manual transmission Citroen XSARA PICASSO 2004 1.G Workshop Manual

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GENERAL
LUBRICANTS TOTAL recommended oils
GEARBOX OILS
ALL TYPES
TOTAL TRANSMISSION BV
norms S.A.E.: 75W80
Part No.: 9730 A2.
TOTAL FLUIDE ATX
TOTAL FLUIDE AT 42
Special oil distributed by
CITROËN
Part No.: 9730 A3
Special oil distributed by
CITROËN
Part No.: 9736 22
TOTAL TRANSMISSION X4Part No.:9730 A4
Manual gearbox and SensoDrive
MB3 automatic gearbox
4HP20 and AL4 autoactive
automatic gearboxes
Transfer box and rear axle
All countries

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SPEEDOMETERALL TYPES
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates:
The speed indicated by a speedometer must never be lower than the actual vehicle speed.
Between the speed displayed «SD»and the speed travelled «ST», there must always be the following relationship:
ST < SD < 1.10 ST + 4 Kph
Example: For an actual speed of 100 Kphthe speed displayed by the speedometer may be between 100and 114 Kph.
The speed indicated by the speedometer may be influenced by:
The speedometer.
The tyres fitted to the vehicle.
The final drive ratio.
The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle
(see information note N° 78-85 TT of 19 October 1978).NOTE:Before replacing the speedometer, check the conformity of the following points:
The tyres fitted to the vehicle.
The gearbox final drive ratio.
The speedometer drive ratio.
CLUTCH
GEARBOX
TRANSMISSION

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GEARBOX
TRANSMISSION
281
CLUTCH SPECIFICATIONS C2
Engine type HFX KFV NFU 8HX
Gearbox type Supplier
BVM BVM/BVMP (*)BVM/BVMP (*)BVM/BVMP (*)
MA 5/S MA 5 N/L MA 5 S/L MA 5/0
Mechanism / typeVALEO LUK
Engine type180 CP0 3400 200 P 3900
Bearing supplier / heightSKF 17 mm
Clutch disc11 R 10??
Ø of lining.Ext/Int180/127200/134
Quality of lining408
1.1i 1.4i 1.6i 16V1.4 HDi
(*): BVM = Manual gearbox.
: BVMP = Piloted manual gearbox.

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
C3 C3 PLURIEL
Engine type HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Gearbox type Supplier
MA/5 BE4/5
Mechanism / typeVALEO ? LUK
Engine type180 CPO 3400200 MF
200 P 3900 230 P 4700
3850
Clutch disc11 R 10 X 200 VTB
Ø Garniture.Ext/Int180/127 ? 200/134 228/155
Quality of liningF408
1.1i 1.4i 16V 1.4 HDi1.4 HDi 16V1.4i 1.6i 16V

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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
XSARA
Engine type 8HZ WJY RHY RHZ
Gearbox type Supplier
BE4/5
Mechanism / typeLUK
Engine type200 P 4200 200 P 3700 230 P 4700 235 T 5700
Clutch disc215 F (D 93) 22 BX 228 228D
Ø Garniture.Ext/Int200/134 200/134 230/155 235/155
Quality of liningF 408F202
1.4 HDi 1.9 D2.0 HDi

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA PICASSO
Engine type NFV 6FZ RFN 9HZ 9HY RHY
Gearbox type Supplier
BE4/5
Mechanism / typeVALEO LUK
Engine type200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700
Clutch disc200X(D95) 230 DNG 4700 215 FD 95 228
11A12X
Ø Garniture.Ext/Int200/137 228/155 215/147 225/150 230/155
Quality of liningF410 F 808 F 810 DS F408
1.6i 1.4 HDi 16V2.0 HDi1.8i 16V 2.0i 16V

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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
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