Gearbox Citroen XSARA 2005 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine PRESENTATION
THIS HANDBOOKsummarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate
handbook.
The handbook is divided into groups representing the main functions:
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
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Downloaded from www.Manualslib.com manuals search engine GENERAL
C41 - 2
XSARA3 - 4
XSARA PICASSO5 - 6
BERLINGO7 - 8
Operations following a repair: C49
C411 - 12
XSARA13 - 14
XSARA PICASSO15
BERLINGO16
Lubricants17 - 39
ENGINE
Specifications40 - 41
Tightening torques: engines all types42 - 147
Cylinder head tightening: all types148 - 150
Auxiliary drive belt152 - 153
Checking and setting the valve timing181 - 182
C4279
XSARA280
XSARA PICASSO281
Valve clearances282Checking the turbo pressure:
Xsara picasso (DW10ATED)295
Checking the air supply circuit: Xsara (DV4TD)
296
Checking the air supply circuit: C4 (DV6ATED4)297
Checking the air supply circuit: C4 (DV6TED4)298
Checking the air supply circuit: C4 (DW10BTED4)299 - 300
Checking the air supply circuit:
Xsara picasso (DW10TD/ATED)301
Checking the exhaust gas recycling circuit:
Xsara (DV4TD)302
Checking the exhaust gas recycling circuit:
Xsara picasso (DV6TED4)303
Checking the exhaust gas recycling circuit:
Xsara picasso (DW10TD/ATED)304
IGNITION
Sparking plugs305
CLUTCH - GEARBOX - TRANSMISSION
C4307 - 308
Xsara309 - 310
Xsara picasso311
CONTENTS
Vehicle
identification
Capacities
INJECTION
Checking the low pressure fuel supply
circuit: Xsara (DV4TD)283
Checking the low pressure fuel supply
circuit: C4 (DV6TED4/ATED4)284
Checking the low pressure fuel supply
circuit: Xsara Picasso (DV6TED4)285
Checking the low pressure fuel supply
circuit: C4 (DW10BTED4)286
Checking the low pressure fuel supply
circuit: Xsara (DW10TD)287
Checking the low pressure fuel supply
circuit: Xsara Picasso (DW10TD/ATED)288 - 289
Checking the turbo pressure: Xsara (DV4TD)
290
Checking the turbo pressure:
C4 (DV6TED4/ATED4)291
Checking the turbo pressure:
Xsara Picasso (DV6TED4)292
Checking the turbo pressure:
C4 (DW10BTED4)293
Checking the turbo pressure:
Xsara picasso (DW10TD)294
Checking the oil
pressureClutch
specifications
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Downloaded from www.Manualslib.com manuals search engine CLUTCH - GEARBOX - TRANSMISSION (continued)
Gearbox specifications312 - 314
Clutch specifications315 - 316
Checking and adjusting the hydraulic
clutch control317 - 318
Tightening torques: manual gearbox
319 - 330
Manual gearbox controls
331 - 343
Recommendations - precautions:
automatic gearbox344 - 346
Tightening torques: manual gearbox
347 - 349
Automatic gearbox controls
350 - 359
Driveshafts360
AXLES - SUSPENSION - STEERING
Axle geometry: C4361 - 364
Tightening torques: front axle365 - 366
Tightening torques: rear axle367
Tightening torques: power steering368 - 369
Setting the steering rack mid-point370
Checking the power steering pressure371 - 374
Axle geometry: Xsara375 - 379Adjusting the handbrake 426
Filling, bleeding the brakes427
AIR CONDITIONING
R134.a: quantities428
Checking the compressor lubricant429 - 430
Pollen filter: all types431 - 433
Filtering and drying cartridge434 - 436
Checking the efficiency of the circuit437 - 446
C4447 - 451
Xsara452
Xsara picasso453 - 456
CONTENTS
Tightening torques: front axle380
Tightening torques: rear axle382
Tightening torques: steering 383 - 384
Tightening torques: power steering385 - 387
Axle geometry: Xsara Picasso388 - 392
Tightening torques: front axle393
Tightening torques: rear axle394
Tightening torques: power steering395 - 397
BRAKES
Brake specifications: C4398 - 399
Tightening torques: Brakes401 - 403
Adjusting the handbrake 405
Filling, bleeding the brakes406 - 410
Brake specifications: Xsara411
Tightening torques 414
Brake specifications415 - 418
Adjusting the handbrake 419
Filling, bleeding the brakes420
Brake specifications: Xsara Picasso421 - 422
Brake specifications423 - 424
Aircon circuit
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Downloaded from www.Manualslib.com manuals search engine GENERAL
1
IDENTIFICATION OF THE VEHICLE
E1AP0EWD
A- Manufacturer's name plate
A1 -Front RH chassis member = All versions except
CITROËN C4Coupé EW10J4S
(right hand drive).A2 -LH centre pillar = CITROËN C4 coupé EW10J4S(right hand drive).
B - Cold stamp
(cold stamp engraved on the bodywork).
C - AS/RP No. and RP paint code
(on the front pillar on driver's side).
D - Tyre pressures and tyre type
(on the front pillar on driver's side).
E - Serial number on bodywork.
F - Gearbox ident. reference - Factory serial no.
