Engine mount Citroen XSARA PICASSO 2004 1.G Workshop Manual

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: NFU
Setting the valve timing.
Loosen the screw (2), remove the belt.
Loosen the six pulley screws (1)on the hubs(there should be a slight amount of friction between the screws and the pinions).
Check that the rollers (2)and (3)rotate freely.
NOTE:The belt bears three identification marks * (a), (b)and (c), facing its own teeth (1), (52) and (72)respectively.
*
(Identification marks = white paint lines on the back of the belt facing the corresponding teeth).
Refit the belt.
Line up mark (A)on the belt with groove (D)of the pinion (4).
Hold the belt against the pinion (4).
B1EP11ECB1EP11DC
XSARA

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engine: NFU
Setting the valve timing.
Remove the tools [1], [2], [3] and [4].
Rotate the engine by 4 turnsin the normal direction (do not turn backwards). Peg the flywheel [2].
Loosen the six screws (5), while ensuring there is still a slight amount of friction with the pulley.
Peg the camshaft hubs using pegs [3]and [4].
WARNING: In certain cases, it may be necessary to slightly turn the camshaft using the hub fixing screw.
Fit the tool [1].
Loosen the tensioner roller screw (2).
Rotate the roller (2)(using tool [5])in an anticlockwise direction to obtain:37 SEEM units.
Tighten the tensioner roller screw (2)to 2 m.daN.
Tighten the six pulley screws (1)to 1m.daN.
Remove the tools.
XSARA

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INJECTION
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
Operations on the fuel additive circuit.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
The work area must be ventilated.
In the event of any significant dispersion of additive:
Wear a breathing mask for filtering the particles.
Recover as much of the product as possible.
Place the product thus recovered in an appropriately labelled container. Wash the soiled area with copious amounts of water.
Dispose of materials and solid residues in an authorised recovery point.
IMPERATIVE:The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be
disposed of.
Cleanliness rules.
ESSENTIAL: The operator should wear clean overalls.
Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components(see corresponding operations).
Fuel filter.
Fuel high pressure pump.
Fuel high pressure regulator.
Fuel high pressure common injection rail. Fuel high pressure piping. Diesel injector carriers.
IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of impurities.
ALL TYPES

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: HFX – KFV – KFU – NFU – 8HX – 8HW – 8HV – 8HY
NOTE:All the clutches are «push»type with hydraulic control.
Description.The declutch control has a declutch fork mounted on a balljoint.(1)The balljoint is screwed into the clutch casing.(2)Declutch fork.(3)Clutch casing.(4)Bearing.(5)Clutch plate.
The clutch control slave cylinder
(7)is fixed by two screws (6)onto the exterior of the clutch casing.
Tightening torques (m.daN).
Fixing of clutch plate / engine flywheel: 2 ± 0,2 Fixing of clutch control slave cylinder / clutch housing:2 ±0,25 Fixing of engine flywheel / crankshaft
Pretightening:1,7 ± 0,1Angular tightening:70° ± 5°
B2BP047CB2BP04QC
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: KFW NFU NFV 6FZ RFN RFS 8HZ 9HZ 9HY WJY RHY RHZ
NOTE:All the clutches are «push»type with hydraulic control.
Description.The declutch control has a declutch fork mounted on a balljoint.(1)The balljoint is screwed into the clutch casing.(2) Declutch fork.(3) Clutch casing.(4) Bearing.(5) Clutch plate.
The clutch control slave cylinder
(7) is fixed by two screws (6)onto the exterior of the clutch casing.
Tightening torques (m.daN).
Fixing of clutch plate / engine flywheel: 2 ± 0,2 Fixing of clutch control slave cylinder / clutch housing:2 ±0,25 Fixing of engine flywheel / crankshaft
Pretightening:1,75 ± 0,1Angular tightening:75° ± 5°: 6,3 ± 2,2
B2BP047CB2BP05SC
XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(29)Topup plug (x1): 2,5 ± 0,5.
(30)Drain plug (x1): 2,5 ± 0,5.
(31)Reverse gear switch (x1): 2,5 ± 0,5.
Strengthened MA gearboxes are marked with the letter «B»or «C»:«B»= Differential diameter 77 mm+ strengthened bearings.«C»= Differential diameter 77 mm+ strengthened bearings + strengthened
intermediate plate.
NOTE:All vehicles are equipped with clutch control by cable.
Features.
This gearbox:
has no adjustment.
has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.
Oil capacity : 2 ± 0,15 Litres.
Checking the oil level : Every 37,500 miles.
Lubrication interval : Lubricated «for life».
B2CP169D
XSARA

