cap Citroen BERLINGO 2004 1.G Repair Manual

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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
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Tools.
[1]
Filling cylinder: ().0341
Draining.
IMPERATIVE:
The gearbox should be drained when the oil is warm (at least 60°C), to
eliminate the impurities in suspension in the oil.
NOTE:Draining is partial, the converter cannot be completely emptied.
Remove the drain plug
(1).
NOTE:Approx. 3 litres of oil should flow out.
Filling.
Refit the drain plug (1)(equipped with a new seal), tighten to2,4 ±0,2 m.daN.
Remove the oil filler cap (2).
Use tool [1].
Oil capacity for dry gearbox:

EW engine:5,85 litres.
DWengine:5,40 litres.
Oil remaining after draining:
3 litres(approx.).Quantity of oil to be put in :3 litres(approx.).Refit the oil filler cap (2)(equipped with a new seal), tighten to 2,4± 0,2 m.daN.
Initialise the oil wear counter (follow the diagnostic tool procedure).
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AYD
B2CP31GC

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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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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
XSARA
Powerassisted steering assembly
Tightening torques (m.daN).
High pressure tube (Rubber seal pump side)
Powerassisted valve and pump union: 2.5
Return pipe.
Powerassisted valve union: 2.5
(16)Upper front fixing (E3) : 2.5
(17) Upper rear fixing (E3) : 2.2
(18)Fixing (E3) : 2.2
Tightening sequence.
Tighten screws (16)and (18).
Lightly tighten screw
(17), then fully tighten.
Pressure switch on the pressure circuit.
Switch opens 30to 35 Bars.
Switch closes 25 Bars.
Tighten to :
2 m.daN. Powerassisted steering system capacity =
1 litre.
Oil type:TOTAL FLUIDE ATX.
SAGINAW Pump adjustment = 100 Bars ± 5.
Pump shaft threading 3/8 16 threads per inch.
B3EP045D

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AXLES
SUSPENSION
STEERING
POWERASSISTED STEERING SPECIFICATIONS
Tightening torques (m.daN).
Unions between pump unions and
power steering valve: 2 ± 0.3
(16)Fixing screw: 2.2 ± 0.3
(17)Fixing screw: 2.2 ± 0.3
(18)Fixing screw: 2.2 ± 0.3
NOTE:
Coat the threads with product «E3».
A pressure switch is implanted in the hydraulic piping between the
high pressure pump and the power steering valve. Opening pressure =
30 / 35 Bars.
Closing pressure = 25 Bars minimum.
Tightening torque = 2 ± 0.2.
Capacity of power steering circuit =
1 Litre.
Oil quality = TOTAL FLUIDE ATX.
Power steering pump: Supplier SAGINAW.
Pump adjustment = 100 ± 5 Bars.
Pump shaft threading 3/8 16 threads per inch.
B3EP118D
XSARA PICASSO

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TU EW
DW
XU10
TU
EW7 DW10
BRESIL ALL TYPES
590 gr + 0 50 gr
725 gr + 0 50 gr
675 gr ± 50 gr
775 gr ± 25 gr
AIR CONDITIONING R 134 a (HFC)
Vehicle Engines DateRefrigerant
refillCompressor
Variable
CapacityOil quantity cc
Oil reference
AIRCON
C2
SD 6 V 12
SD 7 V 16
SD 6 V 12
SD 7 V 16135 SP 10
12/1999
#
03/2001 #
XSARA
XSARA
PICASSO
ALL TYPES 05/2003 #600 + 0 50 gr
09/2000
#
C3ALL TYPES11/2001 #625 + 0 50 grC3 Pluriel

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AIRCONAIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Tools.
[1]
Charge station :(according to workshop equipment)[2]TORX adaptor: TORX 70 FACOM
[3]Inertia extractor:1671T Tool kit 4114T
[4]Endpiece Ø 20 : 1671T.D20
[5]Set of plugs: ().0188.T
[6]Circlip pliers: FACOM
Removing.
Depressurise the aircon circuit, using tool [1].
Remove the grille.At
«a», remove the pin and the plastic cover.
Unclip the condenser at «b»and «c», using a screwdriver.
Tilt the condenser towards the front.
Lift and release the condenser.Clean the area around the cap
(3).
Remove the plastic cap (3), using tool [2].
Remove the safety circlip (4), using tool [6].
Position the tool [3]and[4]in the aperture of the cartridge (5).
Extract the cartridge from the reservoir (6), using tool [3]and [4].
Block the reservoir (6), using tool [5].
C4AP163CC4AP164CC4AP166CC4AP165C
C2 C3 C3 PLURIEL

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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
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM C3 C3 PLURIEL KFV
CHECKING TEMPERATURES (Continued)
Vehicle using R134.a fluid
(Compressor with variable capacity)
Ambient temperature in °C
Temperature
at the central
air vents
in °CEngines
V ehicle
C3
C3 PlurielKFV
22 ± 2 17,6 ± 2 14,4 ± 2 11,5 ± 2 7,6 ± 2 7,2 ± 2
NFU18,5 ± 2 15 ± 2 12,5 ± 2 10 ± 2 8,5 ± 2 6,5 ± 2
8HX 8HW22 ± 2 17,6 ± 2 14,4 ± 2 11,5 ± 2 7,6 ± 2 7,2 ± 2
TU18 ±217 ±214,5 ±211 ± 2 8,5 ± 2
8 ±2
EW19 ± 2 18 ± 2 15 ± 2 12 ± 2 10 ± 2
DW15 ±215,5 ±211 ± 2 9 ± 2 7 ± 2 5 ± 2
All types22 ±3 16 ± 3 12,5 ± 3 10 ± 3 8 ± 3 6,5 ± 3
XSARA
XSARA
PICASSO40 35 30 25 20 15

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26 ± 2 23,2 ± 2 21 ± 2 19,2 ± 2 15,3 ± 2 15 ± 2
4,3 ±2 3,4 ± 2 3,1 ± 2 2,8 ± 2 2,7 ± 2
25,2 ±223,6 ± 2 21,4 ± 2 20 ± 2 17,6 ± 2 14,5 ± 2
3,5 ± 2 3 ± 2 2,8 ± 2 2,5 ± 2 2,4 ± 2
26,2 ± 2 23,2 ± 2 21 ± 2 19,2 ± 2 15,3 ± 2 15 ± 2
4,3 ± 2 3,4 ± 2 3,1 ± 2 2,8 ± 2 2,7 ± 2
CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM
Checking pressures
Tools. 1
charging station. 2thermometers.
Once the preliminary conditions, vehicle equipment and checks havebeen fulfilled
(see table). After the air conditioning has been on for
three minutes, record the following parameters: The temperature of the air coming from the central vents
(see table).
The High Pressure. The Low Pressure.
Compare the values recorded with the table below, or the graphs.
Ambient temperature in °C40 35 30 25 20 15
VehiclesEngines
C3
C3
C3 PlurielKFV
NFUHigh pressure (Bars)
Low pressure (Bars)
Low pressure (Bars)
High pressure (Bars)
Low pressure (Bars)8HX 8HWVehicle using R134.a fluid
(Compressor with variable capacity)
High pressure (Bars)
AIRCONAIRCON
C3 C3 PLURIEL XSARA XSARA PICASSO KFV