2004 Citroen XSARA PICASSO Wheel

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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

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
(1)Circlip.(2) Secondary shaft.(3) Drive pinion (5th gear).(4)Bearing stop screw.(5) Gearbox casing.(6)Intermediate plate.(7) Gearbox casing fixing screw.(8)Clutch bearing guide screw.(9)Clutch housing.(10)Bearing guide.(11)Primary shaft.(12)Differential housing.(13)Speedometer screw.(14)Counter drive.(15) Planet pinions.(16)Satellite pinions.(17) Differential gearwheel.(18)Driven pinion (1st gear).(19)1st / 2nd gear synchroniser and reverse gear driven pinion.(20)Driven pinion (2nd gear).(21)Driven pinion (3rd gear).(22)3rd and 4th gear synchroniser.B2CP3SRP
C2

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: 6FZ RFN RFS WJY 8HV 8HY 8HZ 9HZ 9HY RHY RHZ
Tightening torques (m.daN).
(23)
Clutch bearing guide (3 screws): 1,25 ± 0,2
(24)
Clutch housing (13 screws): 1,3 ± 0,2
(25)
Primary shaft nut (1 screw):7,25 ± 0,5
(26)
Secondary shaft nut (1 screw): 6,5 ± 0,5
(27)
Yoke retaining screw (2 screws): 1,5 ± 0,2
(28)
Differential gearwheel screw (2 screws): 6,5 ± 0,5
Reverse gear switch (1 screw): 2,5 ± 0,3
(29)
Differential housing (4 screws): 5 ± 0,5
(30)
Breather pipe:1,7 ± 0,2
(31)
Rear housing cover screws (7 screws):1,25 ±0,2
(32)
Topup plug (1 screw):2,2 ±0,2
(33)
Differential housing screws (4 screws):1,25 ±0,2
(34)
Drain plug (1 screw):3,5 ±0,3
B2CP3BRD
C3 XSARA XSARA PICASSO

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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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SUSPENSION
STEERING
355
C2 AXLE GEOMETRY
Tyres inflated to correct pressures. Vehicle at reference height.
Steering rack locked at mid point (see corresponding operation).
Conditions for checking and adjusting
Vehicle heights at reference height
E1APOBZD
Front height Rear height
L1L2
H1 = R1 – L1 H2 = R2 + L2
H1
= Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear
subframe and the ground. sill and the ground.
R1= Front wheel radius under load.R2= Rear wheel radius under load.L1= Distance between the wheel axis and the measuring zoneL2= Distance between the wheel axis and the measuring zone
underneath the front subframe. underneath the rear sill.

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SUSPENSION
STEERING
356
C2 AXLE GEOMETRY
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool 8006T
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 referenceExcept CRD (*)Value at referenceExcept CRD (*)heightHFX KFV 8HX NFUheightHFX KFV 8HX NFU
(+ 6 8 mm)L1 = 142,5 mmL1 = 152,5 mm(+ 10 6 mm)L2 = 52 mm L2 = 42 mm
Compress the suspension to obtain the calculated values.
The height difference between the two axle dimensions should be less than 10 mm.(*) = CRD: Difficult road conditions.

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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 camb8er 0° 18. Dissymmetry of lower castor at
0° 30’.
DISSYMMETRY OF LOWER CAMBER 0° 18’.
Distribute symmetrically, LH / RH wheel, the total tracking value.
All types (except CRD)
NFU
Vehicle TrackingCastor Camber Pivot angle
(± 0°18’) (± 0°30’) ± 0°30’
ADJUSTABLE Non adjustable
2 ± 1
0°18’±0°09’ 3°58’ 0°31’ 11°26’
NFU
Vehicle TrackingCastor Camber Pivot angle
±0°30’
ADJUSTABLENon adjustable
2 ± 1
0°18’± 0°09’ 4° 0°32’ 11°35’Tracking Camber
Non adjustable
5,5 ± 1
0°53’ ± 0°09’ 1°30’
TrackingCamber
Non adjustable
5,8 ±1
0°49’ ± 0°09’ 1°31’
All
Typesmm
0°
All
Typesmm
0°
B3CP02UC
C2
± 0°18’ ± 0°30’
HFX KFV 8HX HFX KFV 8HX

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AXLES
SUSPENSION
STEERING
FRONT AXLE
Tightening torques (m.daN).
(1)Nut fixing suspension leg on body: 6,5 ± 0,6
(2)Damper:
(3)Antiroll bar link rod upper balljoint:3,2 ± 0,3
(4)Suspension leg pivot: 5,4 ± 0,5
(5)Antiroll bar link rod lower balljoint: 3,2 ± 0,3
(6) Antiroll bar bearing fixing on subframe:8 ± 0,8
(7)Hub nut: 24,5 ± 0,5
(8)Wheel bolt:9 ±1
(9)Subframe to bodyshell fixing screw:10 ± 1
(10) Antiroll bar:
(11)Pivot lower balljoint fixing on lower arm: 5,5 ± 0,5
(12)Pivot lower balljoint fixing: 4 ± 0,4
(13)Lower arm front and rear mounting fixing: 14 ± 0,4
(14)Stabiliser bar screw:6,6 ±0,7
(15)Steering balljoint fixing:3,5 ± 0,3
Private vehicles Antiroll bar
EuropeDiameter (mm)Colour
HFX KFV 18Violet
NFU 20 Green
8HX19Blue
Entreprise vehiclesDiameter (mm)Colour
HFX 8HX18 Violet
CRD vehicles Diameter (mm) Colour
KFV 8HX18 Violet
NFU 20 Green
B3CP07RP
C2