2004 Citroen C3 Adjust

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS HYDRAULIQUE
B2BP04XC
Bleeding the hydraulic clutch control
IMPERATIVE: Use only new brake brake fluid that is not emulsified, avoid any
ingress of impurities into the hydraulic circuit.
IMPERATIVE: Do not use automatic bleeding equipment
(risk of the brake fluid
emulsifying in the hydraulic circuit).
Couple a transparent tube (5) on the bleed screw, at «c».
Submerge the end of the tube
(5)in the recipient containing the brake fluid, located
below the level of the clutch slave cylinder.
Use the transparent tube
(5)to act as a siphon, at «b».
WARNING:the end of the tube (5)must be submerged in the brake fluid.
Open the bleed screw, at
«c».
C3 PLURIEL XSARA
C2C3XSARA PICASSO

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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
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(29)Topup plug (x1): 2,5 ± 0,5.
(30)Drain plug (x1): 2,5 ± 0,5.
(31)Reverse gear switch (x1): 2,5 ± 0,5.
Strengthened MA gearboxes are marked with the letter «B»or «C»:«B»= Differential diameter 77 mm+ strengthened bearings.«C»= Differential diameter 77 mm+ strengthened bearings + strengthened
intermediate plate.
NOTE:All vehicles are equipped with clutch control by cable.
Features.
This gearbox:
has no adjustment.
has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.
Oil capacity : 2 ± 0,15 Litres.
Checking the oil level : Every 37,500 miles.
Lubrication interval : Lubricated «for life».
B2CP169D
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
Description
(1)
Primary shaft.
(2)Clutch bearing guide.
(3)Gearbox casing.
(4)Clutch housing.
(5)Reverse idle.
(6)Drive gear (3rd gear).
(7)3rd / 4th gear synchroniser.
(8)Drive gear (4th gear).
(9)Drive gear (5th gear).
(10)5th gear synchroniser.
(11)Driven gear (5th gear).
(12)Driven gear (2nd / 4th gear).
(13) Driven gear (2nd gear).
(14)1st / 2nd gear synchroniser.
(15)Driven gear (1st gear).
(16)Secondary shaft.
(17)Differential gear.
(18)Satellite gears.
(19)Planet gears.
(20)Differential housing.
(21)Speedometer drive.
(22)Extension.
«d» Adjusting shims: 0.7 to 2.4 mm
(0.10 mm and increasing by 0.10 mm).
«c»Adjusting shims:1.4 to 1.6 mm
(0.10 mm and increasing by 0.10 mm).
B2CP3BQP
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
(4)Gear engagement balljoint Ø 10 mm.
(5)Gear selection balljoint Ø 10 mm.
C2 C3
Length D Length C Length D Length C
Gear
engagement
1040 mm 815 mm 1015 mm 790 mm
control cable (2)
Length A Length B Length A Length B
Gear
selection
1149 mm800 mm 1093 mm 775 mm
control cable (3)B2CP3HZD
B2CP3HYC
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
Adjustment.
WARNING: Do not use any tool to detach the balljoints.
The gear selection control and gear engagement control
cables cannot be adjusted.
To unlock the balljoint, press at
«a»then pull the balljoint
upwards.
To release the sleeve stops, pull the needles
«b», in the
direction of the arrow, then disengage the sleeve stops from
their supports.
B2CP3J1D
B2CP3J0D
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: KFW NFU 8HZ
1 Gear lever.2 Gear control bar.3 Engagement rod.4 Gear selection rod.5 Torque reaction rod.6 Gear engagement balljoint.7 Fixed point on gearbox.
Adjustment.The gear control assembly is not adjustable.
The rods do not have threaded ends.
Features.Grease the gear engagement balljoint.
WARNING:To secure the balljoints, set the
gearbox control to neutral.After fitting the gear
control assembly, check that all the gears will
engage without any
”tight spot”.
B2CP27WD
XSARA