2004 Citroen XSARA PICASSO Replacement

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
If a gearbox malfunction occurs, there are two possible
configurations depending on the seriousness of the fault:
Gearbox in backup mode with a replacement programme of
(the
fault values are taken in substitution).
Gearbox in backup mode with an emergency programme (3rd
hydraulic).WARNING:In the emergency programme, an impact is felt
when changing P/R, N/R and N/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms.Oil quality Oil level.
Oil quality.
If the gearbox has suffered a serious fault resulting in a malfunction
or the destruction of a clutch, the oil will overheat and become
contaminated with impurities: the oil is said to be
«burnt».
This is characterised by a black colour and the presence of an
unpleasant smell.
ESSENTIAL: The gearbox must be replaced.
Oil level (see corresponding operation).
An excessive oil level can result in the following consequences:
Excessive heating of the oil.
Oil leaks.
An insufficent level causes the destruction of the gearbox.
Top up the level of oil in the gearbox (if necessary).
Check using a diagnostic tool.
Read the fault codes
(engine and gearbox).
Absence of fault codes.Carry out parameter measures, actuator tests and a road test.
Presence of fault codes.Carry out the necessary repairs.
Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the
gearbox ECU parameters
(this is essential after an initialisation
of the ECU).
XSARA XSARA PICASSO
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox

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CLUTCH
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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AXLES
SUSPENSION
STEERING
FRONT AXLE
Evolution: Suspension arm balljoint
XSARA
Application from RPO: 7968.
New components:
Suspension arm balljoint.
Pivot.
Old fitting
ØA = 16 mm.
New fittingØA = 18 mm.
Repair requirements.
ESSENTIAL:Swapping of old and new components is forbidden.
It is permitted to fit a new pivot/balljoint assembly on one side of an old
vehicle.
Replacement Parts.
The old components are still available from Replacement Parts.
B3CP054D

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BRAKES
BRAKE SPECIFICATIONS
Evolution: rear wheel cylinder (applies from RPO 9667)
C3 C3 Pluriel
Evolution.
New wheel cylinders at the rear, with cutoff pressure 27 bars instead of 35 bars.
Assembly.
(1)
Rear wheel cylinder.
Repair.
IMPERATIVE:The mixing of the old and new components is STRICTLY FORBIDDEN.
WARNING:
Identify the type of assembly prior to starting a repair.
ESSENTIAL: Systematically replace the wheel cylinders on both sides on the same axle.
Replacement parts.
Replacement Parts will market only the components for the new assembly.
C3 C3 PLURIEL

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BRAKES
BLEEDING THE BRAKESXSARA
Bleeding:The brakes can be bled either:
using brake bleeding equipment, in which case the pressure of the equipment should be set to 2 Bars.
or in the conventional way.
IMPERATIVE order of bleeding
Wheels:
Rear Right.
Front Left. Rear Left.
Front Right.
Top up using brake fluid supplied by
CITROEN Replacement Parts.