warning Citroen C2 2004 1.G Repair Manual

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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:9607T.
Place the gearbox in neutral.
Couple the cables on the lever.
Fit the balljoints on the gearbox lever.
Lock the cable lengths with the balljoint locking keys.
WARNING: Do not use any tool to unclip the balljoints.
To unlock the balljoint, press at the centre «a», then pull the balljoint upwards.
NOTE:Changing an individual balljoint is possible as long as the locking key is removed.
Unclip at «b», using two small screwdrivers.
Engines: NFV 6FZ RFN RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3BXCB2CP3BYC

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CLUTCH
GEARBOX
TRANSMISSION
CHECKS AND ADJUSTMENTS: BE4/5 GEARBOX CONTROLS
Tools.
[1] Tool for positioning the gear lever: 9607T.
Adjustements.
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 balljoint keys at «a».
Place the gear selection and control levers on
neutral.
Lock the cable lengths with the balljoint 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 RFS WJY 8HZ 9HZ 9HY RHY RHZ
XSARA XSARA PICASSO
B2CP3C6CB2CP3C0C

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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

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
B2CP3ECD
Identification.
«a»
Component reference.
WARNING:This gearbox benefits from a special CITROEN semisynthetic oil,
which cannot be mixed with any other oil.
The gearbox is lubricated for life.
AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
Refitting.
Proceed in the opposite order to removal.
Lubricate the support
(13).
New gear selection control.
Couple the balljoint(6).
WARNING:Do not deform the selection lever on the automatic gearbox.
Push in the component
(a) without bending the cable.
Check all the gear selection control positions.
Reused gear selection control.
Release the component (a).
Couple the balljoint (6).
Push in the component (a) without bending the cable.
Check all the gear selection control positions.
Engine: RFN
XSARA PICASSO
B2CP3GYD

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AXLES
SUSPENSION
STEERING
A < B = Positive figure: + = TOEIN
A > B = Negative figure: = TOEOUT
WARNING
AXLE GEOMETRY
Rear axle Front axle
Dissymmetry of lower camb8er 0° 18. Dissymmetry of lower castor at
0° 30’.
DISSYMMETRY OF LOWER CAMBER 0° 18’.
Distribute symmetrically, LH / RH wheel, the total tracking value.
All types (except CRD)
NFU
Vehicle TrackingCastor Camber Pivot angle
(± 0°18’) (± 0°30’) ± 0°30’
ADJUSTABLE Non adjustable
2 ± 1
0°18’±0°09’ 3°58’ 0°31’ 11°26’
NFU
Vehicle TrackingCastor Camber Pivot angle
±0°30’
ADJUSTABLENon adjustable
2 ± 1
0°18’± 0°09’ 4° 0°32’ 11°35’Tracking Camber
Non adjustable
5,5 ± 1
0°53’ ± 0°09’ 1°30’
TrackingCamber
Non adjustable
5,8 ±1
0°49’ ± 0°09’ 1°31’
All
Typesmm
0°
All
Typesmm
0°
B3CP02UC
C2
± 0°18’ ± 0°30’
HFX KFV 8HX HFX KFV 8HX

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AXLES
SUSPENSION
STEERING
A < B = Positive figure: + = TOEIN
A > B = Negative figure: = TOEOUT
WARNING
AXLE GEOMETRY
Rear axle Front axle
Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower castor at
0° 30’.
Dissymmetry of lower camber at 0° 18’.Distribute symmetrically, LH / RH wheel, the total tracking value.
All types (except CRD) Raised suspension Sports
Vehicle CRD Raised suspension Sports
Vehicle TrackingCastor Camber Pivot angle
(± 0°18’) (± 0°30’) (± 0°30’)
Adjustable Non adjustable
2 ± 1
0°19’±0°10’ 3°57’ 0°28’ 11°26’
Vehicle TrackingCastor Camber Pivot angle
(±0°30’)
Adjustable Non adjustable
2 ± 1
0°19’± 0°10’ 3°53’ 0°26’ 11°14’Tracking Camber (± 0°18’)
Non adjustable
5,5 ± 1
0°50’ ± 0°10’ 1°30’
TrackingCamber
Non adjustable
5,2 ±1
0°47’ ± 0°10’ 1°28’
All
Typesmm
0°
All
Typesmm
0°
B3CP02UC
C3
(± 0°18’) (± 0°30’)

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AXLES
SUSPENSION
STEERING
A < B = Positive figure: + = TOEIN
A > B = Negative figure: = TOEOUT
WARNING
AXLE GEOMETRY
Rear axle Front axle
Dissymmetry of lower camber at 0° 18’. Dissymmetry of lower castor at
0° 30’.
Dissymmetry of lower camber at 0° 18’.
Distribute symmetrically, LH / RH wheel, the total tracking value.
All types
Vehicle TrackingCastor Camber Pivot angle
(± 0°18’) (± 0°30’) (± 0°30’)
Adjustable Non adjustable
2 ± 1
0°18’± 0°09’ 3°53’ 0°26’ 11°14’Tracking Camber (± 0°18’)
Non adjustable
5,7 ± 1
0°51’ ± 0°09’ 1°30’
All
Typesmm
0°
B3CP02UC
C3 PLURIEL

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AXLES
SUSPENSION
STEERING
ESSENTIAL: When checking the suspensions, the vehicle should be at reference height.
XSARA
AXLE GEOMETRY
Values of the front and rear suspensions, at reference height
Tools.
Compress the suspension, to obtain the values at reference height.
[1]Set of two suspension compressors: 9511T.A
[2] Set of four straps : 9511T.B
[3] Set of four shackles :9511T.C
A > B =
Negative figure: – = TOEOUT
A < B = Positive figure: + = TOEIN
WARNING
B3CP04LC

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AXLES
SUSPENSION
STEERING
H1 = R1 – L1 H1’ = R1 – L1’
H1
= From the front suspension arm linkage bolt axis to the ground.R1= Radius of the front wheel when laden.L1= From the centre of the wheel to the front suspension arm linkage
bolt axis.
H1’= From the front jacking point to the ground.L1’= From the front jacking point to the radius of the front wheel when
laden.
H2 = R2 L2
H2
= From the rear axle silentblock face to the ground.R2= Radius of the rear wheel when laden.L2= From the centre of the wheel to the rear axle silentblock face.
AXLE GEOMETRY
Checks at reference height
NOTE:
To make the setting of reference height easier, it is acceptable to take the measurement from the flange of the jacking point.
WARNING: The values shown should only be used as guides. In case of doubt, check the settings at reference height
Rear heightFront height
B3CP05BCB3CP058DB3DP079C
XSARA PICASSO
Conditions for checking and adjusting:Tyres inflated to correct pressures. Vehicle at reference height. Steering rack locked at mid point(see corresponding operation).