Kfw engine Citroen XSARA 2004 1.G Owner's Manual

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INJECTION
Emission standard Engine type
Injection make
and type
PETROL INJECTION
XSARA XSARA PICASSO
Air temperature sensor
resistive value (ohms)
XSARA PICASSO
XSARA 2
SAGEM
S2000M. MARELLI
6LP BOSCH
M.7.4.4.BOSCH
M.7.4.4.SAGEM
S2000M. MARELLI
6LP
Fuel pressure (bars)
Overspeed cutoff (rpm)
Injector resistive value (ohms)
Engine coolant temperature
sensor resistive value (ohms)
Idling actuator or stepper
motor resistive value (ohms)
KFW
L4/IFL5/L5 L4/IFL5 L4/IFL5 L4 IFL5L4/IFL5
1.4i 1.6i 16V 2.0i 16V 1.6i
2.0i 16V
1.8i 16V
RFN
NFU NFV 6FZ RFN
3,53,5
3
3 3,5 3,5
14,5 14,5 14,5
14,512,2 14,5
5500
5700
6000
5800
5500 6000
Stepper motor:53 3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C
3800 at 10° C 2 500 at 20° C 800 at 50° C 230 at 90° C

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1.1iHFX
FR7 DE RFN 58 LZ RC 8 YLC
C2 1.4i KFV
1.6i 16V NFU FR7 ME 0,9 ± 0,1 RFN 58 HZ
1.1i HFX
FR7 DERFN 58 LZ RC 8 YLC
1.4i KFV
C3 1.4i 16V KFU VR8 SE 0,9 ± 0,05
1.6i 16V NFU FR7 ME RFN 58 HZ
C3 1.4i KFV FR7 DE RFN 58 LZ RC 8 YLC
PLURIEL1.6i 16VNFUFR7 MERFN 58 HZ
0,9 ± 0,05 0,9 ± 0,05 2.5 ± 0,2
1.4iKFWFR7 DE0,9 ±0,1 RFN 58 LZ RC 8 YLC mda.N
XSARA 1.6i 16V NFU FR7 ME RFN 58 HZ
2.0i 16V RFN FR8 ME RFN 52 HZ REC 9 YCL
RFSFR6 DE RFN 62 LZ
1.6i90 hp
NFVRFN 58 LZ
XSARA100 hpFR7 DE RC 8 YLC
PICASSO 1.8i 16V 6FZ
FR8 ME0,9 ± 0,1
RFN 52 HZ REC 9 YCL
2.0i 16V RFN
SPARKING PLUGS ALL TYPES
Vehicles
BOSCH Engine
typeEYQUEM
CHAMPION Electrode
gap settingTightening
torque
IGNITION
Electrode
gap settingElectrode
gap setting

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA
Engine type KFW NFU RFN RFS
Gearbox type Supplier
MA/5 MA/5 BE4/5
Mechanism / typeVALEO
Engine type180CPO 3400 200 CPR 3800 230 DNG 4700 215 DT 5250
Clutch disc180 XJF 73 C 200X(D95) 11A12X 230 DNG 4700 215 FD 95
Ø Garniture.Ext/Int180/127 200/137 228/155 215/147
Quality of liningF 408 F 808
1.4i 1.6i 16V2.0i 16V

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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
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Clutch cable.
Removing.
Uncouple the cable from the lever (1).
Unclip the cable from the gearbox by actioning
the side tabs
(2).
Detach the cable from the bulkhead.
Remove the clip
(3).
Uncouple the cable from the clutch pedal.
B2BP001CB2BP002C
XSARA XSARA PICASSO
B2BP02VC
B2BP02WC
«PUSH» clutch
«PULL» clutch
B2BP03BCB2BP002C

