Nfv Citroen XSARA PICASSO 2004 1.G Owner's 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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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
B2CP3BNCB2CP3BPD
(a) Marking zone (sequence and serial no.).(b) Location of identification label.
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
(1)Drain plug.
(2)Filling and topup plug.
(3)Air vent.
NOTE:The air vent aperture can be used for filling.
Quality of oil.Refer to the manufacturer’s instructions.
Quantity of oil.Gearbox empty:1,9 Litres.
After draining:2 Litres.
B2CP3BLD
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
Description
(1)
Primary shaft.
(2)Clutch bearing guide.
(3)Gearbox casing.
(4)Clutch housing.
(5)Reverse idle.
(6)Drive gear (3rd gear).
(7)3rd / 4th gear synchroniser.
(8)Drive gear (4th gear).
(9)Drive gear (5th gear).
(10)5th gear synchroniser.
(11)Driven gear (5th gear).
(12)Driven gear (2nd / 4th gear).
(13) Driven gear (2nd gear).
(14)1st / 2nd gear synchroniser.
(15)Driven gear (1st gear).
(16)Secondary shaft.
(17)Differential gear.
(18)Satellite gears.
(19)Planet gears.
(20)Differential housing.
(21)Speedometer drive.
(22)Extension.
«d» Adjusting shims: 0.7 to 2.4 mm
(0.10 mm and increasing by 0.10 mm).
«c»Adjusting shims:1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
(1)Gear control lever.
(2) Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(4)
Gear selection balljoint Ø 10 mm.
(5) Gear engagement balljoint Ø 10 mm.
(6) Flexible insulating grommet through the bulkhead.
(*)= These two cables cannot be separated.
B2CP3BWD
XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Principles of adjusting the gear controls.
WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are
removed.
Principles.
Lock the gear lever in neutral position, using tool:9607T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the balljoints on the gearbox lever.
Lock the cable lengths with the balljoint locking keys.
WARNING: Do not use any tool to unclip the balljoints.
To unlock the balljoint, press at the centre «a», then pull the balljoint upwards.
NOTE:Changing an individual balljoint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3BXCB2CP3BYC

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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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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 axleRear axle
Front axle
Rear axle Engines:NFV RFN RHY
H1 = R1 – L1 or H1’ = R1 – L1’
NO CRD Vehicle (CRD = Difficult road conditions)
L1 = 75,5 mmL1’ = 109 mmL2 = 23,5 mmH2 = R2 + L2
B3DP079C