2004 Citroen XSARA Gear lever

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2)and return
pipe (1).
Remove:
Screws
(3), (4) and (6).
Screw (7).
The upper timing cover (5).
WARNING:Refit screw (7)equipped with a spacer (17 mm thick), tighten the
screw (7)to 1,5 ± 0,1 m. daN.
NOTE:The screw (7)is one of the screws securing the coolant pump and is there
for its sealing.
Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool
[5].
Peg the engine flywheel, using tool
[3].
B1EP1A7CB1BP2H3CB1BP2H2CB1BP2R2C
XSARA XSARA PICASSO

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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
Clutch cable.
Removing.
Uncouple the cable from the lever (1).
Unclip the cable from the gearbox by actioning
the side tabs
(2).
Detach the cable from the bulkhead.
Remove the clip
(3).
Uncouple the cable from the clutch pedal.
B2BP001CB2BP002C
XSARA XSARA PICASSO
B2BP02VC
B2BP02WC
«PUSH» clutch
«PULL» clutch
B2BP03BCB2BP002C

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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
CLUTCH CONTROLS: FEATURES / CHECKS AND ADJUSTMENTS
Engines: KFW NFU 6FZ RFN RFS 8HX 9HZ 9HY WJY RHY RHZ
Adjusting the pedal height.
Loosen the nut (6)and the screw (7).
Using a lever, raise the stop support (8)to its highest position. In this position, there should be a substantial free
play in the pedal.
Lower the support until there is a free play of
2 ± 1 mm.
Tighten the nut (6) and the screw (7).
Check that the clutch cable sleeve can move freely.
At rest, the clutch cable sleeve should be free and able to lengthen and shorten.
Clutch pedal travel.
The automatic clutch wear adjustment system has no manual adjustment.
Pedal travel is identical on all models:154 ± 5 mm.
The adjustment is achieved by reducing the length of the cable sleeve.
WARNING:Automatic adjustment of the pedal travel is accompanied by a modification of the curvature of the
cable sleeve. Do not add any supplementary fixing points or alter the routing in any way.
«c»Routing of new cable.«b»Routing after adjustment of play.«x» Clutch wear.
B2BP03ECB2BP03FD
XSARA XSARA PICASSO

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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
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
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
MA/5 GEARBOX CONTROLS
Engines: HFX KFV KFU NFU 8HX 8HW
(1)Gear control lever.
(2)Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(*)
The two cables cannot be separated.
B2CP3HXD
C2 C3 C3 PLURIEL