Get Axles, Suspension, Steering Guide for Citroen Xsara SUV Second Generation (1997-2006)

XSARA

RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

Engines : NFU - RFN - RHZ

ECU : Downloading, Configuration, Initialisation (pedal) (continued)

Pedal initialisation.

Downloading.

ECU downloading procedure :

A pedal initialisation must be carried out in the following cases :

- Follow the diagnostic tooling procedure.

- Replacement of the automatic gearbox ECU.

- Replacement of the automatic gearbox.

- Downloading of the ECU configuration.

A new ECU or downloaded update is always configured with the following

options :

- SHIFT LOCK gear selection lever position.

- OBD outlet (emission standard L4).

If the ECU is to be fitted to a vehicle without one or bothof these options:

- Carry out a configuration which inhibits the diagnosis of the option(s)

concerned.

- Adjustment or replacement of the accelerator cable.

- Replacement of the throttle potentiometer.

IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistentgear

selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (auto-

adaptive laws).

202

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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

XSARA

Engines : NFU - RFN - RHZ

SHIFT LOCK

- The shift lock is a system which locks the selection lever in the park position "P".

Unlocking the SHIFT LOCK (In normal operation)

- Switch on the ignition.

- Press and hold down the brake pedal.

- Using the selection lever, disengage from position P.

NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minute

you start applying the brake pedal. Otherwise, release pressure on the brake pedal and then

try again.

Unlocking the SHIFT LOCK (In the event of a malfunction)

- Remove the cover (1).

- Unlock the shift lock (2) using a screwdriver.

- Using the selection lever, disengage from position "P".

B2CP268C

B2CP269C

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ALL TYPES

DRIVESHAFTS - GEARBOXES

Tightening torques

(m.daN)

Gearbox oil seal mandrels

RightLeftToolkit

Driveshaft

bearing

Driveshaft

nut

Gearbox

Engines

HFX-KFW-NFV-NFT-NFX-NFU-VJX

KFW-NFU

MA/4 - MA/5

24.5

NO

7114-T.X

7116-T

MA/5 XSARA

BE4/5

7114-T.W

32

NFV-RFN-6FZ-WJY-RHY-RHZ

KFW

4101-T.E1

+4601-T.E2

NO

4601-T

MB3

24.5

32.5

1.8

Seal extractor

RH / LH (-) 0338 C

(-) 0338

AL 4

NFU-RFN - RHZ

(-) 0338 J1

+ (-) 0338 J2

(-) 0338 H1

+(-) 0338 H2

Tightening torque for wheel bolts : SAXO - XSARA = 8.5 m.daN

204

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AXLE GEOMETRY

SAXO - All Types

Geometry of the axles at reference height.

Front height

Rear height

H1 = R1 – L1

H2 = R2 + L2

H1 = Distance between the ground and

the mounting face of the fixings.

R1 = Distance between the centre of

the front wheel and the ground.

L1 = Distance between the centre of the

front wheel and the mounting face of

the fixings.

H2 = Distance between the ground

and the mounting face of the rear

crossmember.

R2 = Distance between the centre of

the rear wheel and the ground.

L2 = Distance between the centre of the

rear wheel and the rear crossmember.

The values L1 and L2 are given in the table below.

Normal suspension

C4CP0N2C

Raised suspension

Front axle Rear axle

C4CP0N3C

Front axle

Rear axle

L2

Dimension

Value (mm)

L1

L2

71 ± 10 mm

53 ± 6 mm

36 ± 10 mm

82 ± 6 mm

Measure the dimension R1.

Measure the dimension R2.

Calculate the dimension H1 = R1 - L1.

Calculate the dimension H2 = R2 + L2

Compress the suspension until the calculated values «H1» and «H2» are obtained.

NOTE : The difference in height between the two sides at the rear should be less than 7.5 mm.

205

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SAXO - All Types

AXLE GEOMETRY

Geometry of the axles at reference height.

Front height

Rear height

Reminder : Measuring the front height

Reminder : Measuring the rear height

H1 = Distance between the ground and the mounting face of the fixings

H2 = Distance between the ground and the rear crossmember

B3BP07UC

B3BP07VD

The front heights H1 are measured between the ground and the mounting

face of the arm fixings (1) at the point «a».

