key Citroen C4 2005 2.G Workshop Manual

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GENERAL
Structure Version (4)
G Family (1)Depollution levels
J Bodywork (2)L3 L4
Euro IVUS Others K Alcohol
GJ NFUC/IF N F UEngine (3)W3 83/87 K' L3/L4 Euro IV
C Version (4)Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5)Manual 4-speed gearbox E F R W 6 9 2
Family (1)Manual 6-speed gearbox G H S X 3
Automatic 6-speed gearbox D J N U
Body shape (2)Axle and/or gearbox gears K L T Y 7 0 4
Other possible combinations M
No gearbox Z
Engine (3)Variants (5)
KFW 1.4i TU3JP 2 sliding side doors standard for 800 Kg WJY PLC Van Turkey TR
NFU 1.6i 16V TU5JP4 Multi-function roof standard for Car WJY PMF Van Spain ES
WJY 1.9D DW8B Without FAP SF Car/Van 5-seater PL
RHY 2.0 HDi DW10TD Fiscal incentives IF
4x4 DANGEL DGL
Downgraded depollution D
Bi-carburation GPL GL
Bi-carburation GNV GN
STT2 (stop and stard) S
IDENTIFICATION OF THE VEHICLE
Type approval
BERLINGO
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GENERAL
EUROPE
7000 10W40
7000 15W50
9000 0W40
7000 10W40
9000 0W40
7000 10W40
7000 10W40
9000 15W50
9000 0W40 Romania
Russia
Slovenia
Sweden
Switzerland
Turkey
LUBRICANTS - TOTAL recommended oils
ENGINE OILS
TOTAL QUARTZ
Blended oils for all enginesOils specifically for petrol and
dual-fuel petrol / LPG enginesOils specifically for diesel
engines TOTAL QUARTZ DIESEL
9000 5W40
FUTUR 9000 5W30 (*)7000 10W40
(*) Blended oils for all engines, giving fuel economy.
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ENGINE
200
CHECKING AND SETTING THE VALVE TIMING
Engine: NFU
Peg the flywheel, using tool [1].
Position the tools [2a]and [2b].
Slacken the tensioner roller.
Turn the dynamic tensioner roller so as to be able
to position the tool[4], with the aid of an Allen key
placed at «a».
Turn the tensioner roller towards the right to bring
it to the index «c»in position «b».
Peg the tensioner roller in this position in order to
slacken the timing belt to the maximum.
IMPERATIVE: Never make the dynamic tensioner
roller turn by a complete rotation.
Remove the timing belt (8).
Check that the rollers and the pump pulley turn
freely
(no tight spot).
B1BP2MBC
B1EP170C
B1EP18PC
B1EP18QC
C4
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: RFJ
Checking and setting the timing (continued).
Refitting.
Turn the tensioner roller (9), using tool [5a]to go past the notch «b».
Position the tool [5b] to lock the index «a»and remove the tool [5a].
NOTE: Check the presence of the crankshaft pinion keyway (12)before positioning the timing belt.
Reposition the timing belt (8)on the crankshaft pinion (1).
Hold the timing belt in place (8)using tool [3].
Put the timing belt (8)in place, in the following sequence:
- Guide roller (11).
- Inlet camshaft pulley (7).
- Exhaust camshaft pulley (6).
- Coolant pump (13).
- Tensioner roller (9).
NOTE: Make sure that the timing belt (8)is as flush as possible with the outer faces of the various
pinions and rollers.
Remove tools[3], [1]and [5b].
Refit the lower timing cover (5), the pulley (2)and the screw (3)of the crankshaft pulley.
Tighten the screw (3)to 4 ± 0,4 m.daN.
Angular tighten 40°±4°, using tool [4].
B1EP1G2D
B1EP1G3C
C4
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY - RHZ
Slacken the screw (17)of the tensioner roller (18).
Remove the timing belt (14).
Checks.
IMPERATIVE: Just before refitting, carry out the checks below.
Check that:
- The rollers (18)and (15)turn freely
(without play and without any tight spot).
- The coolant pump pulley (16)turns freely
(without play and without any tight spot).
- There are no traces of oil leaks from the crankshaft and camshaft seals, etc.
- The crankshaft pinion travels freely on the keyway.
Replace defective components if necessary.
Peg the crankshaft pinion (19)by inserting tool [9]on the LH side of the keyway.
B1EP1A8D
B1EP1A9C
XSARA - XSARA PICASSO
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: RHR
Remove:
- The screw (8).
- The auxiliaries drive pulley (7).
- The crankshaft position sensor (11).
- The lower timing cover (9).
- The target of the crankshaft position sensor (10), using tool [7].
- The lower torque reaction rod.
- The tool [6].
Slacken the screw (12)of the tensioner roller (17).
Remove the timing belt (13).
Checks.
IMPERATIVE: Just before refitting, carry out the checks below.
Check:
- That the rollers (14)and (17)turn freely
(without play and without
any tight spot).
- That the coolant pump pulley (16)turns freely (without play and
without any tight spot).
- That there are no traces of oil leaks from the crankshaft and
camshaftseals, etc.
- That the crankshaft pinion travels freely on the keyway (15).
Replace defective components if necessary.
B1EP1FCC
B1EP1FDC
B1EP1FEC
C4
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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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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
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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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