Citroen BERLINGO 2005 1.G Workshop Manual

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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
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ
Length A (mm)
Gear engagement control cable643 ± 2
Length B (mm)
Gear selection control cable670 ± 2
NOTE:The gear engagement cable has a black colouridentification
on the sleeve stop at «a».
B2CP3Z1CB2CP3Z2C
C4
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFU - RFN - RFK - 9HX - 9HY - 9HZ
Features.
Unlocking a sleeve stop:
- Press on the tabs of the clip (6)at «b», using a flat screwdriver.
- Disengage the sleeve stops from their supports by pulling upwards.
B2CP3Z3D
C4
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX CONTROLS
Engines: NFV - 6FZ - RFN - WJY - 8HX - 8HZ - 9HY - 9HZ - RHY - RHZ
(1)Gear control lever
(2)Gear engagement control cable (*)
(3) Gear selection control cable (*)
(4)Gear selection ball-joint Ø 10 mm
(5)Gear engagement ball-jointØ 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: 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
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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
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CLUTCH
GEARBOX
TRANSMISSION
ML6 GEARBOX CONTROLS
Engine: RHR
Gear controls.
(1)Gear engagement ball-joint Ø 10 mm
(2)Gear selection ball-joint Ø 10 mm
(3)Gear engagement control cable
(4)Gear control lever
(5)Gear selection control cable
(6)Reverse gear unlocking cable
(7)O-ring seal
(8)Reverse gear unlocking device
B2CP3ZPD
C4
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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
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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
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GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX
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 imperative
that the
converter retaining bracket should be in place when handling the
gearbox.
It is imperative
to 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).
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