GEARBOX RATIO Citroen XSARA PICASSO 2005 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL
C41 - 2
XSARA3 - 4
XSARA PICASSO5 - 6
BERLINGO7 - 8
Operations following a repair: C49
C411 - 12
XSARA13 - 14
XSARA PICASSO15
BERLINGO16
Lubricants17 - 39
ENGINE
Specifications40 - 41
Tightening torques: engines all types42 - 147
Cylinder head tightening: all types148 - 150
Auxiliary drive belt152 - 153
Checking and setting the valve timing181 - 182
C4279
XSARA280
XSARA PICASSO281
Valve clearances282Checking the turbo pressure:
Xsara picasso (DW10ATED)295
Checking the air supply circuit: Xsara (DV4TD)
296
Checking the air supply circuit: C4 (DV6ATED4)297
Checking the air supply circuit: C4 (DV6TED4)298
Checking the air supply circuit: C4 (DW10BTED4)299 - 300
Checking the air supply circuit:
Xsara picasso (DW10TD/ATED)301
Checking the exhaust gas recycling circuit:
Xsara (DV4TD)302
Checking the exhaust gas recycling circuit:
Xsara picasso (DV6TED4)303
Checking the exhaust gas recycling circuit:
Xsara picasso (DW10TD/ATED)304
IGNITION
Sparking plugs305
CLUTCH - GEARBOX - TRANSMISSION
C4307 - 308
Xsara309 - 310
Xsara picasso311
CONTENTS
Vehicle
identification
Capacities
INJECTION
Checking the low pressure fuel supply
circuit: Xsara (DV4TD)283
Checking the low pressure fuel supply
circuit: C4 (DV6TED4/ATED4)284
Checking the low pressure fuel supply
circuit: Xsara Picasso (DV6TED4)285
Checking the low pressure fuel supply
circuit: C4 (DW10BTED4)286
Checking the low pressure fuel supply
circuit: Xsara (DW10TD)287
Checking the low pressure fuel supply
circuit: Xsara Picasso (DW10TD/ATED)288 - 289
Checking the turbo pressure: Xsara (DV4TD)
290
Checking the turbo pressure:
C4 (DV6TED4/ATED4)291
Checking the turbo pressure:
Xsara Picasso (DV6TED4)292
Checking the turbo pressure:
C4 (DW10BTED4)293
Checking the turbo pressure:
Xsara picasso (DW10TD)294
Checking the oil
pressureClutch
specifications
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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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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 6FZ - RFN
Checking the setting of the timing (continued).
A:Pegging on the manualgearbox.
B:Pegging on the automaticgearbox.
Turn the engine by means of the crankshaft pinion screw, to bring it to the pegging position.
Peg the crankshaft, using tool [2].
Peg the camshaft pulleys, using tool [3].
NOTE:The pegs[3]should go in without effort.
WARNING: If the pegs go in only with difficulty, repeat the operation for fitting and
tensioning the timing belt
(see corresponding operation).
Refitting.
Remove tools [2]and [3].
Complete the refitting in reverse order to removal.
B1BP2V3D
B1EP1BAC
XSARA - XSARA PICASSO
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CLUTCH
GEARBOX
TRANSMISSION
SPEEDOMETER
An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled.
This decree stipulates:
- The speed indicated by a speedometer must never be lower than the actual vehicle speed.
- Between the speed displayed «SD»and the speed travelled «ST», there must always be the following relationship:
ST < SD < 1.10 ST + 4 Kph
Example:For an actual speed of 100 Kphthe speed displayed by the speedometer may be between 100and 114 Kph.
The speed indicated by the speedometer may be influenced by:
- The speedometer.
- The tyres fitted to the vehicle.
- The final drive ratio.
- The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle
(see information note N° 78-85 TT of 19 October 1978).
NOTE:Before replacing the speedometer, check the conformity of the following points:
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.
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CLUTCH
GEARBOX
TRANSMISSION
MA MANUAL GEARBOX SPECIFICATIONS
Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio
C4ET3J4 MA/5L 20 CQ 15 13x59 21x18
TU5JP4 MA/5N 20 CQ 16 13x61 None
TU3JP MA/5L20 CP 44 16x65
XSARA20 CP 52 14x60
21x18
TU5JP4MA/5N 20 CP 51 16x65
MA/5L 20 CP 52 14x60
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CLUTCH
GEARBOX
TRANSMISSION
BE4/5 MANUAL GEARBOX SPECIFICATIONS
Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio
TU5JP4
BE4/5N20 DM 81 15x74 21x18
EW10A/J420 DM 71 17x81
C4BE4R/5S 20 DM 74 19x77
EW10J4S BE4/5L 20 DM 68 17x73 None
DV6TED4 BE4R/5L 20 DM 69 19x72
DV6ATED4 MA/5L 20 DM 75 19x72
EW10J4BE4/5J 20 DM 03 19x72
BE4/5N 20 DM 04 17x77
DV4TD BE4/5L20 DM 53
19x75
20 DM 54
XSARA
DW8B BE4/5N20 DM 05 19x75 22x19
20 DM 06 17x77
DW10TD BE4/5L20 DM 07 19x70
20 DM 08 17x77
DW10ATEDBE4/5 20 DM 10
17x61
BE4/5L 20 DM 11
TU5JP+ BE4/5J 20 DM 64 17x73
XSARA EW7J4 BE4/5V 20 DL 69 19x77
22x18
PICASSO DV6TED4
BE4/5L20 DM 62 19x70
DW10TD 20 DM 56 15x64
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CLUTCH
GEARBOX
TRANSMISSION
ML6/AL4 GEARBOX SPECIFICATIONS
Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio
Type ML6
C4 DW10BTED4 ML6C 20 MB 01 17x67 None
Type AL4
C4TU5JP4 AL4 20 TS 12 20x73
EW10A AL4 20 TS 11 21x73
TU5JP4 AL4 20 TP 97 21x73
XSARA EW10J4 AL4 20 TP 89 23x73 None
DW10ATED AL4 20 TP 90 27x70
XSARA
PICASSOEW10J4 AL4 20 TS 02 23x73
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CLUTCH
GEARBOX
TRANSMISSION
HYDRAULIC CLUTCH CONTROL: CHECKS AND ADJUSTMENTS
Bleeding the hydraulic clutch control
Action the clutch pedal manually through its full travel: 7 timesrapidly down and up.
Allow the clutch pedal to come back up to its high position.
Fill the brake fluid reservoir to the maximum of its capacity.
Open the bleed screw at «c».
Action the clutch pedal manually through its entire travel: 7 times
rapidly down and up.
The last time, keep the clutch pedal fully down.
Reclose the bleed screw, at «c».
If necessary, repeat the operation.
Top up the brake fluid to the MAX.level of the brake fluid reservoir.
Work the clutch vigorously 40 times
.
Start the engine.
Apply the handbrake.
Engage a gear.
Check that the clutch starts to engage at a dimension (X)greater than or equal to 45 mm
(the dimension (X)is
given as a guide).
Repeat the bleed operations if necessary.
C5FP0FQC
XSARA PICASSO
B2BP04YC
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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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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX
Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox
If a gearbox malfunction occurs, there are two possible configurations
depending on the seriousness of the fault:
- Gearbox in back-up mode with a replacement programme of
(the fault
values are taken in substitution).
- Gearbox in back-up 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).
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