2004 Citroen BERLINGO pluriel

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
(1)Gear control lever.
(2)Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(*)
The two cables cannot be separated.
B2CP3HXD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
(4)Gear engagement balljoint Ø 10 mm.
(5)Gear selection balljoint Ø 10 mm.
C2 C3
Length D Length C Length D Length C
Gear
engagement
1040 mm 815 mm 1015 mm 790 mm
control cable (2)
Length A Length B Length A Length B
Gear
selection
1149 mm800 mm 1093 mm 775 mm
control cable (3)B2CP3HZD
B2CP3HYC
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
Adjustment.
WARNING: Do not use any tool to detach the balljoints.
The gear selection control and gear engagement control
cables cannot be adjusted.
To unlock the balljoint, press at
«a»then pull the balljoint
upwards.
To release the sleeve stops, pull the needles
«b», in the
direction of the arrow, then disengage the sleeve stops from
their supports.
B2CP3J1D
B2CP3J0D
C2 C3 C3 PLURIEL

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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
Conditions for checking and adjusting
Vehicle heights at reference height
Rear height
Fr ont height
L2
L1
Tyres inflated to correct pressures. Vehicle at reference height.
Steering rack locked at mid point (see corresponding operation).
H1 = R1 L1
H1= Measurement between the measuring zone underneath the front
subframe and the ground.
R1= Front wheel radius under load.L1= Distance between the wheel axis and the measuring zone
underneath the front subframe.
H2 = R2 + L2
H2= Measurement between the measuring zone underneath the rear
sill and the ground.
R2=Rear wheel radius under load.L2= Distance between the wheel axis and the measuring zone
underneath the rear sill.
E1AP0AUD
C3 PLURIEL
C3 Pluriel

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AXLES
SUSPENSION
STEERING
C3 PLURIEL
AXLE GEOMETR Y
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool 4003T
Z1
= Measuring zone underneath the front subframe.Z2 = Measuring zone underneath the rear sill.
Measure the radius of the front wheel
R1 Calculate dimension H1 = R1 – L1Measure the radius of the rear wheel R2 Calculate dimension H2 = R2 + L2
Value at referenceAll TypesValue at referenceAll Typesheight height
(+ 6 8 mm)L1 = 132,5 mm(+ 10 6 mm)L2 = 47 mm
(*) = CRD: Difficult road conditions.
Definition for a type of vehicle whose axles and suspensions are adapted for driving on rough roads.
Compress the suspension to obtain the calculated values. The height difference between the two axle dimensions should be less than
10 mm.
Checks at reference height

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AXLES
SUSPENSION
STEERING
A < B = Positive figure: + = TOEIN
A > B = Negative figure: = TOEOUT
WARNING
AXLE GEOMETRY
Rear axle Front axle
Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower castor at
0° 30’.
Dissymmetry of lower camber at 0° 18’.
Distribute symmetrically, LH / RH wheel, the total tracking value.
All types
Vehicle TrackingCastor Camber Pivot angle
(± 0°18’) (± 0°30’) (± 0°30’)
Adjustable Non adjustable
2 ± 1
0°18’± 0°09’ 3°53’ 0°26’ 11°14’Tracking Camber (± 0°18’)
Non adjustable
5,7 ± 1
0°51’ ± 0°09’ 1°30’
All
Typesmm
0°
B3CP02UC
C3 PLURIEL