length Citroen BERLINGO 2004 1.G Workshop Manual

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ENGINE
CYLINDER HEAD
Engines: HFX KFV NFU
Cylinder head tightening (m.daN) Cylinder head bolts
X =MAX. reusable length
Tightening : 2 ± 0,2
Angular tightening: 240° ± 5°
Tightening :2,5 ±0,2Angular tightening:200 ±5°
(In the order 1 to 10)
B1BP1DVC
KFU HFX KFV
HFX KFV
175,5 ± 0,5 122 ± 0,3NFU
B1BP10KC
NOTE:Retightening of the cylinder head
after a completed repair is prohibited.
C2 C3 C3 PLURIEL
NOTE:Oil the threads and under the heads of
the bolts (use engine oil or Molykote G Rapid
Plus).
Tightening
: 2 ± 0,2Angular tightening:260° ± 5°
(In the order 1 to 10)
NFU
KFV
119

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ENGINE
CYLINDER HEAD (Continued)
Engines: KFW NFV NFU
Cylinder head tightening (m.daN) One Cylinder head bolts
X =MAX. reusable length
Pretightening :2
Angular tightening: 240 ± 5°
XSARA XSARA PICASSO
NOTE:Oil the threads and under the heads of the bolts (use
engine oil or Molykote G Rapid Plus).
B1DP13NC

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ENGINE
CYLINDER HEAD
Engine: 6FZ
X =MAX. reusable length NOTE:
Oil the threads and
under the heads of the bolts
(use engine oil or Molykote G
Rapid Plus)
. Pretightening
: 1,5 ± 0,2
Tightening: 5 ± 0,2
Destightening: 360 ° (1 turn)
Tightening: 2 ± 0,2
Angular tightening: 285° ± 5°
B1DP16FC
A = Washer thickness:4 ± 0,2 mm.X= Length under heads of new bolts = 144,5 ±0,5 mm.
XSARA XSARA PICASSO

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ENGINE
CYLINDER HEAD
Engine: RFN
X =MAX. reusable length NOTE:
Oil the threads and
under the heads of the bolts
(use engine oil or Molykote G
Rapid Plus)
. Pretightening
: 1,5 ± 0,2
Tightening: 5 ± 0,2
Destightening: 360 ° (1 turn)
Tightening: 2 ± 0,2
Angular tightening: 285° ± 5°
B1DP16FC
A = Washer thickness:4 ± 0,2 mm.X= Length under heads of new bolts = 144,5 ±0,5 mm.
XSARA XSARA PICASSO

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ENGINE
CYLINDER HEAD
Engine: RFS
X =MAX. reusable length NOTE:
Oil the threads and
under the heads of the bolts
(use engine oil or Molykote G
Rapid Plus). Pretightening
: 3,5
Slackening:NO
Tightening:7
Angular tightening: 160°
B1DP13PC
B1DP05BC
RFS
RFS
112 mm Cylinder head tightening (m.daN) One Cylinder head bolts
XSARA

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ENGINECYLINDER HEAD
Engines: 8HX 8HW 8HZ 8HV 8HY
Cylinder head tightening (m.daN) One Cylinder head bolts
X =MAX.reusable length
Pretightening: 2 ± 0,2 m.daN
Tightening: 4 ± 0,4 m.daN
Angular tightening: 230° ± 5°
The bolts should have been tho
roughly cleaned and dried with a
dry metal brush.
Oil the threads and under the
heads of the bolts
(use engine oil
or Molykote G Rapid Plus).
Pass a tap into the holes in the
cylinder block.
8HX 8HW 8HZ 8HV 8HY
8HX 8HW 8HZ 8HV 8HY
X = 149 mm
B1DP1CLC
B1DP1DBC
NOTE:Retightening of the cylinder head
after a completed repair is prohibited.
The cylinder head gasket is dryfitted.
C2 C3 C3 PLURIEL

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ENGINECYLINDER HEAD
Engines: 9HZ 9HY
X =MAX. reusable length
Pretightening: 2 ± 0,2 m.daN
Tightening: 4 ± 0,4 m.daN
Angular tightening: 260° ± 5°
(use engine oil or
Molykote G Rapid Plus)
.
Pass a tap into the holes in the
cylinder block.
B1DP1DBC
B1DP1CLC
9HZ 9HY
9HZ 9HY
X = 147 mm Cylinder head tightening (m.daN) One Cylinder head bolts
XSARA PICASSO
NOTE:Retightening of the cylinder head
after a completed repair is prohibited.
The cylinder head gasket is dryfitted.

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ENGINE
113
XSARA XSARA PICASSO
CYLINDER HEAD (Contin ued)
Engines: WJY RHY RHZ
X =MAX. reusable length NOTE:
Oil the threads and under the heads
of the bolts (use engine oil or Molykote G
Rapid Plus).Pretightening
:2
Tightening:6
Angular tightening: 220°
Pretightening:2
Tightening:6
Angular tightening: 180°
B1DP15ECB1DP13PC
RHY RHZ
WJY
WJY RHY RHZ
125,5 mm
133,3 mm Cylinder head tightening (m.daN)
One Cylinder head bolts
WJY RHY RHZ
B1DP05BC

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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
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
(4)Gear engagement balljoint Ø 10 mm.
(5)Gear selection balljoint Ø 10 mm.
C2 C3
Length D Length C Length D Length C
Gear
engagement
1040 mm 815 mm 1015 mm 790 mm
control cable (2)
Length A Length B Length A Length B
Gear
selection
1149 mm800 mm 1093 mm 775 mm
control cable (3)B2CP3HZD
B2CP3HYC
C2 C3 C3 PLURIEL