2004 Citroen XSARA lock

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INJECTION
CHECKS: EXHAUST GASES RECYCLING CIRCUIT
Engines: 8HX 8HW
Engines: 8HV 8HY
Tools.
[1]
Manual pressurevacuum pump: FACOM DA 16
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel
injection (HDi) engines.
EGR v
alve.Connect tool [1]on the capsule takeoff (2).
Apply a vacuum of approx.0,6 barseveral times to activate the rod «a».
In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating.
Regulation electrovalve (EGR).(Engine:8HX8HW).Check to be performed between the electrovalve (1)and the EGR valve (2).
Link the tool [1]in series, between the electrovalve (1)and the capsule (2).
Compare the values noted with those in the table below.
Regulation electrovalve (EGR).(Engine:8HV8HY).Check to be performed between the electrovalve (2)and the EGR valve (1).
Link the tool [1] in series, between the electrovalve (2)and the capsule (1).
Compare the values noted with those in the table below.
Engine speed (rpm) Vacuum value
780 0,5
2500 0
B1HP15GD
B1HP1K6D
C2 C3

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Refitting.
Place the pedal in the high position (contact at “a”).
Attach the cable yoke on the hook of the clutch pedal.
Fit a new clip
(3).
Fit the endpiece (4)to the bulkhead (fit with G6grease).
Clip the endpiece (5)on the gearbox.
Couple the cable to the lever (1).
Depress the clutch cable several times to lodge the cable in place.
Check that the endpiece (4) is correctly lodged on the bulkhead.
Check the operation of the automatic adjusting system.
After fitting the cable, pull the clutch lever in the inverse direction
(direction F), the lever should
move back when pulled by hand.
Press the clutch pedal very lightly and repeat the same operation. The lever should not move
back.
WARNING:If a system blockage is detected when checking, or if the pedal has been removed,
the pedal position must be adjusted. The correct positioning of the pedal is obtained by the
angular displacement of the stop supports
"a"and "b".
B2BP03CD
XSARA XSARA PICASSO
«PUSH» clutch
«PULL» clutch
B2BP03DD

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Operations on electrical components.Do not disconnect:
The battery when the engine is running.
The ECU with the ignition switched on.
The clutch and gearbox actuators with the ignition switched on.
When carrying out electrical checks: The battery must be correctly charged.
Never use a voltage source higher than 16V.
Never use a lamp to supply an actuator directly.
Before disconnecting connector, check: The condition of the various contacts (for deformation, corrosion, etc).
The presence and the status of the mechanical unlocking.
Driving the vehicle.
IMPERATIVE:
Never move the vehicle with the ignition switched off.
Never push the vehicle to attempt to start it
(impossible with a piloted
manual gearbox).
Towing.
Conditions for towing.
It is necessary to lift the front of the vehicle to tow it, after having
positioned the gear lever in neutral. If there is a gearbox fault or
malfunction, the vehicle can remain immobilised depending on theseriousness of the fault.
If a gear is engaged,the conditions for immobilisation of the
vehicle are:
Combustion engine stopped (the engine should not be started).
The clutch is open (clutched).
In these conditions are met, you can lift the front of the vehicle to tow it.
If it should not be possibe to lift the front of the vehicle, there are
ways to unblock it:
Engage «N», using a diagnostic tool.
Engage «N», without using a diagnostic tool.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Engaging of «N», using a diagnostic tool.
Preliminary operations:
Battery voltage higher than 12.5 volts.
Ignition switched on.
Connect the diagnostic tool to the vehicle’s diagnostic socket.
From the diagnostic tool menus, select:
«DIAGNOSIS»
MA type piloted manual gearbox.
Actuator test.
Gearbox actuator test.
Gear engagement test.
N(neutral).
NOTE:The letter «N»should appear on the instrument panel.
If not, see the following solution:
Engaging of
«N», without using a diagnostic tool.
Engaging of «N», without using a diagnostic tool.
In this configuration, the gearbox actuator is blocked, gear engaged.
NOTE:This recovery solution is to be used solely in a case where the
attempt to make the gearbox actuator engage b via the diagnostic toolhas failed.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
Adjustment.
WARNING: Do not use any tool to detach the balljoints.
The gear selection control and gear engagement control
cables cannot be adjusted.
To unlock the balljoint, press at
«a»then pull the balljoint
upwards.
To release the sleeve stops, pull the needles
«b», in the
direction of the arrow, then disengage the sleeve stops from
their supports.
B2CP3J1D
B2CP3J0D
C2 C3 C3 PLURIEL

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Principles of adjusting the gear controls.
WARNING: Cables should be adjusted each time the gearbox, gear controls or power unit are
removed.
Principles.
Lock the gear lever in neutral position, using tool:9607T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the balljoints on the gearbox lever.
Lock the cable lengths with the balljoint locking keys.
WARNING: Do not use any tool to unclip the balljoints.
To unlock the balljoint, press at the centre «a», then pull the balljoint upwards.
NOTE:Changing an individual balljoint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3BXCB2CP3BYC

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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
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