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AXLES
SUSPENSION
STEERING
FRONT AXLE
Tightening torques (m.daN).
(1)Nut fixing suspension leg on body: 6,5 ± 0,6
(2)Damper:
(3)Antiroll bar link rod upper balljoint:3,2 ± 0,3
(4)Suspension leg pivot: 5,4 ± 0,5
(5)Antiroll bar link rod lower balljoint: 3,2 ± 0,3
(6) Antiroll bar bearing fixing on subframe:8 ± 0,8
(7)Hub nut: 24,5 ± 0,5
(8)Wheel bolt:9 ±1
(9)Subframe to bodyshell fixing screw:10 ± 1
(10) Antiroll bar:
(11)Pivot lower balljoint fixing on lower arm: 5,5 ± 0,5
(12)Pivot lower balljoint fixing: 4 ± 0,4
(13)Lower arm front and rear mounting fixing: 14 ± 0,4
(14)Stabiliser bar screw:6,6 ±0,7
(15)Steering balljoint fixing:3,5 ± 0,3
Private vehicles Antiroll bar
EuropeDiameter (mm)Colour
HFX KFV 18Violet
NFU 20 Green
8HX19Blue
Entreprise vehiclesDiameter (mm)Colour
HFX 8HX18 Violet
CRD vehicles Diameter (mm) Colour
KFV 8HX18 Violet
NFU 20 Green
B3CP07RP
C2

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AXLES
SUSPENSION
STEERING
FRONT AXLE
Tightening torques (m.daN).
(1)Nut fixing suspension leg on body: 6,5 ± 0,6
(2)Suspension leg:
(3)Antiroll bar link rod upper balljoint: 3,2 ± 0,3
(4)Suspension leg pivot: 5,4 ± 0,5
(5)Antiroll bar link rod lower balljoint: 3,2 ± 0,3
(6)Antiroll bar bearing fixing on subframe:8 ± 0,8
(7) Hub nut: 24,5 ± 0,5
(8)Wheel bolt:9 ±1
(9)Subframe to bodyshell fixing screw:10 ± 1
(10)Antiroll bar:
(11) Pivot lower balljoint fixing on lower arm: 5,5 ± 0,5
(12)Pivot lower balljoint fixing: 4 ± 0,4
(13)Lower arm front and rear mounting fixing:14 ±0,4
(14)Stabiliser bar screw: 6,6 ± 0,7
(15)Steering balljoint fixing:3,5 ± 0,3
Antiroll bar
Diameter (mm) Colour
HFX KFV
C3KFU NFU 8HX19Blue
8HW 8HV 8HY
C3
Pluriel KFV NFU 8HX 20 Green
B3CP07RP
C3 C3 PLURIEL

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AXLES
SUSPENSION
STEERING
REAR AXLE
Tightening torques (m.daN).
(1)
Rear axle fixing screw: 10 ± 1
(2)Antiroll bar:
(3)Rear axle crossmember:
(4)Rear suspension arm rubber mounting yoke:
(5)Rear suspension arm rubber mounting:
(6)Yoke / suspension arm fixing screw: 7,6 ± 0,5
(7)Rear suspension arm:
(8)Stub axle bearing nut: 20 ± 2 greased
(9) Damper:
(10)Damper upper fixing: 4,5 ± 0,4
(11)Damper lower fixing: 9,3 ± 1
(12)Suspension spring:
(13)Travel stop:
(14)Secondary brake cable guide and its support:
Antiroll bar
Diameter (mm)
HFX KFV
C3KFU NFU 8HX25,5
(tubular)
8HW 8HV 8HY
C3
PlurielKFV NFU 8HX26
(tubular)
B3CP0AFP
C3 C3 PLURIEL