2005 Citroen C4 remove

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INJECTION
CHECKS: TURBO PRESSURE
Tools.
[1] Pressure gauge for checking the turbo pressure: 4073-T Toolkit 4073-T
[2]Pressure take-off extension: 8607-T.A
[3]Pressure take-off union and hose: 8607-T.B
[4] Sleeve for checking the turbo pressure: 4185-T
[5]Adaptor sleeve: 4219-T
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection
engines.
Preliminary operation.
Slacken the clip (1).
Uncouple the air duct (2).
Connect the tool [1]on tool [2]and the tool [3]on tool [2].
Positioning on the vehicle.
Insert the tools [4]and [5]between the air duct (2)and the turbo air cooler outlet at «a».
Connect the tool [3]on tool [4].
Position the tool [1]inside the vehicle.
Start the engine.
Accelerate to 4000 rpm.
The value should be: 1 ± 0,2.
Return the vehicle to conformity.
Remove tools [1], [2], [3], [4]and [5].
Recouple the air duct (2)on the turbo air cooler.
Tighten the clip (1).
B1BP356C
B1HP1ZXC
Engine: RHR
C4
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INJECTION
CHECKS: TURBO PRESSURE
Tools.
[1]Pressure gauge for checking boost pressure: 4073-T.A Kit 4073-T
[2]Sleeve for checking boost pressure: 4185-T
Checks.
IMPERATIVE: respect the following checking requirements: Engine at running temperature.
Vehicle running at full load.
Preparation.
Remove the collar (3)and the sleeve.
Insert the tool [2]between the pipe (1)and the duct (2).
Position tool [1]in the vehicle.
Connect the pressure gauge [1]to the tool [2] with its tube «a»long enough for the gauge to be
positioned inside the vehicle.
Procedure.
Start the engine.
Engage first gearand start the engine.
Engage the gears up to third gear.
Decelerate to 2000 rpm.
Gradually accelerate.
Check the pressure: 0.95 ± 0.05 bar.
Remove the tools, refit the collars (3) and the sleeve.
B1BP1ZXD
Engine: RHY
XSARA PICASSO
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INJECTION
CHECKS: TURBO PRESSURE
Tools.
[1]Pressure gauge for checking boost pressure: 4073-T.A Kit 4073-T
[2] Sleeve for checking boost pressure: 4185-T
[3]Adaptor sleeve: 4229-T
Checks.
IMPERATIVE: respect the following checking requirements: Engine at running temperature.
Vehicle in running order at full load.
Preparation.
Remove the collar fixing (3).
Insert the tool [2]connected with tool [3], between the pipe (1)and the duct (2).
Position tool [1]in the vehicle.
Connect the sleeve [2]to the tool [1]with its tube «a».
Procedure.
Start the engine.
Engage first gear and start the engine.
Engage the gears up to third gear.
Decelerate to 1000 rpm.
Accelerate hard, and check the pressure: 0.6 ± 0.05 bar
(1500 rpm).
Accelerate freely in kick-down (changing from fourthto third gear).
Check the pressure: 0.95 ± 0.05 bar (between 2500and 3500rpm).
Remove the tools, reposition the pipe (1)and refit the collar (3).
B1HP12JD
Engine: RHZ
XSARA PICASSO
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INJECTION
CHECKING THE AIR SUPPLY CIRCUIT
B1BP343C
B1BP344C
Engine: RHR
B1BP345C
Checking the warm air opening.
Remove:
- The air duct (4).
- The air duct (5).
- The air duct (6).
Connect the tool [1]on the warm air butterfly control diaphragm at «e».
Apply a vacuum of 0,7 ± 0,2, the warm air butterfly «f»should be fully open.
Checking the cold air closing.
Connect the tool [1]on the cold air butterfly control diaphragm at «g».
Apply a vacuum of 0,65 ± 0,2, the cold air butterfly «h»should be fully closed.
Refit:
- The air duct (4).
- The air duct (5).
- The air duct (6).
C4
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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: 9607-T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the ball-joints on the gearbox lever.
Lock the cable lengths with the ball-joint locking keys.
WARNING: Do not use any tool to unclip the ball-joints.
To unlock the ball-joint, press at the centre «a», then pull the ball-joint upwards.
NOTE:Changing an individual ball-joint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ
XSARA - XSARA PICASSO
B2CP3BXC
B2CP3BYC
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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1]Tool for positioning the gear lever: 9607-T
Adjustments.
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 ball-joint keys at «a».
Place the gear selection and control levers on neutral.
Lock the cable lengths with the ball-joint 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 - WJY - 8HX - 8HZ - 9HZ - 9HY - RHY - RHZ
XSARA - XSARA PICASSO
B2CP3C6CB2CP3C0C
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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS
Engine: RHR
B2CP3ZQD
Adjustment NO
Length A (mm)
Gear engagement control cable723 ± 2
Adjustment YES at «b»
Length B (mm)
Gear selection control cable674 ± 2
NOTE:In order to differentiate the two gear control cables when they
have been removed, the gear engagement cable has a black colour
identification on the sleeve stop at «a».
Adjustment of the gear selection control cable
C4
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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX
Precautions to be taken
Repairs on mechanical components.
Never place the gearbox on the ground without protection.
In order to avoid breaking the input shaft ring, it is imperative
that the
converter retaining bracket should be in place when handling the
gearbox.
It is imperative
to use the centring peg and the converter retaining
bracket to couple the gearbox on the engine.
After coupling the gearbox on the engine, remove the centring peg. Modification of the oil usage counter value.
Exchanging the gearbox ECU:
- Note down the gearbox counter value.
- Transfer the value read into the the new gearbox ECU.
Exchanging the gearbox:
- Initialise the oil usage counter to 0.
Draining the gearbox:
- Initialise the oil usage counter
(follow the diagnostic tool procedure).
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