2004 Citroen BERLINGO Workshop Manual

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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: MA PILOTED MANUAL GEARBOX
Engaging of «N», using a diagnostic tool.
Preliminary operations:
Battery voltage higher than 12.5 volts.
Ignition switched on.
Connect the diagnostic tool to the vehicle’s diagnostic socket.
From the diagnostic tool menus, select:
«DIAGNOSIS»
MA type piloted manual gearbox.
Actuator test.
Gearbox actuator test.
Gear engagement test.
N(neutral).
NOTE:The letter «N»should appear on the instrument panel.
If not, see the following solution:
Engaging of
«N», without using a diagnostic tool.
Engaging of «N», without using a diagnostic tool.
In this configuration, the gearbox actuator is blocked, gear engaged.
NOTE:This recovery solution is to be used solely in a case where the
attempt to make the gearbox actuator engage b via the diagnostic toolhas failed.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Engines: HFX KFV NFU 8HX
Engaging of «N», without using a diagnostic tool (continued).
Preliminary operation:
Disconnect the battery negative terminal.
Remove the air filter.
Use a
22 mmspanner.
Use the spanner to lift the gear engagement lever the maximum possible until
the axis
«A»of the engagement lever is perpendicular to the axis «B»(mid
point of the gear engagement lever).
When this position is attained, position
«N»is engaged.
B2CP3L8D
C2

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
«a» Identification label.
«b» Location for engraving of serial and gearbox nos.
B2CP3STC
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
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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

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws):2,2 ±0,2
(27)
Gearbox input speed sensor(1 screw): 0,8 ± 0,2
(28)
Reverse gear switch(1 screw): 2,5 ± 0,5
(29)
Drain plug(1 screw): 3,3 ± 0,3
(30)
Level plug(1 screw): 3,3 ± 0,3
B2CP3SUD
C2

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
Features.
The piloted gearbox is a modern manual gearbox with technology that offers
enhancements in every driving situation.
The piloted manual gearbox has two operating programmes:

«Sequential»programme.
«Automatic»programme.
The piloted manual gearbox has:
A gearbox ECU
(supplier:SIEMENS). A gearbox actuator with two electric motors (supplier:SACHS).
A clutch actuator with one electric motor (supplier:SACHS).
A gearbox input speed sensor.
The piloted manual gearbox has no gear control cable and no clutch cable.Changes of gear and clutching/declutching are activated by the gearbox
actuator and the clutch actuator.
Lubrication.
Oil capacity : 2 ± 0,15 litres.
Checking of oil level : No oil level check.(*)Lubrication intervals : Lubricated «for life».
(*)= Only a visual check of the sealing at each engine oil change interval.
B2CP3SUD
C2