The rear heights H2 are measured between the ground and the mounting

face of the rear crossmember (2) at «b» and «c».

WARNING

A < B = Positive figure:

A > B = Negative figure:

+ =

– =

TOE-IN

B3CP02UC

TOE-OUT

206

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AXLE GEOMETRY

SAXO - All Types

Geometry of the axles at reference height.

Normal suspension

Raised suspension

Front

TU1M+ (**)

TU3JP – TU5JP

TU5JP4 – TUD5B

Rear

Front

TU1M+ (**)

TU3JP – TU5JP

TU5JP4 – TUD5B

TU1M+

(*)

TU1M+

(*)

All Types

Engine

All Types

Steering

Manual

Assisted

Manual

Assisted

Tracking

Toe-in

O°

mm

-0°10’ to 0°31’

-1 to -3

-0°10’ to 0°31’ -0°16’ to -1°6’

-0°10’ to 0°31’

-1 to -3

-0°10’ to 0°31’ -0°16’ to -1°6’

+1 to +3

+1.49 to +6.39

+1 to +3

- 0°40’ ± 30’

+1.49 to +6.39

- 1°35 ’± 30

Camber

Castor

- 0°9’ ± 30’

- 0°40’ ± 30’

- 1°35 ’± 30’

- 0°9’ ± 30’

2°13’± 30’

3°14’± 30’

2°13’± 30’3°

3°14’± 30’

King pin inclination

12°± 41’± 40’

12°42’± 40’

12°± 41’± 40’

12°42’± 40’

(*) = Without assisted steering option and ABS. (**) = With assisted steering and ABS options.

WARNING : For the vehicle to be at reference height, compress the suspension until the calcu-

lated values «H1» and «H2» are obtained.

207

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SAXO - All Types

FRONT AXLE

Anti-roll bar Ø 18 and 22 mm

Anti-roll bar Ø 19 and 21 mm

(1) Suspension leg.

(3) Front anti-roll bar.

(9) Lower arm.

Tightening torques m.daN

(2) Anti-roll bar bearing fixing on the bodyshell

(4) Anti-roll bar bearing fixing on the lower arm

(5) Suspension leg upper fixing

(6) Lower ball-joint fixing screw

(7) Anti-roll bar link rod fixing

5.5 ± 0.2

2.2 ± 0.2

2.1 ± 0.2

3.8 ± 0.4

7 ± 0.6

(8) Suspension arm rear fixing nut

(9) Suspension arm front fixing

4.2 ± 0.4

8.5 ± 0.8

B3CP02SD

Suspension – Front anti-roll bar

Raised suspension

TU1M+ (1)

TU3JP

TUD5B

TU1M+ (3)

TU3JP (3)

TU5JP4 (3)

TU1M+ (2)

TU1M+

TU5JP

France

Administration

Export

19

Ø Anti-roll bar

None

21

19

18

22

21

(1) = With airbag. (2) = Without option. (3) = VTS level.

208

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REAR AXLE

SAXO - All Types

(1) Rear axle.

(2) Damper.

(5) Rear suspension arm.

(7) Rear brake drum.

(9) Torsion bar.

The Anti-roll bar is located inside the tube of the rear axle.

Tightening torques m.daN.

(3) Damper upper fixing screw

(4) Damper lower fixing screw

(6) Stub nut

10 ± 1

20 ± 1

8.7 ± 1

(8) Rear axle fixing bolt

B3DP02ND

209

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SAXO - All Types

REAR AXLE - SUSPENSION

Torsion bar

TU1M+ (1) (2) – TU3JP (2)

TU1M+ - TU3JP

TU5JP4 – TUD5B

TU1M+TUD5B (3)

TU5JP4 - TUD5B (1)

Torsion bar Ø (mm)

19

17.9

18.3

Black

White

Green

Colour reference

Torsion bar

LH : 2 rings

RH : 1 ring

(1) = Entreprise.

(2) = VTS trim level

(3) = With raised suspension

Antiroll bar

Raised suspension

France

TU1M+ (3)

TU3JP (3)

TU5JP4 (3)

TU1M+(2)-TU3JP

TU5JP4-TUD5B

TU1M+

Export

Ø Anti-roll bar

(mm)

None

18

15

22

(1) = With airbag.

