transmission oil 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
LUBRICANTS - TOTAL recommended oils
GEARBOX OILS
TOTAL TRANSMISSION BV
Norms S.A.E: 75W80
Part No.: 9730 A2
TOTAL FLUIDE ATX
T O TA L F L U I D E AT 4 2
Special oil distributed by
CITROËN
Part No.: 9730 A6
Special oil distributed by
CITROËN
Part No.: 9736 22 Manual and piloted manual
gearboxes
MB3 automatic gearbox
4HP20 and AL4 autoactive
automatic gearboxes
All countries
Special oil distributed by
CITROËN
Part No.: 9980 D4
TOTAL TRANSMISSION X4
Part No.: 9730 A7 AM6 autoactive automatic gearbox
Transfer box and rear axle
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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX
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 imperative
that the
converter retaining bracket should be in place when handling the
gearbox.
It is imperative
to 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).
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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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CLUTCH
GEARBOX
TRANSMISSION
RECOMMENDATIONS/PRECAUTIONS : AL4 AUTOMATIC GEARBOX
Procedure for initialising the automatic gearbox ECU
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.
- An initialisation of the auto-adaptives.
- 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.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
2750 units.
Using LEXIA.
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 figuresof the oil counter.
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOX
Engines: NFU - RFJ
B2CP3EDD
B2CP3X7D
Tightening torques (m.daN).
(1) Fixing of the electrovalve for modulation of the flow
of oil into the exchanger (EPDE): 1 ± 0,2
(2)Heat exchanger fixing: 5 ± 1
(3) Output speed sensor fixing
(4)Output speed sensor fixing: 1 ± 0,2
(5)Oil overflow and drain fixing(X = 48 mm)
: 0,9 ± 0,2
(6)Oil level plug: 3,3 ± 0,5
(7)Oil pressure sensor fixing: 0,8 ± 0,1
C4 - XSARA - XSARA PICASSO
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CLUTCH
GEARBOX
TRANSMISSION
Engines: NFU - RFJ
B2CP3EGC
(13)Fixing of selector lever position switch: 1,5 ± 0,2
(14)Oil filler plug: 2,4 ± 0,4
TIGHTENING TORQUES: AL4 AUTOMATIC GEARBOXC4 - XSARA - XSARA PICASSO
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CLUTCH
GEARBOX
TRANSMISSION
DRIVESHAFTS - GEARBOX
Tightening torques (m.daN)Gearbox oil seal mandrels
Vehicles GearboxDriveshaft Driveshaft
Engines
bearing nutRH side LH side Toolkit
C4
MA/5ET3J4 TU5JP4
XSARA TU3JP TU5JP4
C4EW10/DV6 7114-T.W 7114-T.X 7116-T
BE4/5All types
XSARA EW7/10J4B DW8
XSARA PICASSO DV6/DW10
C4ML6 DW10BTED4 9017-T.C 5701-T.A 9017-T
TU5JP4 EW10A 2 ± 0,2 32,5 ± 2,6
(-) 0338 J1 (-) 0338 H1
XSARATU5JP EW10J4
+ (-) 0338 J3 (-) 0338 H2
DW10ATED
AL4Seal extractor
RH / LH(-). 0338
XSARA PICASSO EW10J4 (-) 0338 C
(-) 0338 J1 (-) 0338 H1
+ (-) 0338 J3 (-) 0338 H2
Tightening torque (m.daN) for wheel bolts.
C4 = 9 ± 1 XSARA = 8,5 ± 0,8 XSARA PICASSO = 10 ± 1
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