Xsara 2 Citroen XSARA 2004 1.G Workshop Manual

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AXLES
SUSPENSION
STEERING
REAR AXLE
XSARA
Vehicles
Engines Diameter colour reference Diameter colour referenceTorsion bars (mm) Antiroll bar (mm)
3door Entreprise
19,3 Violet 19 Orange
3 and 5door TT
exc. Entreprise
Estates All types
18,7
20 Grey20 Green
3 and 5door TT19,3
Violet19 Orange
Estates All types20 Grey20 Green
3door VTS
3 and 5door TT
Estates All types21Light green
23
19,3Violet19
20
Grey20Without colour,
or white sticker yellow 18 Blue
1.9 D
1.6i 16V 2.i 16V
1.4 HDi 2.0 HDi
2.0i 16V
Grand Export
«CRD»
Orange
Green

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AXLES
SUSPENSION
STEERING
XSARA REAR AXLE
The front silentblocks are aligned at an angle of 45°in relation to the vehicle’s axis.
The rearsilentblocks are in parallel with the vehicle’s axis.
NOTE:There are two suppliers for the silentblocks:

RBT, identified by a Green or Yellow painted dot on the side of the mounting.
PAULSTRA, identified by a Blackpainted dot on the side of the mounting.
It is
FORBIDDENto swap components of different suppliers.
Operating clearance X = 1 to 1.4 mm.
NOTE:
The RH torsion bar can be identified by 1
paint line.
The LH torsion bar can be identified by
2 paint lines.
B3DP04UDB3DP04TC

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AXLES
SUSPENSION
STEERING
Adjusting the rear dummy damper
Lengths of the rear dummy damper (mm)
Grand export
346
339
346
342 Normal driving
339
318
336
XSARA REAR DAMPER
E5AP14WC
Engines
1.9 D
1.6i 16V 3door
1.6i 16V 5door
2.0i 16V (RFN) 1.4 HDi
2.0 HDi
2.0i 16V (RFS)
Estates and
Entreprise all types

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AXLES
SUSPENSION
STEERING
XSARA
Steering wheel Manual steering
MANUAL STEERING SPECIFICATIONS
(a): LHD/RHD = White.
(L): Shaft length = 311 ± 1.5 mm.
(1) Steering wheel fitted with AIRBAG(according to equipment).
(4)Steering column adjustment lever.
Tightening torques (m.daN).
(2) AIRBAG to steering wheel fixing: 0.8 (3)Steering wheel fixing: 3.3 (5) Steering column to support fixing:2.3 (6)Steering cardan joint fixing:2.3
(b) = Locating bush.
The locating bush must be centred in the reference window before
tightening the cardan bolts
(6).
B3EP08PD

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AXLES
SUSPENSION
STEERING
XSARAMANUAL STEERING SPECIFICATIONS
Manual steering
Tightening torques (m.daN).
(7)
Pivot balljoint nut:4
(8)
Link rod lock nut: 4.5
(9)
Balljoint on steering rack:6
(10)
Fixing on cradle:5
(11)
Plunger flange screw: 1.2
B3EP042D

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AXLES
SUSPENSION
STEERING
22/1 Steering ratio
MANUAL STEERING SPECIFICATIONSXSARA
Manual steering (continued)
Number of teeth
Pinion Steering rack
travel
(mm)
73,56 teeth
(RH helix)29(13)
Yellow thicknessmm4,3
Left hand driveSteering rackSteering stop
colour codeNumber
of steering
wheel turns
Length of the steering track rods (Preadjustment)= 371mm (Between balljoint centres)or391mm (Between the centre of the pivot balljoint and the contact face of the steering rack balljoint).

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AXLES
SUSPENSION
STEERING
XSARA POWERASSISTED STEERING SPECIFICATIONS
Steering wheel Powerassisted steering
(a): LHD = Blue.
: RHD = White.
(L): Shaft length = 311 ± 1.5 mm.
(1) Steering wheel fitted with AIRBAG(according to equipment).
(4)Steering column adjustment lever.
Tightening torques (m.daN).
(2) AIRBAGto steering wheel fixing: 0.8 (3)Steering wheel fixing: 3.3 (5)Steering column to support fixing: 2.3 (6)Steering cardan joint fixing: 2.3
(b) = Locating bush.
The locating bush must be centred in the reference
window before tightening the cardan bolts
(6).
B3EP08QD

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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
Powerassisted steering
XSARA
Tightening torques (m.daN).
(7)
Pivot balljoint nut:4
(8)
Link rod lock nut: 4.5
(9)
Balljoint on steering rack:6
(10)
Fixing on subframe:5
(11)
Hydraulic pipe connection: 2.5
(12)
Valve to housing fixing: 1.2
(13)
Plunger flange screw: 1.2
(14)
Screw fixing the steering ram
to the housing: 5.5
(15)
Nut fixing the steering ram
to the yoke: 5.5
B3EP08RD

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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
XSARA
Powerassisted steering (Continued)
Number of teeth
Pignon Steering rack
travel
(mm)
71,7(
*)
(RH helix)
28
Protector colour Vehicles
BLACKAll Types (except 1.6i 16V 1.9 TD)7
Steering valve
Number of teeth (*) 3,3
LHDSteering rackNumber of
steering wheel
turns
Length of the steering link rods (Preadjustment)= 371mm (Between balljoint centres)or391mm (Between the centre of the pivot balljoint and the contact face of the steering rack balljoint).
1.6i 16V 1.9 TDORANGE8
18,8/1 Steering
ratio

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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
XSARA
Powerassisted steering assembly
Tightening torques (m.daN).
High pressure tube (Rubber seal pump side)
Powerassisted valve and pump union: 2.5
Return pipe.
Powerassisted valve union: 2.5
(16)Upper front fixing (E3) : 2.5
(17) Upper rear fixing (E3) : 2.2
(18)Fixing (E3) : 2.2
Tightening sequence.
Tighten screws (16)and (18).
Lightly tighten screw
(17), then fully tighten.
Pressure switch on the pressure circuit.
Switch opens 30to 35 Bars.
Switch closes 25 Bars.
Tighten to :
2 m.daN. Powerassisted steering system capacity =
1 litre.
Oil type:TOTAL FLUIDE ATX.
SAGINAW Pump adjustment = 100 Bars ± 5.
Pump shaft threading 3/8 16 threads per inch.
B3EP045D