2004 Citroen C3 Manual gearbox

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA PICASSO
Engine type NFV 6FZ RFN 9HZ 9HY RHY
Gearbox type Supplier
BE4/5
Mechanism / typeVALEO LUK
Engine type200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700
Clutch disc200X(D95) 230 DNG 4700 215 FD 95 228
11A12X
Ø Garniture.Ext/Int200/137 228/155 215/147 225/150 230/155
Quality of liningF410 F 808 F 810 DS F408
1.6i 1.4 HDi 16V2.0 HDi1.8i 16V 2.0i 16V

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: HFX – KFV – KFU – NFU – 8HX – 8HW – 8HV – 8HY
NOTE:All the clutches are «push»type with hydraulic control.
Description.The declutch control has a declutch fork mounted on a balljoint.(1)The balljoint is screwed into the clutch casing.(2)Declutch fork.(3)Clutch casing.(4)Bearing.(5)Clutch plate.
The clutch control slave cylinder
(7)is fixed by two screws (6)onto the exterior of the clutch casing.
Tightening torques (m.daN).
Fixing of clutch plate / engine flywheel: 2 ± 0,2 Fixing of clutch control slave cylinder / clutch housing:2 ±0,25 Fixing of engine flywheel / crankshaft
Pretightening:1,7 ± 0,1Angular tightening:70° ± 5°
B2BP047CB2BP04QC
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
Engines: KFW NFU NFV 6FZ RFN RFS 8HZ 9HZ 9HY WJY RHY RHZ
NOTE:All the clutches are «push»type with hydraulic control.
Description.The declutch control has a declutch fork mounted on a balljoint.(1)The balljoint is screwed into the clutch casing.(2) Declutch fork.(3) Clutch casing.(4) Bearing.(5) Clutch plate.
The clutch control slave cylinder
(7) is fixed by two screws (6)onto the exterior of the clutch casing.
Tightening torques (m.daN).
Fixing of clutch plate / engine flywheel: 2 ± 0,2 Fixing of clutch control slave cylinder / clutch housing:2 ±0,25 Fixing of engine flywheel / crankshaft
Pretightening:1,75 ± 0,1Angular tightening:75° ± 5°: 6,3 ± 2,2
B2BP047CB2BP05SC
XSARA XSARA PICASSO

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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
XSARA XSARA PICASSO
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
XSARA XSARA PICASSO
«PUSH» clutch
«PULL» clutch
B2BP03DD

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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
Adjusting the pedal height.
Loosen the nut (6)and the screw (7).
Using a lever, raise the stop support (8)to its highest position. In this position, there should be a substantial free
play in the pedal.
Lower the support until there is a free play of
2 ± 1 mm.
Tighten the nut (6) and the screw (7).
Check that the clutch cable sleeve can move freely.
At rest, the clutch cable sleeve should be free and able to lengthen and shorten.
Clutch pedal travel.
The automatic clutch wear adjustment system has no manual adjustment.
Pedal travel is identical on all models:154 ± 5 mm.
The adjustment is achieved by reducing the length of the cable sleeve.
WARNING:Automatic adjustment of the pedal travel is accompanied by a modification of the curvature of the
cable sleeve. Do not add any supplementary fixing points or alter the routing in any way.
«c»Routing of new cable.«b»Routing after adjustment of play.«x» Clutch wear.
B2BP03ECB2BP03FD
XSARA XSARA PICASSO

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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