(2) = With airbag or assisted steering or ABS.

(3) = VTS trim level.

210

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SAXO - All Types

STEERING SPECIFICATIONS

Manual steering

Tyres

NOTE : The steering assembly is secured to the bulkhead..

155/70 R13

165/70 R13

165/65 R14

Pinion (no. of teeth)

Rack (no. of teeth)

Rack travel

6

Length of the steering track rods

(Between the centre lines of the ball-joints).

28

80

72

Pre-adjustment = 520 mm.

Stop (colour)

Black

White

Power-assisted steering

Tyres

165/70 R13

165/70 R14

185/55 R14

Pinion (no. of teeth)

Rack (no. of teeth)

Rack travel

7

28

68

Stop (colour)

211

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MANUAL STEERING

SAXO - All Types

Tightening torques (m.daN)

7 - Pivot ball-joint nut

1 - Airbag

2 - Airbag fixing to steering wheel

3 - Steering wheel fixing

4 - Steering column fixing

5 - Steering cardan joint fixing

6 - Fixing to bulkhead

3.5

4.5

5

2.1

2.4

0.8

3

8 - Lock nut M14

8 - Lock nut M16

2.3

2.2

9 - Track rod articulation

10 - Splined coupling fixing to steering rack

B3EP02UD

B3EP09SC

B3EP09TD

212

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SAXO - All Types

POWER-ASSISTED STEERING

Tightening torques (m.daN)

8 - Track rod lock nut M16

1 - Airbag

5

2 - Airbag fixing to steering wheel

3 - Steering wheel fixing

4 - Steering column fixing

5 - Steering cardan joint fixing

6 - Fixing to bulkhead

0.8

3

9 - Track rod articulation

2.1

2.4

8

1.5

0.7

10 - Splined coupling fixing to steering rack

11 - Steering ram to splined coupling

12 - Steering ram to casing

13 - Nut fixing the pinion to the bearing

14 - Valve/casing fixing

2.3

2.2

3.5

4.5

7 - Pivot ball-joint nut

8 - Track rod lock nut M14

B3EP02TD

B3EP02WD

213

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SAXO - All Types

POWER STEERING (continued)

Power steering system

WARNING : Saxo all types except diesel without aircon

1 - Power steering

2 - Oil dispensing valve

3 - Power-assisted steering ram

4 - Low pressure pipe

5 - High pressure pipe

6 - Upper reservoir

7 - Power steering electro-pump unit and built-in

lower reservoir

8 - Flexible mounting

9 - Electro-pump unit bracket

Tightening torques (m.daN)

Pump support fixing

Pump fixing to support

2

High pressure pump

Electro-pump connection

Power steering valve connection

2

2.5

Low pressure pump

Electro-pump connection

Power steering valve connection

2.5

NOTE : Fluid type TOTAL Fluide ATX capacity : 0.950 L.

B3EP09UD

214

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POWER STEERING (continued)

SAXO - All Types

POWER STEERING SYSTEM

WARNING : Saxo diesel with aircon

Description.

NOTE : The power steering system on vehicles without aircon is supplied

by a mechanical pump driven by the accessories drive belt.

(6) Power steering mechanism.

(7) Upper reservoir.

(8) Lower reservoir.

(9) Radiator.

(10) Power steering pump.

(11) The grooves on the connector (6) indicate that the pump (5) is

constant flow.

Max. pressure : 80 Bars.

Pulley diameter : 112 mm.

Fluid quality : TOTAL Fluide ATX

Capacity : 1.55 litres.

B3EP12XD

215

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XSARA - All Types

AXLE GEOMETRY

Front and rear measuring points

XSARA All Types

Front height

Rear height

B3CP046D

H1 = Dimension between the centre of the front suspension arm mounting and the ground.

H2 = Dimension between the contact face of the rear mounting and the ground.

R1 = Front wheel radius under load.

R2 = Rear wheel radius under load.

L1 = Distance between the centre of the wheel and the centre of the front suspension arm mounting.

L2 = Distance between the centre of the wheel and the contact face of the rear mounting on the bodyshell.

