9hy Citroen BERLINGO 2004 1.G Service Manual

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1] Tool for positioning the gear lever: 9607T.
Adjustements.
WARNING: Cables should be adjusted each
time the gearbox, gear controls or power unit
are removed.
Inside the vehicle:
Remove the trim under the gear lever.
Lock the gear lever in neutral position,
using tool
[1].
Under the bonnet: Remove the air filter assembly.
Unlock the balljoint keys at «a».
Place the gear selection and control levers on
neutral.
Lock the cable lengths with the balljoint locking
keys.
Checks.
Remove the tool [1].
Check that all the gears engage without
«tightness ».
Check that the gear lever moves identically
forwards and backwards and to right and left. If it
does not, repeat the adjustment.
Refit the trim under the gear lever.
Refit the air filter assembly.
Adjusting the gear controls Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3C6CB2CP3C0C

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CLUTCH
GEARBOX
TRANSMISSION
DRIVESHAFTS GEARBOX
Tightening torques (m.daN)
Driveshaft
bearing Engines
V ehiclesGearboxRH side LH side Tool kitGearbox oil seal mandrels
24,5 ± 0,5
32 ± 1,5
32,5 ± 2,57114T.W
Seal extractor
RH / LH
() 0338 C
() 0338 J1
+ () 0338 J3() 0338 H1
+ () 0338 H2
() 0338 J1
+ () 0338 J2() 0338 H1
+ () 0338 H2() 0338 7114T.X
7116T Driveshaft
nut
HFX KFV KFU
8HX 8HW
NFU
KFW NFU
NFV RFS RFN 6FZ WJY
8HZ 9HZ 9HY RHY RHZ
8HV 8HY
NFU RFN RHZ
KFV MA/5
XSARA
XSARA PICASSOC2 C3 C3 Pluriel
XSARANO
2 ± 0,2
1,8 ± 0,1
2 ±0,2
1,8 ±0,1
1 ±0,1
C3
C3
XSARA PICASSO
XSARA
Tightening torque (m.daN) for wheel bolts: XSARA = 8,5 ± 0,8 XSARA PICASSO = 10 ± 1 C2 C3 C3 PLURIEL = 9 ± 1BE4/5
AL 4
C2 C3 C3 PLURIEL XSARA XSARA PICASSO

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AXLES
SUSPENSION
STEERING
AXLE GEOMETRY
Compress the suspension to obtain the calculated values.
NOTE:The difference in height between the two sides should be less than 10 mm. Measure the radius of the rear wheel:
R2.
Calculate dimension H2. Measure the radius of the front wheel:R1.
Calculate dimension H1or H1’.
Checks at reference height (the reference height of the vehicle is set as per the table below).
B3CP05BCB3CP05AC
XSARA PICASSO
Front axlesRear axle
Front axles
Rear axle Engines:NFV 6FZ RFN 9HZ 9HY RHY
H1 = R1 – L1 ou H1’ = R1 – L1’
NO CRD Vehicle (CRD = Difficult road conditions)
L1 = 90,5 mmL1’ = 124 mmL2 = 8,5 mm H2 = R2 + L2
B3DP079C
Value at reference height (8/+3 mm)Value at reference height (+10/3 mm)

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BRAKES
BRAKE SPECIFICATIONS
Engine type6FZ RFN 9HZ 9HY RHY
Master cylinder
23,8
Ø Master vac
mm Master cylinder travel
254/35
FT Piston Makes/CaliperBOSCH ZOH54/54
Disc Ventilated283
Disc thickness/minimum thickness26/24
Makes/Brake pad gradeFERODO/769 (37)
Rear brake caliper
Ø Supplier/Type
TRW C38
mm Disc plain247
RR Disc thickness/minimum thickness9/7
MakeGALFER
Brake lining gradeG 4554
Compensator – cutoff in BarsOn versions with ABS, there is no loadsensitive
rear braking compensator.
(*) ESP = Electronic Stability Program.All types
Ftec ESP (*)
1.8i 16V 2.0i 16V 1.4 HDi 2.0 HDi
XSARA PICASSO