Clutch disc Citroen C3 2004 1.G Workshop Manual

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GEARBOX
TRANSMISSION
281
CLUTCH SPECIFICATIONS C2
Engine type HFX KFV NFU 8HX
Gearbox type Supplier
BVM BVM/BVMP (*)BVM/BVMP (*)BVM/BVMP (*)
MA 5/S MA 5 N/L MA 5 S/L MA 5/0
Mechanism / typeVALEO LUK
Engine type180 CP0 3400 200 P 3900
Bearing supplier / heightSKF 17 mm
Clutch disc11 R 10??
Ø of lining.Ext/Int180/127200/134
Quality of lining408
1.1i 1.4i 1.6i 16V1.4 HDi
(*): BVM = Manual gearbox.
: BVMP = Piloted manual gearbox.

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
C3 C3 PLURIEL
Engine type HFX KFV KFU NFU 8HX 8HW 8HV 8HY
Gearbox type Supplier
MA/5 BE4/5
Mechanism / typeVALEO ? LUK
Engine type180 CPO 3400200 MF
200 P 3900 230 P 4700
3850
Clutch disc11 R 10 X 200 VTB
Ø Garniture.Ext/Int180/127 ? 200/134 228/155
Quality of liningF408
1.1i 1.4i 16V 1.4 HDi1.4 HDi 16V1.4i 1.6i 16V

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA
Engine type KFW NFU RFN RFS
Gearbox type Supplier
MA/5 MA/5 BE4/5
Mechanism / typeVALEO
Engine type180CPO 3400 200 CPR 3800 230 DNG 4700 215 DT 5250
Clutch disc180 XJF 73 C 200X(D95) 11A12X 230 DNG 4700 215 FD 95
Ø Garniture.Ext/Int180/127 200/137 228/155 215/147
Quality of liningF 408 F 808
1.4i 1.6i 16V2.0i 16V

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS
XSARA
Engine type 8HZ WJY RHY RHZ
Gearbox type Supplier
BE4/5
Mechanism / typeLUK
Engine type200 P 4200 200 P 3700 230 P 4700 235 T 5700
Clutch disc215 F (D 93) 22 BX 228 228D
Ø Garniture.Ext/Int200/134 200/134 230/155 235/155
Quality of liningF 408F202
1.4 HDi 1.9 D2.0 HDi

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CLUTCH
GEARBOX
TRANSMISSION
CLUTCH SPECIFICATIONS XSARA PICASSO
Engine type NFV 6FZ RFN 9HZ 9HY RHY
Gearbox type Supplier
BE4/5
Mechanism / typeVALEO LUK
Engine type200 DNG 3800 230 DNG 4700 215 DT 5250 225 DNG 5100 230 P 4700
Clutch disc200X(D95) 230 DNG 4700 215 FD 95 228
11A12X
Ø Garniture.Ext/Int200/137 228/155 215/147 225/150 230/155
Quality of liningF410 F 808 F 810 DS F408
1.6i 1.4 HDi 16V2.0 HDi1.8i 16V 2.0i 16V

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CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: HFX KFV NFU 8HX 8HW
Tightening torques (m.daN).
(26)
5th gear cover fixing screw(3 screws): 2,2 ± 0,2
(27) Reverse gear switch (1 screw): 2,5 ± 0,5
(28)Drain plug (1 screw):3,3 ± 0,3
(29) Topup plug (1 screw): 3,3 ± 0,3 (*)
(*) =
The oil topup plug is discontinued from RPO 9919
Features.This gearbox:
has no adjustment. has a reverse gear braking device
(5th gear synchroniser).
has a device for prohibiting a change from 5th gear into reverse gear.
The clutch control has a balljoint mounted declutch fork.
Lubrication.Oil capacity :2 ±0,15 Litres.Checking the oil level: No oil level check (*)Lubrication interval:Lubricated «for life».
NOTE:There should be a visual check on the sealing at each engine oil
change.
B2CP3SSD
C2 C3 C3 PLURIEL

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RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Safety requirements.
ESSENTIAL:Given the special features of the MA type piloted
manual gearbox, observe the requirements detailed below.
IMPERATIVE: Always disconnect the battery negative terminal
before operating on the actuators.
NOTE:
After disconnecting the battery, never try to remove the clutch
actuator on the vehicle before having checked that it is in the closed
position
(rod pushed in).
IMPERATIVE:After Sales checks done with the engine running must be
performed with «Neutral»engaged and the handbrake on (unless there
is a clear mention otherwise in the repair procedures).
IMPERATIVE:The areas of movement of the clutch fork and of the gear
engagement lever must always be kept free during the actuatoroperating phases.
CLUTCH
GEARBOX
TRANSMISSION
IMPERATIVE:When initialising the clutch actuator and/or gearbox
actuator, do not allow any person to walk or stand in front of the vehicle.
WARNING:When the engine is running, it is forbidden to perform
repairs on the clutch and gearbox actuators on the vehicle (whether
manually or using a diagnostic tool).
WARNING:Each time the driver’s door is opened and each time the
igntion is switched on, the gearbox ECU prompts the initialising of the
clutch and gearbox actuators
(there is movement of the clutch fork and
of the gear lever).
WARNING:Whether the ignition is switched on or not, an action on the
gear selector causes the clutch fork and the gear engagement lever to
move on the gearbox.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Operations on electrical components.Do not disconnect:
The battery when the engine is running.
The ECU with the ignition switched on.
The clutch and gearbox actuators with the ignition switched on.
When carrying out electrical checks: The battery must be correctly charged.
Never use a voltage source higher than 16V.
Never use a lamp to supply an actuator directly.
Before disconnecting connector, check: The condition of the various contacts (for deformation, corrosion, etc).
The presence and the status of the mechanical unlocking.
Driving the vehicle.
IMPERATIVE:
Never move the vehicle with the ignition switched off.
Never push the vehicle to attempt to start it
(impossible with a piloted
manual gearbox).
Towing.
Conditions for towing.
It is necessary to lift the front of the vehicle to tow it, after having
positioned the gear lever in neutral. If there is a gearbox fault or
malfunction, the vehicle can remain immobilised depending on theseriousness of the fault.
If a gear is engaged,the conditions for immobilisation of the
vehicle are:
Combustion engine stopped (the engine should not be started).
The clutch is open (clutched).
In these conditions are met, you can lift the front of the vehicle to tow it.
If it should not be possibe to lift the front of the vehicle, there are
ways to unblock it:
Engage «N», using a diagnostic tool.
Engage «N», without using a diagnostic tool.
Engines: HFX KFV NFU 8HX
C2

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: MA PILOTED MANUAL GEARBOX
Engines: HFX KFV NFU 8HX
Engaging of «N», without using a diagnostic tool (continued).
Preliminary operation:
Disconnect the battery negative terminal.
Remove the air filter.
Use a
22 mmspanner.
Use the spanner to lift the gear engagement lever the maximum possible until
the axis
«A»of the engagement lever is perpendicular to the axis «B»(mid
point of the gear engagement lever).
When this position is attained, position
«N»is engaged.
B2CP3L8D
C2

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CLUTCH
GEARBOX
TRANSMISSION
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