2004 Citroen BERLINGO start

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INJECTION
SPECIAL FEATURES: FORCED REGENERATION OF THE PARTICLE FILTER
Tools.
Diagnostic stations: LEXIA or PROXIA
Imperative: Respect the safety and cleanliness requirements.
Forced regeneration of the particle filter.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
ESSENTIAL: Connect the vehicle to a gas extractor approved for this type of operation.In the absence of the required installations,carry out the forced regeneration of the particle filter outside the workshop, in a concreted
area well away from any inflammable materials. Place the vehicle in the high position.
WARNING:
Check that the fuel level is sufficient (at least 20 litres).
Start the engine and allow it to warm up (60°C minimum).
Connect the diagnostic tool to the vehicle’s central socket.
Trigger the regeneration cycle, with the diagnostic tool.
Automatic running of the regeneration cycle of the particle filter:
Autocheck by the engine ECU. Stabilisation of engine speed at
4000 rpm, operating with post injection.
Change to idling speed (for 30 seconds).
Stabilisation of engine speed at 3000 rpm, checking of the efficiency of the regeneration of the particle filter.
Change to idling speed.
NOTE:Let the engine run at idling speed for the benefit of cooling.
Stop the engine.
IMPERATIVE: Wait for at least an hour before any operation on the exhaust line.
ALL TYPES

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
Bleeding the hydraulic clutch control
Action the clutch pedal manually through its full travel:7 times rapidlydown and up.
Allow the clutch pedal to come back up to its high position.
Fill the brake fluid reservoir to the maximum of its capacity.
Open the bleed screw, at
«c».
Action the clutch pedal manually through its entire travel:7 timesrapidly down and up.
The last time, keep the clutch pedal fully down.
Reclose the bleed screw, at
«c».
If necessary, repeat the operation.
Top up the brake fluid to the MAX. level of the brake fluid reservoir.
Work the clutch vigorously
40 times.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension
(X)greater than or equal to 45 mm(the dimension (X)is
given as a guide).
Repeat the bleed operations if necessary.
C5FP0FQCB2BP04YC
C2 C3 C3 PLURIEL
XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Operations on electrical components.Do not disconnect:
The battery when the engine is running.
The ECU with the ignition switched on.
The clutch and gearbox actuators with the ignition switched on.
When carrying out electrical checks: The battery must be correctly charged.
Never use a voltage source higher than 16V.
Never use a lamp to supply an actuator directly.
Before disconnecting connector, check: The condition of the various contacts (for deformation, corrosion, etc).
The presence and the status of the mechanical unlocking.
Driving the vehicle.
IMPERATIVE:
Never move the vehicle with the ignition switched off.
Never push the vehicle to attempt to start it
(impossible with a piloted
manual gearbox).
Towing.
Conditions for towing.
It is necessary to lift the front of the vehicle to tow it, after having
positioned the gear lever in neutral. If there is a gearbox fault or
malfunction, the vehicle can remain immobilised depending on theseriousness of the fault.
If a gear is engaged,the conditions for immobilisation of the
vehicle are:
Combustion engine stopped (the engine should not be started).
The clutch is open (clutched).
In these conditions are met, you can lift the front of the vehicle to tow it.
If it should not be possibe to lift the front of the vehicle, there are
ways to unblock it:
Engage «N», using a diagnostic tool.
Engage «N», without using a diagnostic tool.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
Precautions to be taken.
Towing.
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised:
IMPERATIVE: Put gear lever in position «N».
Do not add any oil.
Do not exceed
30 mphover a distance of 30 milesof maximum.
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it
(impossible with an automatic gearbox).
NOTE:The automatic gearbox is only lubricated when the engine is
running.
Repairs on electrical components.
Do not disconnect:
The battery when the engine is running.
The ECU when the ignition is switched on.
Before reconnecting a switch,check: The condition of the various contacts (for deformation, corrosion etc).
The presence and condition of the mechanical locking.
When performing electrical checks: The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
In passenger compartment.The gear selector is guided by the shape of the stepped gate and by a retaining spring which
pulls it to the left hand side.
The gear selector control has
5 positions:
Position
«P»: Park (locking and immobilisation of the vehicle).
Position «R»:Reverse gear.
Position «N»: Neutral.
Position «D»: Drive (use of the 4 gears in their autoadaptive automatic function).
Position «M»: Manual (this position lets the driver select his own gears in sequential mode
by pulling the gear selector to «M-»or pushing it to «M+»).
NOTE:Only the positions «P»or «N»authorise the starting of the engine.
In position
«M», selection is by an electronic sensor located close to the gear lever.
The variation of flux necessary to the movement of the sensor cells is obtained by a magnet
located on the lever itself. This enables the change of status.
Engines: KFV RFN
C3 XSARA PICASSO
B2CP3H7DB2CP3MUD
XSARA PICASSOC3

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
In passenger compartment (continued).
The information is transmitted to the gearbox ECU.
NOTE:The vehicle is equipped with the «shift lock»«P».
Two switches placed on the gear control gate permit the driver to choose one of the following
three driving programmes:

Normal programme: Operates as the default programme (eco law, autoadaptive mode).
Sport programme (a): Permits a more dynamic, sporty performance.
Snow programme (b): Facilitates starting and adhesion on slippery surfaces.
To return to the normal programme, press a second time on the sport switch or snow switch.
Engine: KFV
C3
B2CP3DKD

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
In passenger compartment.
The selector control has 6 positions:
The gear selector is guided by the shape of the stepped gate and by a retaining spring
which pulls it to the left hand side.
Push the lever to the right to exit from position
«P».
NOTE:The vehicle is equipped with the «shift lock»«P».
P:Park (system locked).R:Reverse gear.N:Neutral.D:Automatic (1st to 4th gear).3:Automatic (1st to 3rd gear).2:Automatic (1st to 2nd gear).
A switch located to the left of the gear control allows the driver to choose from these
programmes:
Normal:Conventional use of the automatic gearbox.Sport:This programme favours performance.Snow:In position «D», starting is in 2nd gear for dieseland in 3rd gear for petrol.
NOTE:Only the positions «P»or «N»authorise the starting of the engine.
Engines: NFU RFN RHZ
XSARA
B2CP3ADC
XSARA

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BRAKES
BRAKE SPECIFICATIONS
Evolution: rear wheel cylinder (applies from RPO 9667)
C3 C3 Pluriel
Evolution.
New wheel cylinders at the rear, with cutoff pressure 27 bars instead of 35 bars.
Assembly.
(1)
Rear wheel cylinder.
Repair.
IMPERATIVE:The mixing of the old and new components is STRICTLY FORBIDDEN.
WARNING:
Identify the type of assembly prior to starting a repair.
ESSENTIAL: Systematically replace the wheel cylinders on both sides on the same axle.
Replacement parts.
Replacement Parts will market only the components for the new assembly.
C3 C3 PLURIEL