clutch cable adjustment Citroen XSARA 2005 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine PRESENTATION
THIS HANDBOOKsummarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate
handbook.
The handbook is divided into groups representing the main functions:
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
Angl-t2-Index-2005 9/01/06 10:05 Page I

Downloaded from www.Manualslib.com manuals search engine 331
CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX CONTROLS
Engines: KFU - NFU
B2CP3ZCD
Gear controls
C4
The gear selection and engagement cables have no adjustment.
NOTE:The two gear control cables cannot be separated.
(1)Gear engagement ball-joint: Ø 10 mm
(2)Gear engagement control cable
(3)Gear control lever
(4)Gear selection control cable
(5)Gear selection ball-joint: Ø 10 mm
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 331

Downloaded from www.Manualslib.com manuals search engine 335
CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ
The gear selection and engagement cables have noadjustment.
Gear controls.
(1)Gear engagement ball-joint: Ø 10 mm
(2)Gear engagement control cable
(3)Gear control lever
(4)Gear selection control cable
(5)Gear selection ball-joint: Ø 10 mm
B2CP3ZOD
C4
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 335

Downloaded from www.Manualslib.com manuals search engine 339
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: 9607-T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the ball-joints on the gearbox lever.
Lock the cable lengths with the ball-joint locking keys.
WARNING: Do not use any tool to unclip the ball-joints.
To unlock the ball-joint, press at the centre «a», then pull the ball-joint upwards.
NOTE:Changing an individual ball-joint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ
XSARA - XSARA PICASSO
B2CP3BXC
B2CP3BYC
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 339

Downloaded from www.Manualslib.com manuals search engine 340
CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1]Tool for positioning the gear lever: 9607-T
Adjustments.
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 ball-joint keys at «a».
Place the gear selection and control levers on neutral.
Lock the cable lengths with the ball-joint 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 - WJY - 8HX - 8HZ - 9HZ - 9HY - RHY - RHZ
XSARA - XSARA PICASSO
B2CP3C6CB2CP3C0C
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 340

Downloaded from www.Manualslib.com manuals search engine 342
CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS
Engine: RHR
B2CP3ZQD
Adjustment NO
Length A (mm)
Gear engagement control cable723 ± 2
Adjustment YES at «b»
Length B (mm)
Gear selection control cable674 ± 2
NOTE:In order to differentiate the two gear control cables when they
have been removed, the gear engagement cable has a black colour
identification on the sleeve stop at «a».
Adjustment of the gear selection control cable
C4
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 342

Downloaded from www.Manualslib.com manuals search engine 343
CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: ML6 GEARBOX CONTROLS
Engine: RHR
Peform the following operations simultaneously:
- Move the cylinder «f»in the direction of the arrow «e».
- Pull the locking key «c»in the direction of the arrow «d».
Check that the gear lever (18)is in the mid position on the control housing (17).
Couple the ball-joint (19).
Press on the locking key «c».
IMPERATIVE: Check that all the gears engage.
B2CP3ZWD
Adjustment of the gear selection control cable
C4
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 343

Downloaded from www.Manualslib.com manuals search engine 350
CLUTCH
GEARBOX
TRANSMISSION
AL4 GEARBOX CONTROLS
Engines: NFU - RFJ
B2CP3H8C
Gearbox end.
The automatic gearbox is controlled by a cable.
«c»Push-button
(1)Control lever with ball-joint
(2)Automatic adjustment
Pull out the button to adjust the control.
Push it in to lock the adjustment of the control.
(3)Sleeve stop
(4) Selection control locking clip (5)on the sleeve stop (3)
C4
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 350

Downloaded from www.Manualslib.com manuals search engine 353
CLUTCH
GEARBOX
TRANSMISSION
AL4 GEARBOX CONTROLS
Gearbox end.
The automatic gearbox is controlled by a cable.
«c»or «d»Push-button.
(1)Control lever with ball-joint
(2)Automatic adjustment
(pull out the button to adjust the control, push it in to lock the
adjustment of the control)
(3)Sleeve stop
(4)Selection control locking clip (5)on the sleeve stop (3)
Engines: KFV - RFN
C4 - XSARA - XSARA PICASSO
B2CP3N7C
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 353

Downloaded from www.Manualslib.com manuals search engine 355
CLUTCH
GEARBOX
TRANSMISSION
AL4 GEARBOX CONTROLS
Gearbox end.
(1)Control lever
(2)Automatic adjustment
(3)Sleeve stop
The automatic gearbox is controlled by a cable.
Engines: NFU - RFN - RHZ
XSARA
B2CP3AEC
Angl.-t2-page306-360-2005 9/01/06 10:20 Page 355