2004 Citroen BERLINGO Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
Precautions to be taken.
Repairs on mechanical components.
Never place the gearbox on the ground without protection.
In order to avoid breaking the input shaft ring, it is
imperativethat
the converter retaining bracket should be in place when handlingthe gearbox.
It is
imperativeto use the centring peg and the converter retaining
bracket to couple the gearbox on the engine.
After coupling the gearbox on the engine, remove the centring peg.
Modification of the oil usage counter value.
Exchanging the gearbox ECU:
Note down the gearbox counter value.
Transfer the value read into the the new gearbox ECU.
Exchanging the gearbox :
Initialise the oil usage counter to 0.
Draining the gearbox:
Initialise the oil usage counter(follow the diagnostic tool procedure).
C3 XSARA XSARA PICASSO

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GEARBOX
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Engines: KFV NFU RFN RHZ
Downloading.
Updating the gearbox ECU by downloading:
Follow the procedure using the diagnostic tool.
The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
After the downloading operation, carry out the following: A clearing of faults.
A pedal initialisation.
A reinitialisation of the autoadaptives.
A programming
(if necessary).
A writing of the value of the oil usage counter previously read.
A road test.
ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU

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GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
Updating the value of the oil usage counter.
Using PROXIA.
Access to reading and recording of the oil counter is via the menu:
«Configuration
(integrated circuit button)/ Oil counter».
Adjustment of the oil counter value is done in incremental steps of
2750units.
Using LEXIA or ELIT.Access to reading and recording of the oil counter is via the menu:
«Oil counter».
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
Downloading.
ECU downloading procedure:
Follow the diagnostic tool procedure.
A new ECU or downloaded update is always configured with the
following options:
SHIFT LOCK gear selection lever position.
Without OBD outlet
(depollution L4).
If the ECU is to be fitted to a vehicle with depollution
L4or not
equipped with gear lever locking safety: Perform a configuration operation.
Pedal initialisation.
A pedal initialisation must be carried out in the following cases:
Replacement of the automatic gearbox ECU.
Replacement of the automatic gearbox.
Downloading of the ECU configuration.
Adjustment or replacement of the accelerator cable.
Replacement of the butterfly potentiometer.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOXC3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
B2CP3ECD
Identification.
«a»
Component reference.
WARNING:This gearbox benefits from a special CITROEN semisynthetic oil,
which cannot be mixed with any other oil.
The gearbox is lubricated for life.
AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
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AL4 AUTOMATIC GEARBOX
Tightening torques (m.daN).
(1)
Oil flow modulation electrovalve fixing: 1 ± 0,2
(2)
Heat exchanger fixing:5 ±1
(3)
Output speed sensor fixing:1 ±0,2
(4)
Output speed sensor fixing: 1 ± 0,2
(5)
Oil overflow and drain fixing: 4 ± 0,2
(6)
Oil level plug:2,4 ±0,4
(7)
Oil pressure sensor fixing: 0,8 ± 0,1
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3EDDB2CP311D

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
B2CP3EED
Tightening torques (m.daN).
(8)
Fixing of converter on diaphragm
Pretightening
: 1 ± 0,1Tightening:3 ±0,3
(9)
Plug fixing: 0,8 ± 0,2
(10)
Gearbox fixing on engine: 5,2 ± 1
AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO

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GEARBOX
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AL4 AUTOMATIC GEARBOX
Tightening torques (m.daN).
A: EW7
and EW10engines
Hydraulic block fixing.
Centre the hydraulic block, using screws (11)and (12).
Pretighten(no strict order): 0,9 Slacken: All 7 screws Tighten(respect the order indicated):0,75
NOTE:
The screw (11)is shouldered.
B: DW10engine.
Hydraulic block fixing.
Centre the hydraulic block, using screws (11)and (12).
Pretighten(no strict order): 0,9 Slacken:All 7 screwsTighten(respect the order indicated):0,75
NOTE:
The screw (11)is shouldered.
(13)Fixing of selector lever position switch: 1,5 ± 0,2
(14) Oil filler plug: 2,4 ± 0,4
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3EFDB2CP3EGC

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GEARBOX
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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