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Refitting.
Place the pedal in the high position (contact at “a”).
Attach the cable yoke on the hook of the clutch pedal.
Fit a new clip
(3).
Fit the endpiece (4)to the bulkhead (fit with G6grease).
Clip the endpiece (5)on the gearbox.
Couple the cable to the lever (1).
Depress the clutch cable several times to lodge the cable in place.
Check that the endpiece (4) is correctly lodged on the bulkhead.
Check the operation of the automatic adjusting system.
After fitting the cable, pull the clutch lever in the inverse direction
(direction F), the lever should
move back when pulled by hand.
Press the clutch pedal very lightly and repeat the same operation. The lever should not move
back.
WARNING:If a system blockage is detected when checking, or if the pedal has been removed,
the pedal position must be adjusted. The correct positioning of the pedal is obtained by the
angular displacement of the stop supports
"a"and "b".
B2BP03CD
XSARA XSARA PICASSO
«PUSH» clutch
«PULL» clutch
B2BP03DD

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Adjusting the pedal height.
Loosen the nut (6)and the screw (7).
Using a lever, raise the stop support (8)to its highest position. In this position, there should be a substantial free
play in the pedal.
Lower the support until there is a free play of
2 ± 1 mm.
Tighten the nut (6) and the screw (7).
Check that the clutch cable sleeve can move freely.
At rest, the clutch cable sleeve should be free and able to lengthen and shorten.
Clutch pedal travel.
The automatic clutch wear adjustment system has no manual adjustment.
Pedal travel is identical on all models:154 ± 5 mm.
The adjustment is achieved by reducing the length of the cable sleeve.
WARNING:Automatic adjustment of the pedal travel is accompanied by a modification of the curvature of the
cable sleeve. Do not add any supplementary fixing points or alter the routing in any way.
«c»Routing of new cable.«b»Routing after adjustment of play.«x» Clutch wear.
B2BP03ECB2BP03FD
XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS
Petrol
XSARA
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque1.4i1.6i 16V
AUTOMATIC AUTOMATIC
2.0i 16V
KFW NFU RFN RFS
195/55 R15 1,815 m
MA/5 AL4 BE4/5 AL4 BE3/5
20 CP 13
(1)20 CP 51 (2)20 TP 49
20 DL 40
20 TP 4720 TE 47
16x65 21x73 19x72 23x73 14x62
21x18 24x21 22x19 24x21 22x19
Diesel
1.9 D
1.4 HDi2.0 Hdi
WJY 8HZ RHY (3) RHZAUTOMATIC
195/55 R15 – 1,815 m
BE4/5
AL4
20 DL 41
19x75
22x19 20 DM 54 20 DL 42
19x7020 DM 10
17x6120 TP 48
14x62
22x19
NOTE:(RHY engine BE4/5 gearbox) (1) Estate = 20 CP 44 (16x65) (21x18) (2) DAIC = 20 CP 52 (14x60) (21x18) (3)XSARA DAIC RHD = 20 DM 08Right hand drive: 6FZRFN= 20 DM 03 WJY= 20 DM 05 8HZ= 20 DM 53 RHY = 20 DM 07 RHZ= 20 DM 11

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
«a»Identification label.
«b»Location for engraving of serial and gearbox nos.
B2CP3HTC
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(1)Primary shaft.(2)Clutch bearing guide.(3)Clutch housing.(4) Gearbox casing.(5) Intermediate plate.(6)Bearing retaining clip.(7) Drive pinion (5th gear).(8) Secondary shaft.(9)5th gear synchroniser.(10)Driven pinion (5th gear).(11)Driven pinion (4th gear).(12)3rd / 4th gear synchroniser.(13)Driven pinion (3rd gear).(14)Driven pinion (2nd gear).(15) 1st / 2nd gear synchroniser and reverse gear driven pinion.(16) Driven pinions (1st gear).(17)Differential gearwheel.(18)Satellite pinions.(19)Planet pinions.(20)Counter drive.(21)Speedometer screw.(22) Differential housing.B2CP167P
XSARA