR = Compensator integral to the wheel cylinder)Braking compensator (Vehicle without ABS)REF= Electronic brakeforce distribution.
Supplier/Type/Cutoff pressure (Bar) :LUCAS/CICR/27
Braking compensator (Vehicle with ABS)NOTE:Braking compensators = The compensator and limiter functions for the main brakes are assured by the ABS REF system.
C3 PLURIEL
Sans ABS REF Ftec ABS REF
1.4i 1.4 HDi 1.4i 1.6i 16V 1.4 HDi

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BRAKES
B3FP161D
BRAKE SPECIFICATIONS
Braking circuit without ABS REF (drum brakes at the rear)
Braking system specifications
Braking circuit at «X».
Front brakes with ventilated discs
(*).
Rear brakes with eitther drums or discs
(*).
Handbrake lever controlling cables acting on the rear
wheels.
The compensator and main brake limiter functions are
assured by the
ABS EBD system.
NOTE: REF= Electronic Brakeforce Distribution.
(*)= according to version.
C3 C3 PLURIEL