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AXLE GEOMETRY

XSARA - All Types

Reference heights

Tools

[1] Gauge for measuring the radius of wheels with 4 bolts

Front

: 8006-T

Setting the reference height.

Rear

Measure the dimension «R1».

Calculate the dim. H1 = R1 - L1.

Measure the dimension «R2».

Calculate the dim. H2 = R2 + L2.

Compress the suspension until the values (H1) and (H2) are obtained.

NOTE : The difference in height between the two sides should be less than 10 mm.

B3CP04AD

Front axle

Rear axle

All engines

(except 2.0i 16V

and CRD)

All saloons

(except 2.0i 16V

and CRD)

2.0i 16V

(RFS)

All CRD

engines

2.0i 16V

(RFS)

All CRD

engines

Estate

88

Engines

Reference heights

(in mm)

115.5

75.5

73

103

90.5

83

217

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XSARA - All Types

AXLE GEOMETRY

Values of the front and rear suspensions, at reference height

ESSENTIAL : When checking the suspensions, the vehicle should be at reference height.

Tools used :

Compress the suspension, to obtain the values at reference height.

[1] Set of two suspension compressors

[2] Set of four straps

[3] Set of four shackles

: 9511-T.A

: 9511-T.B

: 9511T.C

WARNING

A < B = Positive figure:

+ =

– =

TOE-IN

TOE-OUT

B3CP04LC

A > B = Negative figure:

218

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XSARA

AXLE GEOMETRY

Values of the front and rear suspensions, at reference height

Front axle

All engines (except 2.0i 16V)

2.0i 16V

- 1.5 ± 1

- 0°15' ±10'

3° ± 40’

All CRD engines

Adjustable

YES

mm

0°

Tracking

Castor

NO

King pin inclination

Camber

11° ± 1°

0° ± 1°

10° 40’ ± 1°

Rear axle

All engines

(except 2.0i 16V)

All CRD engines

Estate

Adjustable

NO

2.0i 16V

4.6 ± 1

5.2 ± 1

4.4 ± 1

3.5 ± 1

mm

0°

Tracking

Camber

0° 41’ ± 10’

0° 47’ ± 10’

0° 40’ ± 10’

0° 32’ ± 10’

- 1° 30’ ± 1°

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AXLE GEOMETRY

XSARA - All Types

a = Angle which defines the tracking between the front and rear axles.

Its value must not exceed 12'

B3CP04UC

220

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FRONT AXLE

XSARA - All Types

Tightening torques (m.daN).

(1) Damper nut

4.5 ± 0.4

2.5 ± 0.3

(2) Cup screw

(3) Suspension leg

(4) Anti-roll bar link rod upper ball-joint

(5) Suspension leg pivot (hollow pivot)

(5) Suspension leg pivot (pivot «H»)

(6) Anti-roll bars

3.7 ± 0.3

4.5 ± 0.5

5.5 ± 0.5

(7) Anti-roll bar link rod lower ball-joint

(8) Pivot lower ball-joint

3.7 ± 0.3

4 ± 0.4

(9) Driveshaft nut

32.5 ±2.5

9 ± 1

(10) Wheel bolt

(11) Lower arm front mounting

(12) Lower arm rear mounting and anti-roll bar bearing

(13) Screw under rear mounting

(14) Ball-joint fixing on lower arm

Subframe to bodyshell fixing screw

7.6 ± 0.7

6.8 ± 0.6

3.1 ± 0.3

5± 0.5

Vehicles 09/2000 # are all equipped

8.5 ± 0.8

as standard with ventilated discs.

B3CP040P B3CP041D

221

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FRONT AXLE

XSARA - All Types

Evolution : Suspension arm ball-joint

Application from RPO : 7968.

New components :

- Suspension arm ball-joint.

- Pivot.

Old fitting ØA = 16 mm.

New fitting ØA = 18 mm.

Repair requirements.

ESSENTIAL : Swapping of old and new components is forbidden.

It is permitted to fit a new pivot/ball-joint assembly on one side of an old

vehicle.

Replacement Parts.

The old components are still available from Replacement Parts.

