2004 Citroen XSARA PICASSO air

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INJECTION
CHECKING THE AIR SUPPLY CIRCUIT
Engines: RHY RHZ
XSARA PICASSO
Tools.
[1]Manual vacuum pump : FACOM DA 16
IMPERATIVE: Respect the safety and cleanliness requirements.
Vacuum pump.
Connect the tool [1]on the vacuum pump (1).
Start the engine.
Pressure should be
0.8 barat 780 rpm.Boost pressure regulator electrovalve. Connect the tool [1]between the electrovalve (2)and the valve (3)of the boost pressure
regulator.
Compare readings with the values in the table below.
Pressure regulator valve. Connect the tool [1]on the valve (3).
Appy a pressure of 0.5 barto activate the rod "a":
Rod "a"should be moved 12 mm.
Engine speed (rpm) Pressure (Bar)
780 0,6
4000 0,25
B1HP12FD

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INJECTION
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
General.
ESSENTIAL: Given the very high pressures prevailing in the fuel high pressure circuit (1600 Bars), respect the following regulations.
It is forbidden to smoke in the immediate proximity of the high pressure circuit during a repair.
Avoid working close to flames or sparks.When the engine is running:
Do touch the fuel high pressure circuit.
Always keep out of range of possible projections of fuel, which could cause serious injuries.
Do not place your hand near to any leak on the fuel high pressure circuit. After the engine has stopped, wait 30 seconds before starting any operation.
NOTE:The waiting time is necessary to allow the fuel high pressure circuit to return to atmospheric pressure.
Safety rules.
IMPERATIVE:Wait at least an hour before starting any repair on the exhaust line.
Forced regeneration of the particle filter:
Check that there are no aerosols or inflammable products inside the vehicle’s boot.
Wear high temperature gloves.
Connect the vehicle to a gas extractor approved for this type of operation.
IMPERATIVE: In the absence of the required installations, carry out the forced regeneration of the particle filter outside the workshop,
in a concreted area well away from any inflammable materials. Place the vehicle in the high position.
ALL TYPES

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INJECTION
PARTICLE FILTER SAFETY AND CLEANLINESS REQUIREMENTS
Operations on the fuel additive circuit.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are resistant to hydrocarbons.
The work area must be ventilated.
In the event of any significant dispersion of additive:
Wear a breathing mask for filtering the particles.
Recover as much of the product as possible.
Place the product thus recovered in an appropriately labelled container. Wash the soiled area with copious amounts of water.
Dispose of materials and solid residues in an authorised recovery point.
IMPERATIVE:The filling kit should be recycled following a repair. All «Eolys» additive containers that have been opened should be
disposed of.
Cleanliness rules.
ESSENTIAL: The operator should wear clean overalls.
Before working on the injection circuit, it may be necessary to clean the unions of the following sensitive components(see corresponding operations).
Fuel filter.
Fuel high pressure pump.
Fuel high pressure regulator.
Fuel high pressure common injection rail. Fuel high pressure piping. Diesel injector carriers.
IMPERATIVE: After dismantling, immediately blank the unions of the sensitive components with plugs, to prevent any ingress of impurities.
ALL TYPES

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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
BE4/5 GEARBOX
Engines: NFV 6FZ RFN RFS 8HV 8HY 9HZ 9HY WJY RHY RHZ
(1)Drain plug.
(2)Filling and topup plug.
(3)Air vent.
NOTE:The air vent aperture can be used for filling.
Quality of oil.Refer to the manufacturer’s instructions.
Quantity of oil.Gearbox empty:1,9 Litres.
After draining:2 Litres.
B2CP3BLD
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1] Tool for positioning the gear lever: 9607T.
Adjustements.
WARNING: Cables should be adjusted each
time the gearbox, gear controls or power unit
are removed.
Inside the vehicle:
Remove the trim under the gear lever.
Lock the gear lever in neutral position,
using tool
[1].
Under the bonnet: Remove the air filter assembly.
Unlock the balljoint keys at «a».
Place the gear selection and control levers on
neutral.
Lock the cable lengths with the balljoint locking
keys.
Checks.
Remove the tool [1].
Check that all the gears engage without
«tightness ».
Check that the gear lever moves identically
forwards and backwards and to right and left. If it
does not, repeat the adjustment.
Refit the trim under the gear lever.
Refit the air filter assembly.
Adjusting the gear controls Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3C6CB2CP3C0C

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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