2004 Citroen XSARA drive

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CLUTCH
GEARBOX
TRANSMISSION
GEARBOX AND TYRE SPECIFICATIONS
Petrol
XSARA
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque
Engine type
Tyresrolling Circumference
Speedometer ratio Gearbox type
Gearbox ident. plate
Reduction box torque1.4i1.6i 16V
AUTOMATIC AUTOMATIC
2.0i 16V
KFW NFU RFN RFS
195/55 R15 1,815 m
MA/5 AL4 BE4/5 AL4 BE3/5
20 CP 13
(1)20 CP 51 (2)20 TP 49
20 DL 40
20 TP 4720 TE 47
16x65 21x73 19x72 23x73 14x62
21x18 24x21 22x19 24x21 22x19
Diesel
1.9 D
1.4 HDi2.0 Hdi
WJY 8HZ RHY (3) RHZAUTOMATIC
195/55 R15 – 1,815 m
BE4/5
AL4
20 DL 41
19x75
22x19 20 DM 54 20 DL 42
19x7020 DM 10
17x6120 TP 48
14x62
22x19
NOTE:(RHY engine BE4/5 gearbox) (1) Estate = 20 CP 44 (16x65) (21x18) (2) DAIC = 20 CP 52 (14x60) (21x18) (3)XSARA DAIC RHD = 20 DM 08Right hand drive: 6FZRFN= 20 DM 03 WJY= 20 DM 05 8HZ= 20 DM 53 RHY = 20 DM 07 RHZ= 20 DM 11

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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
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
(1)Retaining clip.(2)Secondary shaft.(3)Drive pinion (5th gear).(4) Bearing retaining clip 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 / 4th gear synchroniser.B2CP3SRP
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
(23)Driven pinion (4th gear).(24)Driven pinion (5th gear).(25)5th gear synchroniser.
Tightening torques (m.daN).
(4)
Bearing retaining clip screw(x4):1,8 ± 0,2
(6)
Intermediate plate (11 fixing screws): 5 ± 0,5
(7)
Gearbox casing(15 fixing screws):1,9 ± 0,216 fixing screws RPO 9784
17 fixing screws RPO 9786

(8)Clutch bearing guide screw(3 fixing screws):0,6 ±0,15
B2CP3SRP
C2 C3 C3 PLURIEL

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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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RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Safety requirements.
ESSENTIAL:Given the special features of the MA type piloted
manual gearbox, observe the requirements detailed below.
IMPERATIVE: Always disconnect the battery negative terminal
before operating on the actuators.
NOTE:
After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position
(rod pushed in).
IMPERATIVE:After Sales checks done with the engine running must be
performed with «Neutral»engaged and the handbrake on (unless there
is a clear mention otherwise in the repair procedures).
IMPERATIVE:The areas of movement of the clutch fork and of the gear
engagement lever must always be kept free during the actuatoroperating phases.
CLUTCH
GEARBOX
TRANSMISSION
IMPERATIVE:When initialising the clutch actuator and/or gearbox
actuator, do not allow any person to walk or stand in front of the vehicle.
WARNING:When the engine is running, it is forbidden to perform
repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
WARNING:Each time the driver’s door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators
(there is movement of the clutch fork and
of the gear lever).
WARNING:Whether the ignition is switched on or not, an action on the
gear selector causes the clutch fork and the gear engagement lever to
move on the gearbox.
Engines: HFX KFV NFU 8HX
C2

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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
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
(23)Driven pinion (4th gear).(24)Driven pinion (5th gear).(25)5th gear synchroniser.
Tightening torques (m.daN).
(4)
Bearing stop screw(x4): 1,8 ± 0,2
(6)
Intermediate plate(11 fixing screws):5 ± 0,5
(7)
Gearbox casing(15 fixing screws): 1,9 ± 0,216 fixing screws RPO 9784
17 fixing screws RPO 9786

(8)Clutch bearing guide screw(3 fixing screws):0,6 ± 0,15
B2CP3SRP
C2