plug Citroen C3 2004 1.G Owner's Manual

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: 6FZ RFN RFS WJY 8HV 8HY 8HZ 9HZ 9HY RHY RHZ
Tightening torques (m.daN).
(23)
Clutch bearing guide (3 screws): 1,25 ± 0,2
(24)
Clutch housing (13 screws): 1,3 ± 0,2
(25)
Primary shaft nut (1 screw):7,25 ± 0,5
(26)
Secondary shaft nut (1 screw): 6,5 ± 0,5
(27)
Yoke retaining screw (2 screws): 1,5 ± 0,2
(28)
Differential gearwheel screw (2 screws): 6,5 ± 0,5
Reverse gear switch (1 screw): 2,5 ± 0,3
(29)
Differential housing (4 screws): 5 ± 0,5
(30)
Breather pipe:1,7 ± 0,2
(31)
Rear housing cover screws (7 screws):1,25 ±0,2
(32)
Topup plug (1 screw):2,2 ±0,2
(33)
Differential housing screws (4 screws):1,25 ±0,2
(34)
Drain plug (1 screw):3,5 ±0,3
B2CP3BRD
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
Tightening torques (m.daN).
(1)
Oil flow modulation electrovalve fixing: 1 ± 0,2
(2)
Heat exchanger fixing:5 ±1
(3)
Output speed sensor fixing:1 ±0,2
(4)
Output speed sensor fixing: 1 ± 0,2
(5)
Oil overflow and drain fixing: 4 ± 0,2
(6)
Oil level plug:2,4 ±0,4
(7)
Oil pressure sensor fixing: 0,8 ± 0,1
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3EDDB2CP311D

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
B2CP3EED
Tightening torques (m.daN).
(8)
Fixing of converter on diaphragm
Pretightening
: 1 ± 0,1Tightening:3 ±0,3
(9)
Plug fixing: 0,8 ± 0,2
(10)
Gearbox fixing on engine: 5,2 ± 1
AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
Tightening torques (m.daN).
A: EW7
and EW10engines
Hydraulic block fixing.
Centre the hydraulic block, using screws (11)and (12).
Pretighten(no strict order): 0,9 Slacken: All 7 screws Tighten(respect the order indicated):0,75
NOTE:
The screw (11)is shouldered.
B: DW10engine.
Hydraulic block fixing.
Centre the hydraulic block, using screws (11)and (12).
Pretighten(no strict order): 0,9 Slacken:All 7 screwsTighten(respect the order indicated):0,75
NOTE:
The screw (11)is shouldered.
(13)Fixing of selector lever position switch: 1,5 ± 0,2
(14) Oil filler plug: 2,4 ± 0,4
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3EFDB2CP3EGC

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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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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Thread of oil then "dripdrip".
Refit the plug (3), Tighten to 2,4± 0,2 m.daN.
"Dripdrip" or nothing.
Refit the oil level plug (3).
Stop the engine.Add
0.5 litresextra oil into the gearbox.
Repeat the oil level procedure.
NOTE:The level is correct at the moment the thread of oil becomes “dripdrip”.
Refit the oil level plug
(3)(equipped with a new seal), tighten to2,4±0,2 m.daN.
Checking the oil level (continued).
Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.
An excessive level of oil can lead to the following consequences:
Oil heating up abnormally,
Oil leaks.
A level that is too low will result in the destruction of the gearbox.
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AZD

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ELECTRICAL
SYSTEMNAGARES 960411P
CARTIER 735068
NAGARES 960411P
CARTIER 735068
NAGARES 960411P
NAGARES 960411P
CARTIER 735068
NAGARES 960411P
NAGARES 960411P
CARTIER 735068
CARTIER 735068
NAGARES 960411P
CARTIER 735068
NAGARES 960411P
CARTIER 735068
NAGARES 960411P NGK YE04
NGK YE04
NGK YE04
BERU 0 100 226 371
CHAMPION CH 185
NGK YE04
CHAMPION CH170
CHAMPION CH 170
CHAMPION CH 170
PREHEATING AND STARTING SYSTEMSTOUS TYPES
Vehicles models
Preheater plugs Preheater control unitPre/Post heating (pre-heating duration at 20°C)
C2
C3
XSARA
PICASSO1.4 HDi
1.4 HDi
1.4 HDi 16V
1.9 D
1.4 HDi
2.0 HDi
2.0 HDi
2.0 HDi8HX
8HW
8HX
8HV
8HY
WJY
8HZ
RHY
RHZ
RHY
Controlled by the diesel injection ECU.
10s / 150s
Controlled by the diesel injection ECU.

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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
Move aside the radiator/condenser assembly.
Remove the plug (6), using tool [2].
Support the radiator/condenser assembly thus moved aside.
Remove the filtering/drying cartridge
(7), using pliers.
Refitting.Refit the filtering/drying cartridge (7).
Clean the threads of the plug (6).
It is essntial to change the Oring seals (8).
Lubricate the Oring seals (8)with aircon compressor oil.
Refit:
The plug
(6), using tool [2], tighten to 1,4 ±0,2 m.daN.
The brackets (5).
The screws (4).
The cardboard from the radiator harness.
The nuts
(1).
The air filter assembly (3).
Couple the hose (2).
Recharge the circuit (R134.a) (according to equipment)
(see corresponding operation).
Check the operation of the air conditioning.
C5HP14NCC5HP14PCC5HP14QC
XSARA PICASSO