controls Citroen BERLINGO 2004 1.G User Guide

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: MA/5 GEARBOX CONTROLS
Engines: KFW NFU 8HZ
1 Gear lever.2 Gear control bar.3 Engagement rod.4 Gear selection rod.5 Torque reaction rod.6 Gear engagement balljoint.7 Fixed point on gearbox.
Adjustment.The gear control assembly is not adjustable.
The rods do not have threaded ends.
Features.Grease the gear engagement balljoint.
WARNING:To secure the balljoints, set the
gearbox control to neutral.After fitting the gear
control assembly, check that all the gears will
engage without any
”tight spot”.
B2CP27WD
XSARA

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: 8HV 8HY
(1)Gear control lever.
(2)Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(*)
These two cables cannot be separated.
B2CP3J3D
C3

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Engines: 8HV 8HY
(4)Gear engagement balljoint Ø 10 mm.
(5) Gear selection balljoint Ø 10 mm.
Length ALength B
Gear
selection907 mm 645 mmcable(5)
Length D Length C
Gear
engagement965 mm 610 mmcable(4)B2CP3J5D
B2CP3J4C
C3

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Engines: 8HV 8HY
Adjustment.
The gear selection control and gear engagement
control cables cannot be adjusted.
To release the balljoint, press at
«d»then pull the
balljoint upwards.
To release sleeve stops:
Press on the tabs of the clip
(6)at «a».
Disengage the sleeve stops from their supports.
B2CP3J6D
C3

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
(1)Gear control lever.
(2) Gear engagement control cable.(*)
(3)
Gear selection control cable.(*)
(4)
Gear selection balljoint Ø 10 mm.
(5) Gear engagement balljoint Ø 10 mm.
(6) Flexible insulating grommet through the bulkhead.
(*)= These two cables cannot be separated.
B2CP3BWD
XSARA XSARA PICASSO

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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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AIRCONAIRCON
AIR CONDITIONING SYSTEM R 134.a
Testing procedure
Conditions inside the vehicle.
Positions of the air conditioning controls:
Maximum cold.
Maximum blower power.
Air distribution on
«ventilation»with the air vents open.
Position the air inlet flap to outside air.
WARNING:For RFTA (1), disconnect the air inlet motor connector, first
ensuring that it is in the outside air position.
(1) RFTA= Fully automatic air conditioning.
Test procedure.When all these conditions are met, proceed in the following order:
Measure the temperature in the workshop approx. one metre in front of
the vehicle’s air inlet grille.
Start the engine
(without the air conditioning, or the blower, operating)and wait for the cooling fan slow speed to trigger (should the engine tem
perature not rise sufficiently, it is permissable to increase the engine
speed to 2000 rpm)
.
Once it is sufficiently hot in the engine compartment, return the engine
to idle and commence the test.Switch on the air conditioning and adjust the engine speed to
2500 rpm.
In an ambient temperature of 40°C, the engine speed will be brought
down to 2000 rpm, in order for the pressure safety threshold to cut off the
compressor.
For further temperatures/pressures: see Tables and Graphs on following
pages
221, 222 and 226.
After
3 minutesof operation, note down the following 3 parameters:
The temperature of the blown air coming out of the 2 central air vents
(take the average).
The high pressure, via the intermediary of the clickfit union (at the
pressure reducer inlet).
The low pressure, via the intermediary of the clickfit union (at the pressure
reducer outlet).NOTE:The low and high pressures are absolute pressures.
When measuring the blown air temperatures, avoid any contact between
the thermocouple and the air vents.
At the conclusion of the test involving vehicles with
«RFTA»
ALL TYPES