B3CP054D

222

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XSARA - All Types

FRONT AXLE

Anti-roll bars

Engines

1.6i-1.6i 16V-1.9D

Diameter

Colour reference

Saloon

Estate

Saloon

19

20

21

Blue

Yellow

White

2.0i 16V (RFV)-2.0 HDi

2.0i 16V (RFS)

223

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XSARA - All Types

FRONT AXLE

XSARA # 07/1999

XSARA 07/1999 # 09/2000

XSARA 09/2000 #

The angle of castor changes to 3° except for

LPG vehicles, DRC vehicles, and Estates All

Types.

DRC = Difficult Road Conditions : this type of

vehicle has axles and suspensions designed for

driving on rough road surfaces.

Lug "a" to the rear.

Lug "a" to the front.

Pivot ball joint

Manual steering, groove at "b".

Power-assisted steering, groove at "b".

NOTE : Vehicles after 09/2000 # are all equipped as standard with ball-joints without the groove at «b».

B3CP042D B3CP049C

B3CP043D

224

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REAR AXLE

XSARA - All Types

Tightening torques (m.daN)*

(1) Anti-roll bar lever

(2) Anti-roll bar

3.2 ± 0.3

(3) Transversal torsion bars

(4) Rear crossmember flanges

(5) Front mountings

8.3 ± 0.8

5.5 ± 0.5

4.5 ± 0.4

(6) Rear mountings

(7) Anti-vibration clamp.

(8) Damper pin

9.6 ± 0.9

18.5 ± 1

(9) Stub axle nuts (lubricated)

NOTE

- The RH torsion bar can be identified by 1 paint line.

- The LH torsion bar can be identified by 2 paint lines.

B3DP04SP

225

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XSARA - All Types

REAR AXLE

Vehicles

Torsion bars (mm)

Anti-roll bars (mm)

Engines

19.D

Diameter

Colour reference

Diameter

Colour reference

3-door Entreprise

19.3

Violet

19

18

Orange

3- and 5-door TT

exc. Entreprise

18.7

Yellow

Blue

20

19.3

20

Grey

Violet

Grey

20

19

20

Green

Orange

Green

Estates All types

3- and 5-door TT

Estates All types

1.6i 16V-2.i 16V

2.0 HDi

Without colour,

or white sticker

Light green

2.0i 16V

3-door VTS

21

23

3- and 5-door TT

Estates All types

Violet

Grey

19

20

19.3

20

Orange

Green

Grand Export «GRD»

226

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REAR AXLE

XSARA - All Types

Evolution : Rear hub nut

Old # 15/12/1999.

New 15/12/1999 #

Evolution :

- New rear hub nut (3).

- Washer discontinued (2).

Old fitting (A)

(1) Rear hub nut.

(2) Thrust washer.

ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN

New fitting (B)

(3) Rear hub nut.

ESSENTIAL : Tighten to : 25 ± 2.5 m.daN.

NOTE : It is possible to have both types of fitting on the same axle.

The old nut (1) requires the fitting of the thrust washer (2).

WARNING : do not fit a thrust washer (2) with a new nut (3).

ESSENTIAL: Respect the tightening torque to be applied when fitting.

WARNING: Identify the type of fitting, before starting a repair.

B3DP08AD

227

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REAR AXLE

XSARA - All Types

- The front mountings are aligned at an angle of 45° in relation to the vehicle’s axis.

- The rear mountings are in parallel with the vehicle’s axis.

NOTE : There are two suppliers for the mountings:

- RBT, identified by a Green or Yellow painted dot on the side of the mounting.

- PAULSTRA, identified by a Black painted dot on the side of the mounting.

It is ABSOLUTELY FORBIDDEN to swap components of different suppliers.

Operating clearance - X = 1 to 1.4 mm.

NOTE : The RH torsion bar can be identified by

1 paint line.

The LH torsion bar can be identified by 2 paint

lines.

