Clutch Citroen BERLINGO 2004 1.G Repair Manual

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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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GEARBOX
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RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
If a gearbox malfunction occurs, there are two possible
configurations depending on the seriousness of the fault:
Gearbox in backup mode with a replacement programme of
(the
fault values are taken in substitution).
Gearbox in backup mode with an emergency programme (3rd
hydraulic).WARNING:In the emergency programme, an impact is felt
when changing P/R, N/R and N/D.
Réception client.
Discuss with the customer, to find out all the malfunction symptoms.Oil quality Oil level.
Oil quality.
If the gearbox has suffered a serious fault resulting in a malfunction
or the destruction of a clutch, the oil will overheat and become
contaminated with impurities: the oil is said to be
«burnt».
This is characterised by a black colour and the presence of an
unpleasant smell.
ESSENTIAL: The gearbox must be replaced.
Oil level (see corresponding operation).
An excessive oil level can result in the following consequences:
Excessive heating of the oil.
Oil leaks.
An insufficent level causes the destruction of the gearbox.
Top up the level of oil in the gearbox (if necessary).
Check using a diagnostic tool.
Read the fault codes
(engine and gearbox).
Absence of fault codes.Carry out parameter measures, actuator tests and a road test.
Presence of fault codes.Carry out the necessary repairs.
Delete the fault codes.
Carry out a road test to check the repair and, if need be, modify the
gearbox ECU parameters
(this is essential after an initialisation
of the ECU).
XSARA XSARA PICASSO
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox

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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

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
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
imperativethat
the converter retaining bracket should be in place when handlingthe gearbox.
It is
imperativeto 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).
C3 XSARA XSARA PICASSO

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GEARBOX
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Engines: KFV NFU RFN RHZ
Downloading.
Updating the gearbox ECU by downloading:
Follow the procedure using the diagnostic tool.
The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
After the downloading operation, carry out the following: A clearing of faults.
A pedal initialisation.
A reinitialisation of the autoadaptives.
A programming
(if necessary).
A writing of the value of the oil usage counter previously read.
A road test.
ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU

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GEARBOX
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Engines: KFV NFU RFN RHZ
Updating the value of the oil usage counter.
Using PROXIA.
Access to reading and recording of the oil counter is via the menu:
«Configuration
(integrated circuit button)/ Oil counter».
Adjustment of the oil counter value is done in incremental steps of
2750units.
Using LEXIA or ELIT.Access to reading and recording of the oil counter is via the menu:
«Oil counter».
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
Downloading.
ECU downloading procedure:
Follow the diagnostic tool procedure.
A new ECU or downloaded update is always configured with the
following options:
SHIFT LOCK gear selection lever position.
Without OBD outlet
(depollution L4).
If the ECU is to be fitted to a vehicle with depollution
L4or not
equipped with gear lever locking safety: Perform a configuration operation.
Pedal initialisation.
A pedal initialisation must be carried out in the following cases:
Replacement of the automatic gearbox ECU.
Replacement of the automatic gearbox.
Downloading of the ECU configuration.
Adjustment or replacement of the accelerator cable.
Replacement of the butterfly potentiometer.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOXC3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU