2004 Citroen XSARA remove

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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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AXLES
SUSPENSION
STEERING
SPECIAL FEATURES: STEERING
Engines: HFX KFV NFU 8HX
Centring the steering rack
Preliminary operation.
Raise and support the vehicle on a twocolumn lift.
Remove, on the RH side of the steering rack:
Clip
(1).
Clip (2).
Release the steering rack rpotection gaiter.
Setting.
Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension
Y.
Calculate the dimension:
L = (Y – X) : 2.
Refit:
The steering rack rpotection gaiter.
New clips
(1)and (2).
B3EP13UC
B3EP13VD
C2

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AXLES
SUSPENSION
STEERING
SPECIAL FEATURES: STEERING
Engines: HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Centring the steering rack
Preliminary operation.
Raise and support the vehicle on a twocolumn lift.
Remove, on the RH side of the steering rack:
Clip
(1).
Clip (2).
Release the steering rack rpotection gaiter.
Setting.
Move the steering to full left hand lock.
Measure the dimension X.
Move the steering to full right hand lock.
Measure the dimension
Y.
Calculate the dimension:
L = (Y – X): 2.
Refit:
The steering rack rpotection gaiter
New clips
(1)and (2).
B3EP13UC
B3EP13VD
C3 C3 PLURIEL

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BRAKES
C5FP0ELD
HANDBRAKE (Adjustment)
Adjustment.
Lift and chock the vehicle.
Remove:
The rear cover
(8).
The nut (9).
The handbrake trim (6).
The gear lever gaiter (5).
The front cover (3).
The screws (1).
Disconnect the connectors of the following components:
The cigar lighter
(2).
The electric window buttons (4).
Remove the central console
(7).
WARNING:Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal
(Then repeat the ope
ration 3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C2

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BRAKES
B3FP16ED
HANDBRAKE (Adjustment)
Adjustment (continued).
A
: Drum brakes.B:Disc brakes.(10)Nut for adjusting cable tensions.
Remove:
The rear wheels.
The drums
(according to version).
Release the handbrake.Use a gauge set to measure at
«a»the travel of the lever
from its stop.
Adjust the nut
(10)to obtain a travel of less than or equal
to 1 mmat «a».
Refit the brake drums without tightening them (according
to version).
Action the handbrake lever 8 times with an effort of 40 m.daN.
With the handbrake released, check the travel of the
lever at
«a», using a gauge set.NOTE:The travel should be less than 1 mmand more
than 0,05 mm.
Refit:
The brake drums. The wheels.
The central console.
Check the operation of the handbrake.
C2

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BRAKES
B3FP15XC
BLEEDING AND FILLING THE BRAKING SYSTEM
Tools.
[1]
Generic bleeding apparatus :«LURO»Bleeding, refilling.
Draining.
Drain the brake fluid reservoir (1)to the maximum(if necessary, use a clean syringe).
Disconnect the connector (4).
Uncouple the pipe (2).
Unscrew the shaft (3).
Remove the reservoir (1).
Empty the brake fluid reservoir (1).
Clean the brake fluid reservoir (1).
Refit:
The brake fluid reservoir
(1).
The shaft (3).
Couple the pipe (2).
Reconnect the connector (4).
Filling the braking system.WARNING:Use only those hydraulic fluids that are approved and recommended.
Fill the brake fluid reservoir (1).
Bleeding the braking system.WARNING:During the bleeding operation, take care to maintain the level of brake fluid in the reservoir
and to top it up, using only brake fluid that is clean and clear.
C2

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BRAKES
B3FP160C
BLEEDING AND FILLING THE BRAKING SYSTEM (Continued)
With the bleeding apparatus.
Connect the bleeding apparatus [1]on the brake fluid reservoir (1).
Adjust the apparatus pressure to
2 Bars.
For each circuit:
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles. Close the bleed screw.
Remove the bleeding apparatus
[1].
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE:Two operators are necessary.
For each circuit:
Apply the brake pedal to place the circuit under pressure.
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles.
Close the bleed screw. Remove the tool
[1].
NOTE:Recommence the process a second time if that is necessary.
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
C2

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BRAKES
C5FP0ELD
HANDBRAKE (Adjustment)
Adjustment.
Lift and chock the vehicle.
Remove:
The rear cover
(8).
The nut (9).
The handbrake trim (6).
The gear lever gaiter (5).
The front cover (3).
The screws (1).
Disconnect the connectors of the following components:
The cigar lighter
(2).
The electric window buttons (4).
Remove the central console (7).
WARNING:Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal
(Then repeat the operation3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C3 C3 PLURIEL