2004 Citroen C2 length

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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
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: BE4/5 GEARBOX CONTROLS
Engines: 8HV 8HY
(4)Gear engagement balljoint Ø 10 mm.
(5) Gear selection balljoint Ø 10 mm.
Length ALength B
Gear
selection907 mm 645 mmcable(5)
Length D Length C
Gear
engagement965 mm 610 mmcable(4)B2CP3J5D
B2CP3J4C
C3

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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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AXLES
SUSPENSION
STEERING
Adjusting the rear dummy damper
Lengths of the rear dummy damper (mm)
Grand export
346
339
346
342 Normal driving
339
318
336
XSARA REAR DAMPER
E5AP14WC
Engines
1.9 D
1.6i 16V 3door
1.6i 16V 5door
2.0i 16V (RFN) 1.4 HDi
2.0 HDi
2.0i 16V (RFS)
Estates and
Entreprise all types

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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
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).