spec Citroen C3 2004 1.G Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS XSARA PICASSO
Engine typeNFV 6FZ RFN
Tyresrolling
185/65 R15
Circumference1,895 m
Gearbox type BE4/5 AL4
Gearbox ident. plate20 DL 67 20 DL 69 20 TS 02
Reduction box torque15x6419x77 21x73
Speedometer ratio22x1824x20
Diesel
1.6 16V HDi 2.0 HDi
Engine type 9HZ 9HY RHYTyresrolling
185/65 R15
Circumference1,895 m
Gearbox typeBE4/5
Gearbox ident. plate20 DM 62 20 DL 65
Reduction box torque19x70 19x72
Speedometer ratio22x18 22x18
Right hand drive:NFV = 20 DL 676FZ = 20 DL 69RHY = 20 DL 65.
1.6i
1.8i 16V2.0i 16V PetrolAUTOMATIC

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RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Safety requirements.
ESSENTIAL:Given the special features of the MA type piloted
manual gearbox, observe the requirements detailed below.
IMPERATIVE: Always disconnect the battery negative terminal
before operating on the actuators.
NOTE:
After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position
(rod pushed in).
IMPERATIVE:After Sales checks done with the engine running must be
performed with «Neutral»engaged and the handbrake on (unless there
is a clear mention otherwise in the repair procedures).
IMPERATIVE:The areas of movement of the clutch fork and of the gear
engagement lever must always be kept free during the actuatoroperating phases.
CLUTCH
GEARBOX
TRANSMISSION
IMPERATIVE:When initialising the clutch actuator and/or gearbox
actuator, do not allow any person to walk or stand in front of the vehicle.
WARNING:When the engine is running, it is forbidden to perform
repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
WARNING:Each time the driver’s door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators
(there is movement of the clutch fork and
of the gear lever).
WARNING:Whether the ignition is switched on or not, an action on the
gear selector causes the clutch fork and the gear engagement lever to
move on the gearbox.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
B2CP3ECD
Identification.
«a»
Component reference.
WARNING:This gearbox benefits from a special CITROEN semisynthetic oil,
which cannot be mixed with any other oil.
The gearbox is lubricated for life.
AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
Tightening torques (m.daN).
A: EW7
and EW10engines
Hydraulic block fixing.
Centre the hydraulic block, using screws (11)and (12).
Pretighten(no strict order): 0,9 Slacken: All 7 screws Tighten(respect the order indicated):0,75
NOTE:
The screw (11)is shouldered.
B: DW10engine.
Hydraulic block fixing.
Centre the hydraulic block, using screws (11)and (12).
Pretighten(no strict order): 0,9 Slacken:All 7 screwsTighten(respect the order indicated):0,75
NOTE:
The screw (11)is shouldered.
(13)Fixing of selector lever position switch: 1,5 ± 0,2
(14) Oil filler plug: 2,4 ± 0,4
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3EFDB2CP3EGC

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AXLES
SUSPENSION
STEERING
SPECIAL FEATURES: STEERING
Engines: HFX KFV NFU 8HX
Centring the steering rack
Preliminary operation.
Raise and support the vehicle on a twocolumn lift.
Remove, on the RH side of the steering rack:
Clip
(1).
Clip (2).
Release the steering rack rpotection gaiter.
Setting.
Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension
Y.
Calculate the dimension:
L = (Y – X) : 2.
Refit:
The steering rack rpotection gaiter.
New clips
(1)and (2).
B3EP13UC
B3EP13VD
C2

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AXLES
SUSPENSION
STEERING
SPECIAL FEATURES: STEERING
Engines: HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Centring the steering rack
Preliminary operation.
Raise and support the vehicle on a twocolumn lift.
Remove, on the RH side of the steering rack:
Clip
(1).
Clip (2).
Release the steering rack rpotection gaiter.
Setting.
Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension
Y.
Calculate the dimension:
L = (Y – X): 2.
Refit:
The steering rack rpotection gaiter
New clips
(1)and (2).
B3EP13UC
B3EP13VD
C3 C3 PLURIEL

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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