B3DP04TC

B3DP04UD

228

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REAR DAMPER

XSARA - All Types

Adjusting the rear dummy damper

Normal driving

Lengths of the rear dummy damper (mm)

Engines

Grand export

346

339

1.9 D

1.6i 16V 3-door

339

1.6i 16 V 5-door

2.0i 16V (RFN) -2.0 HDi

346

318

336

2.0i 16V (RFS)

Estates and

Entreprise all types

342

E5AP14WC

229

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MANUAL STEERING SPECIFICATIONS

XSARA - All Types

Steering wheel - Manual steering

- (a) : L.H.D./R.H.D = 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

- (3) Steering wheel fixing

: 0.8

: 3.3

: 2.3

- (5) Steering column to support fixing

- (6) Steering cardan joint fixing

- (b) = Locating bush.

The locating bush must be centred in the reference window

before tightening the cardan bolts (6).

B3EP08PD

230

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MANUAL STEERING SPECIFICATIONS

XSARA - All Types

Manual steering

Tightening torques (m.daN)

(7) Pivot ball-joint nut

(8) Link rod lock nut

: 4

: 4.5

: 6

(9) Ball-joint on steering rack

(10) Fixing on cradle

: 5

(11) Plunger flange screw

: 1.2

B3EP042D

231

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MANUAL STEERING SPECIFICATIONS

XSARA - All Types

Manual steering (continued)

Number of teeth

Number of

steering wheel

turns

Steering rack

travel

Steering ratio

Steering stop

Pinion

Steering rack

(mm)

6 teeth

(13)

4.3

22/1

L.H.D.

73.5

29

(RH helix)

Yellow thickness mm

- Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm

(Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).

232

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POWER-ASSISTED STEERING SPECIFICATIONS

XSARA - All Types

Steering wheel - Power-assisted steering

- (a) : L.H.D. = Blue.

: R.H.D. = 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

- (3) Steering wheel fixing

- (5) Steering column to support fixing

- (6) Steering cardan joint fixing

: 0.8

: 3.3

: 2.3

- (b) = Locating bush.

The locating bush must be centred in the reference

window before tightening the cardan bolts (6).

B3EP08QD

233

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XSARA - All Types

POWER-ASSISTED STEERING SPECIFICATIONS

Power-assisted steering

Tightening torques (m.daN)

(7) Pivot ball-joint nut

: 4

(8) Link rod lock nut

: 4.5

: 6

(9) Ball-joint on steering rack

(10) Fixing on subframe

(11) Hydraulic pipe connection

(12) Valve to housing fixing

(13) Plunger flange screw

: 5

: 2.5

: 1.2

(14) Screw fixing the steering ram to the housing : 5.5

(15) Nut fixing the steering ram to the yoke : 5.5

B3EP08RD

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POWER-ASSISTED STEERING SPECIFICATIONS

XSARA - All Types

Power-assisted steering (continued)

Number of teeth

Steering rack

Number of

steering wheel

turns

travel

(mm)

Steering ratio

Pinion

Steering rack

( )

*

L.H.D.

71.7

28

3.3

18.8/1

(RH helix)

Steering valve

Vehicles

Number of teeth ( )

Protector colour

*

All types (except 1.8i 16V - 1.9TD)

1.8 i 16V - 1.9 TD

BLACK

7

8

ORANGE

- Length of the steering link rods (Pre-adjustment) = 371 mm (Between ball-joint centres) or 391 mm

Between the centre of the pivot ball-joint and the contact face of the steering rack ball-joint).

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POWER-ASSISTED STEERING SPECIFICATIONS

XSARA - All Types

Power-assisted steering assembly

Tightening torques (m.daN)

High pressure tube (Rubber seal pump side)

- Power-assisted valve and pump union

: 2.5

Return pipe.

- Power-assisted valve union

(16) - Upper front fixing (E3)

(17) - Upper rear fixing (E3)

(18) - Fixing (E3)

: 2.5

: 2.2

Tightening sequence.

- Tighten screws (16) and (18)

- Lightly tighten screw (17), then fully tighten.

Power-assisted steering system capacity = 1 litre.

Oil type: TOTAL FLUIDE ATX.

SAGINAW Pump adjustment = 100 Bars ± 5.

Pump shaft threading 3/8 - 16 threads per inch.

Pressure switch on the pressure circuit.

- Switch opens 30 to 35 Bars.

- Switch closes 25 bars.

- Tighten to : 2 m.daN.

B3EP045D

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AXLE GEOMETRY

XSARA PICASSO - All Types

Measurements at reference height

NOTE : To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point.

