2004 Citroen XSARA check oil

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 PILOTED MANUAL GEARBOX
Engines: KFV 8HX
Features.
The piloted gearbox is a modern manual gearbox with technology that offers
enhancements in every driving situation.
The piloted manual gearbox has two operating programmes:

«Sequential»programme.
«Automatic»programme.
The piloted manual gearbox has:
A gearbox ECU
(supplier:SIEMENS). A gearbox actuator with two electric motors (supplier:SACHS).
A clutch actuator with one electric motor (supplier:SACHS).
A gearbox input speed sensor.
The piloted manual gearbox has no gear control cable and no clutch cable.Changes of gear and clutching/declutching are activated by the gearbox
actuator and the clutch actuator.
Lubrication.
Oil capacity : 2 ± 0,15 litres.
Checking of oil level : No oil level check.(*)Lubrication intervals : Lubricated «for life».
(*)= Only a visual check of the sealing at each engine oil change interval.
B2CP3SUD
C2

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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
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
Precautions to be taken.
Towing.
The front of the vehicle must be raised in order to be towed.
If the front of the vehicle cannot be raised:
IMPERATIVE: Put gear lever in position «N».
Do not add any oil.
Do not exceed
30 mphover a distance of 30 milesof maximum.
Driving.
Never drive with the ignition switched off.
Never push the vehicle to try to start it
(impossible with an automatic gearbox).
NOTE:The automatic gearbox is only lubricated when the engine is
running.
Repairs on electrical components.
Do not disconnect:
The battery when the engine is running.
The ECU when the ignition is switched on.
Before reconnecting a switch,check: The condition of the various contacts (for deformation, corrosion etc).
The presence and condition of the mechanical locking.
When performing electrical checks: The battery should be correctly charged.
Never use a voltage source higher than 16V.
Never use a test lamp.
C3 XSARA XSARA PICASSO

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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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AIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Refitting.
Remove the new cartridge from its packaging.
Do not expose the cartridge, the filter and seals to pollutants.
Lightly oil the seals
(compressor oil).
Remove tool [5] from the reservoir (6).
Insert the new cartridge (5)into the reservoir (6).
Refit the safety circlip (4), using tool [6].
Make sure that the circlip (4)is correctly positioned in its location.
WARNING: Not more than 5 minutes should elapse between the removal of
the cartridge (6) from its packaging and its being fitted.
Refit:
The plastic cap (3), using tool [5] Tighten to 1,2 ±0,1 m.daN.
The condenser (reclip, pushing at «b»and «c»).
The plastic cover and the pins at «a».
The grille (2).
The screws (1).
Proceed to:
Recharge the circuit
(see corresponding operation).
Check the operation of the air conditioning (see corresponding operation).
C4AP167CC4AP165CC4AP164CC4AP163C
C2 C3 C3 PLURIEL

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AIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Move aside the radiator/condenser assembly.
Remove the plug (6), using tool [2].
Support the radiator/condenser assembly thus moved aside.
Remove the filtering/drying cartridge
(7), using pliers.
Refitting.Refit the filtering/drying cartridge (7).
Clean the threads of the plug (6).
It is essntial to change the Oring seals (8).
Lubricate the Oring seals (8)with aircon compressor oil.
Refit:
The plug
(6), using tool [2], tighten to 1,4 ±0,2 m.daN.
The brackets (5).
The screws (4).
The cardboard from the radiator harness.
The nuts
(1).
The air filter assembly (3).
Couple the hose (2).
Recharge the circuit (R134.a) (according to equipment)
(see corresponding operation).
Check the operation of the air conditioning.
C5HP14NCC5HP14PCC5HP14QC
XSARA PICASSO

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SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Compressor lubricant
ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.
Checking the compressor oil level
There are three specific cases:
1/
Repairs to a system without leaks.2/Slow leak.3/Fast leak.
1/ Repairing a system without leaks.
a)Using draining/recovery equipment not fitted with an oil decanter.
Drain the system as slowly as possible via the LOW PRESSUREvalve, so as not to lose any oil.
No more oil should be added when filling the system with
R 134.a fluid.
b) Using draining/filling equipment fitted with an oil decanter. Drain the R 134.afluid from the system in accordance with the instructions in the equipment handbook.
Measure the amount of oil recovered.
Add the same amount of
NEWoil when filling the system with R 134.afluid.
c) Replacing a compressor. Remove the old compressor, drain it and measure the oil quantity.
Drain the new compressor (supplied full), so that the same amount of NEWoil is left in the compressor as was in the old compressor.
No more oil should be added when filling the system with R 134.afluid.
AIRCONAIRCON