gear change Citroen XSARA PICASSO 2004 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine 31
C2
CAP ACITIES (in litres)
GENERAL
HFX KFV NFU 8HX RPO 9884 8HX RPO 9885
3 3,25 3,75
1,51,81,5
2
2
±0,15
0,7 Litre version with front calipers Ø 48 / rear drums
0,8 Litre version with front calipers Ø 54 / rear discs
75,6
40 45
Diesel
P etrolC2
1.1i 1.4i 1.6i 16V 1.4 HDi
ESSENTIAL: Systematically check the oil level using the oil dipstick.
Engine type
Drain by gravity: engine
with filter change
Bandween min. and max.
MA5 5speed gearbox
MA5 piloted 5speed gearbox
Braking circuit
Cooling system
Fuel tank capacity

Downloaded from www.Manualslib.com manuals search engine 32
GENERALEngine type
Drain b
y gravity: enginewith filter changeBandween min. and max.
Drain by suction: enginewith filter changeBandween min. and max.5speed gearboxAutomatic gearboxAfter oil change
Braking circuit
Cooling system
Fuel tank capacity
RPO 9884 RPO 9885 RPO 9884 RPO 9885
HFXKFV KFU NFU 8HX 8HW 8HX 8HW 8HV 8HY 8HV 8HY
33,753,253,75
1,5 1,2 1,5 1,8 1,5 1,8 1,5
3,1 3,1
1,5 1
221,9
0,7 Litreversion with front calipers Ø 48 / rear drums
0,8 Litreversion with front calipers Ø 54 / rear discs
7 7 5,7 5,6
45
C3 CAPACITIES (in litres)
Diesel
P etrolC3
1.1i
1.4i
1.4i
16V1.4 HDI 16V
ESSENTIAL:systematically check the oil level using the oil dipstick.
(1)= The gearbox is lubricated for life. (For yorr information, the TOTAL capacity is 5,85 litres, after draining:3 litres).
AUTO.
1.4 HDi1.6i
16V
(1)

Downloaded from www.Manualslib.com manuals search engine 33
GENERAL
1.4i 1.6i 16V 1.4 HDi
Engine type KFV NFU 8HX
Drain b
y gravity: engine with filter change 3 3,25 3,75
Bandween min. and max. 1,5 1,5 1,55speed gearbox2
Braking circuit0,7 Litre
version with front calipers Ø 48 / rear drums
0,8 Litre
version with front calipers Ø 54 / rear discs
Cooling system 7 5,7
Fuel tank capacity45
ESSENTIAL: systematicall
y check the oil level using the oil dipstick.
(1)= The gearbox is lubricated for life.(For yorr information, the TOTAL capacity is 5,85 litres, after draining : 3 litres)
CAPACITIES (in litres)
PetrolC3 Pluriel
Diesel
C3 PLURIEL

Downloaded from www.Manualslib.com manuals search engine 263
INJECTION
CHECKS: TURBO PRESSURE
Engines: 8HX 8HW
B1BP2NXD
C5FP0F5C
C2 C3
Tools.
[1]Pressure gauge for checking boost pressure: 4073T.A
[2]Sleeve for checking boost pressure: ().0171.F
Checks.IMPERATIVE: Respect the following test conditions:
Engine at operating temperature.
Vehicle in running order. Engine under full load.Preparation.
Remove the clips (1).
Fit the tool [2]in the place of the duct (2).
Couple the sleeve [2]on the pressure gauge [1]using the tube «a».Mode of operation.Position tool [1]in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of
1000 rpm.
Check the pressure:0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear).
Check the pressure:0,9 ± 0,05 bar(between 2500 and 3500 rpm).
Remove tools [1], [2]at «a».
Reposition the tube (2)and tighten the clips (1).

Downloaded from www.Manualslib.com manuals search engine 264
INJECTION
CHECKS: TURBO PRESSURE
Engines: 8HV 8HY
Tools.
[1]Pressure gauge for checking boost pressure: 4073T.A
[2]Sleeve for checking boost pressure: ().0171.F
Checks.
IMPERATIVE:
Respect the following test conditions:
Engine at operating temperature.
Vehicle in running order. Engine under full load.
Preparation.Remove the clips (1).
Fit the tool [2]in the place of the duct (2).
Couple the sleeve [2]on the pressure gauge [1] using the tube «a».Mode of operation.Position tool [1]in the vehicle.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of
1000 rpm.
Check the pressure:0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear)Check the pressure:0,9 ± 0,05 bar(between 2500 and 3500 rpm).
Remove tools[1],[2]at «a».
Reposition the tube (2)and tighten the clip (1).
C5FP0EJC
B1BP2NBD
C3

Downloaded from www.Manualslib.com manuals search engine 265
INJECTION
CHECKS: TURBO PRESSURE
Engines: 9HZ 9HY
IMPERATIVE: Respect the safety and cleanliness requirements.
Preparation.
IMPERATIVE: Respect the following test conditions:
Engine at operating temperature.
Vehicle in running order.
Engine under full load.
Connect the diagnostic tool to the vehicle’s diagnostic socket, carry out parameter measures.
Mode of operation.
Start the engine.
Engage first gear, start the vehicle.
Engage the gears up to third gear.
Decelerate to an engine speed of
1000 rpm.
Check the pressure:0,6 ± 0,05 bar (1500 rpm).
Accelerate freely (change from fourth gear to third gear).
Check the pressure:0,9 ±0,05 bar(between 2500 and 3500 rpm).
XSARA PICASSO

Downloaded from www.Manualslib.com manuals search engine 303
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

Downloaded from www.Manualslib.com manuals search engine 307
CLUTCH
GEARBOX
TRANSMISSION
MA/5 GEARBOX
Engines: KFW NFU
(29)Topup plug (x1): 2,5 ± 0,5.
(30)Drain plug (x1): 2,5 ± 0,5.
(31)Reverse gear switch (x1): 2,5 ± 0,5.
Strengthened MA gearboxes are marked with the letter «B»or «C»:«B»= Differential diameter 77 mm+ strengthened bearings.«C»= Differential diameter 77 mm+ strengthened bearings + strengthened
intermediate plate.
NOTE:All vehicles are equipped with clutch control by cable.
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 : Every 37,500 miles.
Lubrication interval : Lubricated «for life».
B2CP169D
XSARA

Downloaded from www.Manualslib.com manuals search engine 316
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

Downloaded from www.Manualslib.com manuals search engine 337
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