2004 Citroen C2 remove gearbox

Downloaded from www.Manualslib.com manuals search engine ENGINE
171
CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 # NEW ASSEMBLY2003 #
(6)Crankshaft pinion
(7)Accessories drive pulley
(8)Washer
(9)Screw
The pinion
(6)is fitted as an idler on the crankshaft.
The accessories drive pulley
(7)is immobilised on the crankshaft by a halfmoon keyway and
by the tightening of washer
(8)and screw (9).
A:Pegging on manual gearbox.
B:Pegging on automatic gearbox.
The pegging of the crankshaft is done on the flywheel, or on the converter drive plate
(automatic gearbox).
The pegging hole on the cylinder block
(exhaust end)is calibrated and reinforced.
IMPERATIVE: Never turn the crankshaft with the accessories drive pulley slackened.
IMPERATIVE: Never remove the accessories drive pulley without pegging the crank
shaft and the camshafts.
IMPERATIVE: Always turn the crankshaft in the direction of engine rotation.
B1EP1B9D
B1BP2V2D
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173
CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 #
Checking the setting of the timing (continued).
A:
Pegging on the manual gearbox.
B:Pegging on the automatic gearbox.
Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position.
Peg the crankshaft, using tool
[2].
Peg the camshaft pulleys, using tool
[3].
NOTE:The pegs [3]should go in without effort.
WARNING:If the pegs go in only with difficulty, repeat the operation for fitting and
tensioning the timing belt
(see corresponding operation).
Refitting.
Remove tools [2]and [3].
Complete the refitting in reverse order to removal.
B1BP2V3D
B1EP1BAC
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175
CHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ RFN 2003 #
Setting the timing (continued).
A:
Pegging on the manual gearbox.
B:Pegging on the automatic gearbox.
Peg:
The crankshaft, using tool
[2].
The camshaft pulleys
(5)and (6), using tool [1].
Remove:
The screw
(3)of the crankshaft pulley (2).
The lower timing cover
(4)(by moving the engine).
IMPERATIVE: Never remove the crankshaft pulley (2) without pegging the crankshaft
and the camshafts.
Slacken the screw (9)of the tensioner roller (8).
Turn the tensioner roller
(8)(clockwise).
Remove the timing belt
(7).
I
MPERATIVE: Systematically replace the following components: timing belt, exhaust
manifold fixing nuts, timing belt tensioner roller nut.
B1BP2V3DB1EP1BBD
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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Clutch cable.
Removing.
Uncouple the cable from the lever (1).
Unclip the cable from the gearbox by actioning
the side tabs
(2).
Detach the cable from the bulkhead.
Remove the clip
(3).
Uncouple the cable from the clutch pedal.
B2BP001CB2BP002C
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B2BP02VC
B2BP02WC
«PUSH» clutch
«PULL» clutch
B2BP03BCB2BP002C

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Refitting.
Place the pedal in the high position (contact at “a”).
Attach the cable yoke on the hook of the clutch pedal.
Fit a new clip
(3).
Fit the endpiece (4)to the bulkhead (fit with G6grease).
Clip the endpiece (5)on the gearbox.
Couple the cable to the lever (1).
Depress the clutch cable several times to lodge the cable in place.
Check that the endpiece (4) is correctly lodged on the bulkhead.
Check the operation of the automatic adjusting system.
After fitting the cable, pull the clutch lever in the inverse direction
(direction F), the lever should
move back when pulled by hand.
Press the clutch pedal very lightly and repeat the same operation. The lever should not move
back.
WARNING:If a system blockage is detected when checking, or if the pedal has been removed,
the pedal position must be adjusted. The correct positioning of the pedal is obtained by the
angular displacement of the stop supports
"a"and "b".
B2BP03CD
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«PUSH» clutch
«PULL» clutch
B2BP03DD

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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
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
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Principles of adjusting the gear controls.
WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are
removed.
Principles.
Lock the gear lever in neutral position, using tool:9607T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the balljoints on the gearbox lever.
Lock the cable lengths with the balljoint locking keys.
WARNING: Do not use any tool to unclip the balljoints.
To unlock the balljoint, press at the centre «a», then pull the balljoint upwards.
NOTE:Changing an individual balljoint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
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B2CP3BXCB2CP3BYC