WARNING : The values shown should only be used as guides. In case of doubt, check the settings at reference height

Front height

Rear height

B3CP05BC

B3DP079C

B3CP058D

H1 = R1 – L1

H1’ = R1 – L1’

H2 = R2 - L2

H1= From the front suspension arm linkage bolt axis to the ground.

R1= Radius of the front wheel when laden.

H2 = From the rear axle flexible mounting face to the ground.

R2 = Radius of the rear wheel when laden.

L1 = From the centre of the wheel to the front suspension arm linkage

bolt axis.

L2 = From the centre of the wheel to the rear axle flexible mounting

face.

H1’ = From the front jacking point to the ground.

L1’

=

From the front jacking point to the radius of the front wheel when laden.

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AXLE GEOMETRY

(The reference height of the vehicle is set as per the table below).

Rear axle

XSARA PICASSO - All Types

Measurements at reference height (continued).

Front axle

B3CP05BC

B3CP05AC

B3DP079C

H1 = R1 – L1

ou

FRONT AXLE

H1’ = R1 – L1’

H2 = R2 + L2

Essieu rear

Vehicles all types

L1 = 90.5mm

H1 = R1 – L1

L1’ = 124 mm

H2 = R2 + 8.5 mm

H2 = R2 + L2

CRD vehicles (Difficult Road Conditions)

or

H1’ = R1 – L1’

6FZ - RHZ

L1

L2

L1’

75.5

23.5

109

Measure the radius of the front wheel : R1.

Calculate dimension H1 or H1’.

Measure the radius of the rear wheel: R2.

Calculate dimension H2.

Compress the suspension to obtain the calculated values. The difference in height between the two sides should be less than 10 mm.

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AXLE GEOMETRY

XSARA PICASSO - All Types

Measurements at reference height (continued). Compress the suspension to obtain the calculated values.

Vehicle all types

Front axle

Rear axle

Vehicle

Tracking

Castor

King pin inclination

Camber

Tracking

Camber

Adjustable

Non-adjustable

0 mm ± 1mm

0 ± 0°09’

4.8 mm ± 1mm

0° 43’ ± 0° 09’

3° ± 20’

10° 45’ ± 30’

0° ± 30’

1°20’ ± 20’

All Types

Vehicle all types CRD (Difficult Road Conditions)

Front axle

Rear axle

Vehicle

Tracking

Castor

King pin inclination

Camber

Tracking

Camber

Adjustable

Non-adjustable

-1 mm ± 1mm

- 0°09’ ± 0°09’

3.8 mm ± 1mm

0°34’ ± 0° 09’

2°93’ ± 20’

10°42’ ± 30’

0°12’ ± 30’

- 1°23’ ± 20’

All Types

NOTE : When checking axles, the vehicle should be at reference height.

(*) = Fuel tank full.

WARNING

Ground clearance

All Types

A < B = Positive figure:

A > B = Negative figure:

+ =

– =

TOE-IN

Unladen (*)

150 mm (Minimum value)

TOE-OUT

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FRONT AXLE

XSARA PICASSO - All Types

Tightening torques m.daN.

(1) Damper nut

: 4.5 ± 0.4

: 2.5 ± 0.3

(2) Cup screw

(3) Suspension arm.

(4) Anti-roll bar link rod ball-joint

(5) Suspension arm swivel

(6) Anti-roll bar

: 3.7 ± 0.3

: 4.5 ± 0.4

(7) Anti-roll bar link rod ball-joint

(8) Lower swivel ball-joint

(9) Hub nut

: 3.7 ± 0.3

: 4 ± 0.4

: 32.5 ± 2

: 9 ± 1

(10) Wheel bolt

(Face and threads not lubricated).

(11) Lower arm front pivot

(12) Lower arm rear pivot and

anti-roll bar bearing

(13) Screw under rear pivot

Fixing bolt : subframe on bodyshell

: 7.6 ± 0.7

: 6.8 ± 0.6

: 3.7 ± 0.3

: 8.5 ± 0.8

Anti-roll bar

Engines

Diameter

21

Colour mark

WHITE

Damper upper bracket :

NFZ-6FZ

RHY

Lug «a» to the front.

