2004 Citroen XSARA PICASSO Workshop Manual

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
Refitting the gearbox control.
Proceed in the opposite order to removal.
IMPERATIVE: To adjust the gear selection control, place the gear selection lever in the
park position. Press on the component (25) without bending the cable, then release.
IMPERATIVE: Check that all the gears can engage.
Engines: NFU RFN RHZ
XSARA
B2CP3AXC

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
Refitting.
Proceed in the opposite order to removal.
Lubricate the support
(13).
New gear selection control.
Couple the balljoint(6).
WARNING:Do not deform the selection lever on the automatic gearbox.
Push in the component
(a) without bending the cable.
Check all the gear selection control positions.
Reused gear selection control.
Release the component (a).
Couple the balljoint (6).
Push in the component (a) without bending the cable.
Check all the gear selection control positions.
Engine: RFN
XSARA PICASSO
B2CP3GYD

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Tools.
[1]
Filling cylinder: ().0341
Draining.
IMPERATIVE:
The gearbox should be drained when the oil is warm (at least 60°C), to
eliminate the impurities in suspension in the oil.
NOTE:Draining is partial, the converter cannot be completely emptied.
Remove the drain plug
(1).
NOTE:Approx. 3 litres of oil should flow out.
Filling.
Refit the drain plug (1)(equipped with a new seal), tighten to2,4 ±0,2 m.daN.
Remove the oil filler cap (2).
Use tool [1].
Oil capacity for dry gearbox:

EW engine:5,85 litres.
DWengine:5,40 litres.
Oil remaining after draining:
3 litres(approx.).Quantity of oil to be put in :3 litres(approx.).Refit the oil filler cap (2)(equipped with a new seal), tighten to 2,4± 0,2 m.daN.
Initialise the oil wear counter (follow the diagnostic tool procedure).
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AYD
B2CP31GC

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Checking the oil level.
Prior conditions:
Vehicle in horizontal position.
Check gearbox is not in backup mode.
Remove the oil filler cap
(2).
Add 0.5 litres extra oilinto the gearbox.
Foot on the brake, change through all the gears.
Selection lever in position
"P".
Engine running, at idle.
Oil temperature:
60°C (+8°C; 2°C).
Remove the oil level plug (3).
C3 TU3enginesDimension «X» = 81 mm
XSARA TU5
and EW10 enginesDimension «X» = 81 mm
XSARADW10
enginesDimension «X» = 77 mm
XSARA PICASSO EW10
enginesDimension «X» = 81 mm
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AZD

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Thread of oil then "dripdrip".
Refit the plug (3), Tighten to 2,4± 0,2 m.daN.
"Dripdrip" or nothing.
Refit the oil level plug (3).
Stop the engine.Add
0.5 litresextra oil into the gearbox.
Repeat the oil level procedure.
NOTE:The level is correct at the moment the thread of oil becomes “dripdrip”.
Refit the oil level plug
(3)(equipped with a new seal), tighten to2,4±0,2 m.daN.
Checking the oil level (continued).
Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.
An excessive level of oil can lead to the following consequences:
Oil heating up abnormally,
Oil leaks.
A level that is too low will result in the destruction of the gearbox.
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AZD

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CLUTCH
GEARBOX
TRANSMISSION
DRIVESHAFTS GEARBOX
Tightening torques (m.daN)
Driveshaft
bearing Engines
V ehiclesGearboxRH side LH side Tool kitGearbox oil seal mandrels
24,5 ± 0,5
32 ± 1,5
32,5 ± 2,57114T.W
Seal extractor
RH / LH
() 0338 C
() 0338 J1
+ () 0338 J3() 0338 H1
+ () 0338 H2
() 0338 J1
+ () 0338 J2() 0338 H1
+ () 0338 H2() 0338 7114T.X
7116T Driveshaft
nut
HFX KFV KFU
8HX 8HW
NFU
KFW NFU
NFV RFS RFN 6FZ WJY
8HZ 9HZ 9HY RHY RHZ
8HV 8HY
NFU RFN RHZ
KFV MA/5
XSARA
XSARA PICASSOC2 C3 C3 Pluriel
XSARANO
2 ± 0,2
1,8 ± 0,1
2 ±0,2
1,8 ±0,1
1 ±0,1
C3
C3
XSARA PICASSO
XSARA
Tightening torque (m.daN) for wheel bolts: XSARA = 8,5 ± 0,8 XSARA PICASSO = 10 ± 1 C2 C3 C3 PLURIEL = 9 ± 1BE4/5
AL 4
C2 C3 C3 PLURIEL XSARA XSARA PICASSO

Downloaded from www.Manualslib.com manuals search engine AXLES
SUSPENSION
STEERING
355
C2 AXLE GEOMETRY
Tyres inflated to correct pressures. Vehicle at reference height.
Steering rack locked at mid point (see corresponding operation).
Conditions for checking and adjusting
Vehicle heights at reference height
E1APOBZD
Front height Rear height
L1L2
H1 = R1 – L1 H2 = R2 + L2
H1
= Measurement between the measuring zone underneath the front H2 = Measurement between the measuring zone underneath the rear
subframe and the ground. sill and the ground.
R1= Front wheel radius under load.R2= Rear wheel radius under load.L1= Distance between the wheel axis and the measuring zoneL2= Distance between the wheel axis and the measuring zone
underneath the front subframe. underneath the rear sill.

Downloaded from www.Manualslib.com manuals search engine AXLES
SUSPENSION
STEERING
356
C2 AXLE GEOMETRY
B3CP07SD
Measuring front height Measuring rear height
[1]
Gauge for measuring the wheel radius, 4 bolts, tool 8006T
Z1
= Measuring zone underneath the front subframe.Z2= Measuring zone underneath the rear sill.
Measure the radius of the front wheel
R1 Calculate dimension H1 = R1 – L1Measure the radius of the rear wheel R2 Calculate dimension H2 = R2 + L2
Value at referenceExcept CRD (*)Value at referenceExcept CRD (*)heightHFX KFV 8HX NFUheightHFX KFV 8HX NFU
(+ 6 8 mm)L1 = 142,5 mmL1 = 152,5 mm(+ 10 6 mm)L2 = 52 mm L2 = 42 mm
Compress the suspension to obtain the calculated values.
The height difference between the two axle dimensions should be less than 10 mm.(*) = CRD: Difficult road conditions.