engine cover Citroen XSARA 2004 1.G Service Manual

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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 GEARBOX
Engines: 6FZ RFN RFS WJY 8HV 8HY 8HZ 9HZ 9HY RHY RHZ
Tightening torques (m.daN).
(23)
Clutch bearing guide (3 screws): 1,25 ± 0,2
(24)
Clutch housing (13 screws): 1,3 ± 0,2
(25)
Primary shaft nut (1 screw):7,25 ± 0,5
(26)
Secondary shaft nut (1 screw): 6,5 ± 0,5
(27)
Yoke retaining screw (2 screws): 1,5 ± 0,2
(28)
Differential gearwheel screw (2 screws): 6,5 ± 0,5
Reverse gear switch (1 screw): 2,5 ± 0,3
(29)
Differential housing (4 screws): 5 ± 0,5
(30)
Breather pipe:1,7 ± 0,2
(31)
Rear housing cover screws (7 screws):1,25 ±0,2
(32)
Topup plug (1 screw):2,2 ±0,2
(33)
Differential housing screws (4 screws):1,25 ±0,2
(34)
Drain plug (1 screw):3,5 ±0,3
B2CP3BRD
C3 XSARA XSARA PICASSO

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CLUTCH
GEARBOX
TRANSMISSION
AL4 AUTOMATIC GEARBOX
NOTE:The «shift lock»«P».
Unlocking the «SHIFT LOCK»(normal operation).
Switch on the ignition.
Press the brake pedal and keep it pressed.
Move the gear selection lever out of position
«P».
Unlocking the «SHIFT LOCK»(with an operating fault).NOTE:It is impossible to unlock the «shift lock»
«Shift lock».
Gear lever position switch. Automatic gearbox ECU.
Electrical harnesses.
Battery voltage.
Remove:
The gear lever knob
(1)(pull upwards).
The cover (2)(Unclip).
The top of the central console (3).
Unlock the «shift lock» (4)with the aid of a screwdriver.
Move the gear selection lever out of position «P».
Engine: KFV
C3
C5FP0ETCB2CP3GZC

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CLUTCH
GEARBOX
TRANSMISSION
XSARAAL4 AUTOMATIC GEARBOX
Engines: NFU RFN RHZ
SHIFT LOCK.
NOTE:
The «shift lock»«P».
U
nlocking the «SHIFT LOCK»(normal operation).
Switch on the ignition.
Press the brake pedal and keep it pressed. Move the gear selection lever out of position
«P».
Unlocking the «SHIFT LOCK»(with an operating fault).NOTE:It is impossible to unlock the «shift lock»
«Shift lock».
Gear lever position switch.
Automatic gearbox ECU.
Electrical harnesses. Battery voltage.
Remove:
The cover
(1).
Unlock the «shift lock» (2) with the aid of a screwdriver.
Move the gear selection lever out of position «P».
C5FP06ZC
C5FP06YC

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BRAKES
C5FP0ELD
HANDBRAKE (Adjustment)
Adjustment.
Lift and chock the vehicle.
Remove:
The rear cover
(8).
The nut (9).
The handbrake trim (6).
The gear lever gaiter (5).
The front cover (3).
The screws (1).
Disconnect the connectors of the following components:
The cigar lighter
(2).
The electric window buttons (4).
Remove the central console
(7).
WARNING:Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal
(Then repeat the ope
ration 3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C2

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BRAKES
C5FP0ELD
HANDBRAKE (Adjustment)
Adjustment.
Lift and chock the vehicle.
Remove:
The rear cover
(8).
The nut (9).
The handbrake trim (6).
The gear lever gaiter (5).
The front cover (3).
The screws (1).
Disconnect the connectors of the following components:
The cigar lighter
(2).
The electric window buttons (4).
Remove the central console (7).
WARNING:Check that the brake cables are correctly
routed under the vehicle.
Slacken the handbrake lever.
Press gently on the brake pedal
(Then repeat the operation3 times).
Pull vigorously on the handbrake lever 4 or 5 times.
C3 C3 PLURIEL

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ELECTRICAL
SYSTEM
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter
Note:
The pollen filter is located in the engine compartment on the RH side.
Removing.
To remove:
Pull on the tab of the plastic cover (1), at «a».
Tilt the flap
(2).
Remove the pollen filter
(3).
Refitting.
Proceed in reverse order.
C4AP1BRCC4AP1BSCC4AP1BTC
C2

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ELECTRICAL
SYSTEM
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter
Note:
The pollen filter is located in the engine compartment on the RH side.
Removing.
Remove:
The three screws (1).
The plastic cover (2).
Tilt the flap
(3).
Remove the pollen filter
(4).
Refitting.
Proceed in reverse order.
C4AP169CC4AP16ACC4AP16BC
C3 C3 PLURIEL

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AIRCONAIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Tools.
[1]
Charge station :(according to workshop equipment)[2]TORX adaptor: TORX 70 FACOM
[3]Inertia extractor:1671T Tool kit 4114T
[4]Endpiece Ø 20 : 1671T.D20
[5]Set of plugs: ().0188.T
[6]Circlip pliers: FACOM
Removing.
Depressurise the aircon circuit, using tool [1].
Remove the grille.At
«a», remove the pin and the plastic cover.
Unclip the condenser at «b»and «c», using a screwdriver.
Tilt the condenser towards the front.
Lift and release the condenser.Clean the area around the cap
(3).
Remove the plastic cap (3), using tool [2].
Remove the safety circlip (4), using tool [6].
Position the tool [3]and[4]in the aperture of the cartridge (5).
Extract the cartridge from the reservoir (6), using tool [3]and [4].
Block the reservoir (6), using tool [5].
C4AP163CC4AP164CC4AP166CC4AP165C
C2 C3 C3 PLURIEL

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AIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Changing the filtering/drying cartridge
Refitting.
Remove the new cartridge from its packaging.
Do not expose the cartridge, the filter and seals to pollutants.
Lightly oil the seals
(compressor oil).
Remove tool [5] from the reservoir (6).
Insert the new cartridge (5)into the reservoir (6).
Refit the safety circlip (4), using tool [6].
Make sure that the circlip (4)is correctly positioned in its location.
WARNING: Not more than 5 minutes should elapse between the removal of
the cartridge (6) from its packaging and its being fitted.
Refit:
The plastic cap (3), using tool [5] Tighten to 1,2 ±0,1 m.daN.
The condenser (reclip, pushing at «b»and «c»).
The plastic cover and the pins at «a».
The grille (2).
The screws (1).
Proceed to:
Recharge the circuit
(see corresponding operation).
Check the operation of the air conditioning (see corresponding operation).
C4AP167CC4AP165CC4AP164CC4AP163C
C2 C3 C3 PLURIEL

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AIRCONAIRCON
SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a)
Pollen filter
XSARA
Removingrefitting.
Remove:
The interior trim (1).
The cover (4).
The pollen filter(3).
Concerns vehicles equipped with aircon without temperature regulation.
Fitting of a new pollen filter necessitates the following operations:
Engage the pollen filter upwards (following arrow «c»).
Slide the pollen filter towards the rear (following arrow «d»).
Position the index (4)on the cover forward of the pollen filter((4)Index on the cover).
C5HP07JC
C5FP075D