too low Citroen C3 2004 1.G Repair Manual

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INJECTION
SPECIAL FEATURES: PARTICLE FILTER / CHECKING THE ADDITIVE PUMP
Engine: 9 HZ
IMPERATIVE: Respect the safety and cleanliness requirements.
Tools.
[1]
Manual pressure/vacuum pump: FACOM DA 16
[2]Additive container: ().1613.G Kit 1613
Checks.
IMPERATIVE: Respect the safety and cleanliness requirements specific to HDi engines.
IMPERATIVE: For all operations on the additive circuit, wear protective goggles and gloves that are
resistant to hydrocarbons.
Place the vehicle on a lift.
Raise the vehicle
To test the flow of the additive pump :
Uncouple the tube
(1).
Couple tool [2]on the outlet «a»of the additive reservoir.
Operate for 50 secondsthe actuator test «Additive pump»with the aid of LEXIA or PROXIA.
IMPERATIVE:The volume collected by the tool [2] should be 20 ± 5 ml.
NOTE:
Replace the additive pump if it is defective.
Couple the tube (1).
Operate the actuator test «Filling the tube: additive pump – additive injector», with the aid of LEXIAorPROXIA.
B1HP1UTC
XSARA PICASSO

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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
Engaging of «N», using a diagnostic tool.
Preliminary operations:
Battery voltage higher than 12.5 volts.
Ignition switched on.
Connect the diagnostic tool to the vehicle’s diagnostic socket.
From the diagnostic tool menus, select:
«DIAGNOSIS»
MA type piloted manual gearbox.
Actuator test.
Gearbox actuator test.
Gear engagement test.
N(neutral).
NOTE:The letter «N»should appear on the instrument panel.
If not, see the following solution:
Engaging of
«N», without using a diagnostic tool.
Engaging of «N», without using a diagnostic tool.
In this configuration, the gearbox actuator is blocked, gear engaged.
NOTE:This recovery solution is to be used solely in a case where the
attempt to make the gearbox actuator engage b via the diagnostic toolhas failed.
Engines: HFX KFV NFU 8HX
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

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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX
Engines: KFV NFU RFN RHZ
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
imperativethat
the converter retaining bracket should be in place when handlingthe gearbox.
It is
imperativeto 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).
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
Downloading.
Updating the gearbox ECU by downloading:
Follow the procedure using the diagnostic tool.
The downloading operation enables the automatic gearbox to be updated, or adapted to an evolution of the engine ECU.
Before commencing the downloading, take the value of the oil usage counter present in the automatic gearbox ECU.
After the downloading operation, carry out the following: A clearing of faults.
A pedal initialisation.
A reinitialisation of the autoadaptives.
A programming
(if necessary).
A writing of the value of the oil usage counter previously read.
A road test.
ESSENTIAL: Every update of the automatic gearbox ECU should be accompanied by an update of the engine ECU.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOX C3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU

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CLUTCH
GEARBOX
TRANSMISSION
Engines: KFV NFU RFN RHZ
Updating the value of the oil usage counter.
Using PROXIA.
Access to reading and recording of the oil counter is via the menu:
«Configuration
(integrated circuit button)/ Oil counter».
Adjustment of the oil counter value is done in incremental steps of
2750units.
Using LEXIA or ELIT.Access to reading and recording of the oil counter is via the menu:
«Oil counter».
Adjustment of the oil counter value is done by entering directly the
5 figures of the oil counter.
Downloading.
ECU downloading procedure:
Follow the diagnostic tool procedure.
A new ECU or downloaded update is always configured with the
following options:
SHIFT LOCK gear selection lever position.
Without OBD outlet
(depollution L4).
If the ECU is to be fitted to a vehicle with depollution
L4or not
equipped with gear lever locking safety: Perform a configuration operation.
Pedal initialisation.
A pedal initialisation must be carried out in the following cases:
Replacement of the automatic gearbox ECU.
Replacement of the automatic gearbox.
Downloading of the ECU configuration.
Adjustment or replacement of the accelerator cable.
Replacement of the butterfly potentiometer.
RECOMMENDATIONS PRECAUTIONS: AL4 AUTOMATIC GEARBOXC3 XSARA XSARA PICASSO
Procedure for initialising the automatic gearbox ECU

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Tools.
[1]
Filling cylinder: ().0341
Draining.
IMPERATIVE:
The gearbox should be drained when the oil is warm (at least 60°C), to
eliminate the impurities in suspension in the oil.
NOTE:Draining is partial, the converter cannot be completely emptied.
Remove the drain plug
(1).
NOTE:Approx. 3 litres of oil should flow out.
Filling.
Refit the drain plug (1)(equipped with a new seal), tighten to2,4 ±0,2 m.daN.
Remove the oil filler cap (2).
Use tool [1].
Oil capacity for dry gearbox:

EW engine:5,85 litres.
DWengine:5,40 litres.
Oil remaining after draining:
3 litres(approx.).Quantity of oil to be put in :3 litres(approx.).Refit the oil filler cap (2)(equipped with a new seal), tighten to 2,4± 0,2 m.daN.
Initialise the oil wear counter (follow the diagnostic tool procedure).
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AYD
B2CP31GC

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CLUTCH
GEARBOX
TRANSMISSION
DRAINING / FILLING / TOPUP: AL4 GEARBOX
Thread of oil then "dripdrip".
Refit the plug (3), Tighten to 2,4± 0,2 m.daN.
"Dripdrip" or nothing.
Refit the oil level plug (3).
Stop the engine.Add
0.5 litresextra oil into the gearbox.
Repeat the oil level procedure.
NOTE:The level is correct at the moment the thread of oil becomes “dripdrip”.
Refit the oil level plug
(3)(equipped with a new seal), tighten to2,4±0,2 m.daN.
Checking the oil level (continued).
Refit the oil filler plug (3) (equipped with a new seal), tighten to 2,4± 0,2 m.daN.
An excessive level of oil can lead to the following consequences:
Oil heating up abnormally,
Oil leaks.
A level that is too low will result in the destruction of the gearbox.
Engines: KFV NFU RFN RHZ
C3 XSARA XSARA PICASSO
B2CP3AZD

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BRAKES
B3FP160C
BLEEDING AND FILLING THE BRAKING SYSTEM (Continued)
With the bleeding apparatus.
Connect the bleeding apparatus [1]on the brake fluid reservoir (1).
Adjust the apparatus pressure to
2 Bars.
For each circuit:
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles. Close the bleed screw.
Remove the bleeding apparatus
[1].
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
Without the bleeding apparatus.
NOTE:Two operators are necessary.
For each circuit:
Apply the brake pedal to place the circuit under pressure.
Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container.
Open the bleed screw, wait until the fluid is flowing out without air bubbles.
Close the bleed screw. Remove the tool
[1].
NOTE:Recommence the process a second time if that is necessary.
Check the brake fluid level
(should be between «MINI»level and «MAXI»level).
Fill if necessary with the approved and recommended synthetic brake fluid.
C2