G - Engine legislation type - Factory serial no.
GENERAL
C4
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GENERAL
Structure Version (4)
L Family (1)Depollution levels
A Bodywork (2)L3 L4 L5 US Others K Alcohol
LA KFUC KFU Engine (3)W3 83/87 K' L3/L4 L5
C Version (4)Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5)Manual 4-speed gearbox E F R W 6 9 2
Family (1)Manual 6-speed gearbox G H S X 3
L C4 Automatic 6-speed gearbox D J N U
Body shape (2)Axle and/or gearbox gears K L T Y 7 0 4
A 3-door saloon Other possible combinations M
C 5-door saloon No gearbox Z
G3-door saloon not
convertible from van
R5-door saloon not
convertible from van
Engine (3) Variants (5)
KFU 1.4i 16V ET3J4 Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
RFJ EW10A Without FAP SF
RFN 2.0i 16V EW10J4 Fiscal incentives IF
RFK EW10J4S Piloted manual gearbox P
9HY
DV6TED4Downgraded depollution D
9HZ 1.6 16V HDi LPG dual fuel GL
9HX DV6ATED4 CNG dual fuel GN
RHR 2.0 16V HDi DW10BTED4 STT2 (Stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
C4
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Downloaded from www.Manualslib.com manuals search engine GENERAL
3
IDENTIFICATION OF THE VEHICLE
E1AP08WD
A- Manufacturer's name plate (estate).
B -Chassis stamp, cold stamp.
C -Manufacturer's name plate (saloon).
D -Label:
(label affixed to the front pillar on driver's side)
- Tyre pressures.
- RP organisation no.
- Paint code.
E - Serial number (visible through the windscreen).
F -Engine legislation type - Factory serial no.
G - Gearbox ident. reference - Factory serial no.
XSARA
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GENERAL
Structure Version (4)
N Family (1)Depollution levels
2 Bodywork (2)15.04Spécif US93/59 96/69 98/69A 98/69B Alcohol
N2 RFN1/IFRFN Engine (3)K ≠ CEE L/W2 L3/W3 L4 L5 L3/L4
1 Version (4)Manual 4-speed gearbox V
/IF Variant (5)Manual 5-speed gearbox G H E F B 1 K
Family (1)Manual 6-speed gearbox
N XSARA Automatic 3-speed gearbox T D L 2
Body shape (2)Automatic 4-speed gearbox U R M N 3 4
2 Estate Axle and/or gearbox gears W S J C P 9
Manual 5-speed gearbox
Mercosur/IranXYA5
No gearbox Z
Engine (3) Variants (5)
KFW 1.4i TU3JP Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
RFN 2.0i 16V EW10J4 Without FAP SF
8HZ 1.4 HDi DV4TD Fiscal incentives IF
8HY 1.4 16V HDi DV4TED4 Piloted manual gearbox P
WJY 1.9D DW8B Downgraded depollutionD (car or van not
TD (van convertible)
convertible)
RHY
2.0 HDiDW10TD LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
RHZ DW10ATED STT2 (stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
XSARA
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Downloaded from www.Manualslib.com manuals search engine GENERALGENERAL
5
IDENTIFICATION OF THE VEHICLEXSARA PICASSO
E1AP088D
A- Chassis stamp
(cold stamp on bodywork).
B -Chassis no. reminder
(label located at bottom of windscreen right hand side).
C -Manufacturer's data plate
(located at bottom of RH central pillar).
D -Label:
(located on front LH door inner panel)
- Tyre pressures.
- Tyre identification.
- Spare wheel identification.
E -Label:
(located on fuse box cover)
- Factory code.
- A-S / RP N°.
- Paint code.
F -Gearbox identification ref.
G -Engine legislation type - Factory serial number.
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GENERAL
Structure Version (4)
C Family (1)Depollution levels
H Bodywork (2)L3 L4 L5 US Others K Alcohol
CH 6FZC/IF 6 F ZEngine (3)W3 83/87 K' L3/L4 L5
C Version (4)Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5)Manual 4-speed gearbox E F R W 6 9 2
Family (1)Manual 6-speed gearbox G H S X 3
C XSARA PICASSO Automatic 6-speed gearbox D J N U
Body shape (2)Axle and/or gearbox gears K L T Y 7 0 4
H Monoshell Other possible combinations M
No gearbox Z
Engine (3)Variants (5)
NFV 1.6i TU5JP Entreprise convertible T
6FZ 1.8i 16V EW7J4 Integral alternator-starter (ADIN) AD
RFN 2.0i 16V EW10J4 Without FAP SF
9HZ
1.6 16V HDi DV6TED4Fiscal incentives IF
9HY Piloted manual gearbox P
RHY 2.0 HDi DW10TD Downgraded depollutionD (car or van not
convertible)TD (van convertible)
LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
STT2 (stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
XSARA PICASSO
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GENERAL
BERLINGO IDENTIFICATION OF THE VEHICLE
E1AP0AMD
A- Chassis stamp, cold stamp.
B - Manufacturer's vehicle plate.
C -Label
- RPO No.
- Paint colour code.
- Tyre pressures.
D -Gearbox ident. reference - Factory serial no.
E - Engine legislation type - Factory serial no.
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