B3CP056P B3CP057D B3CP043D

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XSARA PICASSO - All Types

REAR AXLE

Tightening torques m.daN.

(14) Front flexible mounting on subframe

(15) Anti-roll bar bolt

: 9.5 ± 0.9

: 5.5 ± 0.5

(16) Rear torsion bar

(17) Anti-roll bar

(18) Tubular axle

(19) Front flexible mounting on bodyshell

(20) Rear upper arm.

(21) Wheel bolt

: 4 ± 0.4

: 9 ± 0.9

(Face and threads not lubricated)

(22) Damper

(23) Rear flexible mounting on subframe

(24) Damper pin nut

: 5.5 ± 0.5

: 11 ± 0.1

25 ±n0u.t2s

(25) Stub

axle

(26) Rear flexible mounting on bodyshell

: 5.5 ± 0.5

Anti-roll bar

Torsion bar

Colou

Colour

Ø (mm)

21

Engines

mark

NFZ-6FZ

RHY

ORANGE

19.6

PINK

NOTE : The RH torsion bar can be identified by 1 paint line.

The LH torsion bar can be identified by 2 paint lines.

B3DP078D

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XSARA PICASSO - All Types

REAR AXLE

Evolution : Rear hub nut

New 15/12/1999 #

Old # 15/12/1999.

Evolution :

- New rear hub nut (3).

- Washer discontinued (2).

Old fitting (A)

(1) Rear hub nut.

(2) Thrust washer.

ESSENTIAL : Tighten to : 27.5 ± 2.7 m.daN

New fitting (B)

(3) Rear hub nut.

ESSENTIAL : Tighten to : 25 ± 2.5 m.daN.

NOTE : It is possible to have both types of fitting on the same axle.

The old nut (1) requires the fitting of the thrust washer (2).

WARNING : do not fit a thrust washer (2) with a new nut (3).

ESSENTIAL: Respect the tightening torque to be applied when fitting.

WARNING : Identify the type of fitting, before starting a repair.

B3DP08AD

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XSARA PICASSO - All Types

SUSPENSION

Height of the vehicle in running order

(The vehicle height, when in running order, is set according to the measurements shown in the table below).

The vehicle is said to be in running order when it is empty, with all

reservoirs full, including the fuel tank.

B3CP058D

Vehicles all types (except CRD)

Front

Rear

H1 = R1 – L1

H2 = R2 – L2

Engine

L1

1.6i - 1.8 i 16 V

2.0 HDi

66.5 mm

100 mm

Engine

L2

1.6i - 1.8 i 16 V - 2.0 HDi

51 mm

62.5

96

L1’

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SUSPENSION

Measurements at the front and rear axles, vehicle in running order

Vehicles all types (except CRD)

XSARA PICASSO - All Types

Front axle

Rear axle

1.6i - 1.8i 16 V

2.0 HDi

Adjustable

Yes

1.6i - 1.8i 16 V

2.0 HDi

Adjustable

2 mm ± 1 mm 1.7 mm ± 1 mm

0° 18’ ± 0° 09’

1.2 mm ± 1 mm

0° 11’ ± 0° 09’

Tracking

Camber

Oui

Tracking

Castor

0° 15’ ± 0° 09’

2° 54’ ± 20’

Non

1° 15’ ± 20’

King pin

inclination

No

10° 6’ ± 30’

0° 20’ ± 30’

10° 12’ ± 30’

0° 15’ ± 30’

Camber

WARNING

TOE-IN

A < B = Positive figure:

A > B = Negative figure:

+ =

– =

TOE-OUT

B3CP02UC

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STEERING COLUMN SPECIFICATIONS

XSARA PICASSO - All Types

Left hand drive = Green marking.

Right hand drive = White marking.

(1) Steering wheel.

(4) Steering column adjustment.

Tightening torques m.daN.

(2) Airbag to steering wheel fixing

(3) Steering wheel fixing

(5) Steering column to support fixing

(6) Steering cardan joint fixing

0.8 ± 0.1

3.3 ± 0.6

4 ± 1

2.3 ± 0.2

B3EP116D

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Axles, Suspension, Steering for Your Citroen Xsara SUV Second Generation (1997-2006)

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