Get Clutch, Gearbox, Driveshafts Guide for Citroen C3 SUV First Generation (2002-2009)

CLUTCH SPECIFICATION

Petrol

Diesel

1.1i

1.4i

1.6i 16V

1.4 HDi

1.4 HDi 16V

Engine type

Gearbox type

Supplier

HFX

KFV

NFU

8HX - 8HW

MA/50

8HV - 8HY

MA/5N

VALEO

MA/5S

BE4/5

LUK

Mechanism / type

Clutch disc

180 CP0 3400

11 R 10X

200 P 3900

230 P 4700

Identification

of

4 outer

4 inner

4

springs

No. of splines

Ø of lining. Ext/Int

Quality of lining

180/127

200/134

228/155

408

142

CLUTCH SPECIFICATION

Engines : HFX – KFV – NFU - 8HX – 8HW – 8HV – 8HY

NOTE : All the clutches are «push» type with hydraulic control.

Description.

The declutch control has a declutch fork mounted on a ball-joint.

(1) The ball-joint is screwed into the clutch casing

(2) Declutch fork.

(3) Clutch casing.

(4) Bearing.

(5) Clutch plate.

The clutch control slave cylinder (7) is fixed by two screws (6) onto the exterior of the clutch casing.

Tightening torques (m.daN).

- Fixing of clutch plate/engine flywheel

- Fixing of engine flywheel/crankshaft

Pre-tightening

: 2 ± 0.2

: 1.7 ± 0.1

: 70° ± 5°

Angular tightening

B2BP047C B2BP04QC

143

GEARBOX AND TYRE SPECIFICATIONS

Petrol

1.6i 16V

1.1i

1.4i

Auto.

X - SX

Exclusive

X - SX

Exclusive

Trim level

Exclusive

X - SX

Engine type

HFX

KFV

NFU

165/70 R14

1.804 m

185/60 R15

1.828 m

165/70 R14

1.804 m

185/60 R15

1.828 m

Tyres-Rolling circumference

Gearbox type

MA/5N

AL4

MA/5S

20 CN 40

17x64

Gearbox ident. plate

Differential ratio

Speedo drive ratio

20 CN 14

14x60

20 CF 15 ou 20 CF 16 ( )

20 TP 75

21x73

*

16x63 ou 14x60 ( )

*

21x18

Kick-down ratio

Auto.

52/67

( ) = Export

*

144

GEARBOX AND TYRE SPECIFICATIONS

Diesel

1.4 HDi

1.4 HDi 16V

Trim level

X – SX - Exclusive

Engine type

8HX

8HW

8HV

8HY

Tyres-Rolling circumference

165/70 R14 1.804 m

MA/50

185/60 R15 1.828 m

BE4/5

Gearbox type

Gearbox ident. plate

Differential ratio

Speedo drive ratio

20 CN 33

17x61

20 CN 36 (*)

16x65 (*)

21x18

20 DM 25

19x72

20 DM 26

19x77

22x19

( ) = Export

*

145

MA/5 GEARBOX

Engines : HFX - KFV - NFU - 8HX - 8HW

"a" Identification label.

"b" Location of engraving of serial and gearbox nos.

B2CP3HTC

146

MA/5 GEARBOX

Engines : HFX - KFV - NFU - 8HX - 8HW

Draining – filling – level

(1) Gearbox drain plug.

(2) Filling and level cap.

Oil quality.

Refer to the manufacturer’s instructions.

Oil quantity.

After draining : 2 Litres.

Draining intervals.

«Lubricated for life »

Check the oil level: Every 37 500/40 000 miles.

B2CP3HWC

147

MA/5 GEARBOX

Engines : HFX - KFV - NFU - 8HX - 8HW

(1) Primary shaft.

(2) Clutch bearing guide.

(3) Clutch housing.

(4) Gearbox casing.

(5) Intermediate plate.

(6) Bearing retaining clip.

(7) Drive pinion (5th gear).

(8) Secondary shaft.

(9) 5th gear synchroniser.

(10) Driven pinion (5th gear).

(11) Driven pinion (4th gear).

(12) 3rd / 4th gear synchroniser.

(13) Driven pinion (3rd gear).

(14) Driven pinion (2nd gear).

(15) 1st / 2nd gear synchroniser and reverse gear driven pinion.

(16) Driven pinions (1st gear).

(17) Differential gearwheel.

(18) Satellite pinions.

(19) Planet pinions.

(20) Counter drive.

(21) Speedometer screw.

(22) Differential housing.

B2CP167P

148

MA/5 GEARBOX

Engines : HFX - KFV - NFU - 8HX - 8HW

Tightening torques: m.daN.

(23) Clutch bearing guide (3 fixing screws)

(24) Intermediate plate (11 fixing screws)

(25) Rear cover (3 fixing screws)

(26) Bearing retaining clip (4 fixing screws)

(27) Secondary shaft nut (1 nut)

(28) Gearbox casing (15 fixing screws)

(29) Top-up plug (1)

: 0.6 ± 0.15.

: 5 ± 0.5.

: 2.2 ± 0.2.

: 1.8 ± 0.2.

: 14 ± 1.

: 1.8 ± 0.2.

: 2.5 ± 0.5.

(30) Drain plug (1)

(31) Reverse gear switch (1)

B2CP3HUD

149

BE4/5 GEARBOX

Engines : 8HV - 8HY

B2CP3BNC

B2CP3BPD

(a) Engraving zone (sequence and serial no.)

(b) Location of identification label.

150

BE4/5 GEARBOX

Engines : 8HV - 8HY

Draining – filling – levelu

(1) Drain plug.

(2) Filling and top-up plug.

(3) Air vent.

NOTE : The air vent aperture can be used for filling.

Quality of oil

Refer to the manufacturer’s instructions.

Quantity of oil

Gearbox empty : 1,9 Litres.

After draining : 2 Litres.

B2CP3BLD

151

BE4/5 GEARBOX

Engines : 8HV - 8HY

Description.

(1) Primary shaft.

(2) Clutch bearing guide.

(3) Gearbox casing.

(4) Clutch housing.

(5) Reverse idle.

(6) Drive gear (3rd gear).

(7) 3rd /4th gear synchroniser

(8) Drive gear (4th gear).

(9) Drive gear (5th gear).

(10) 5th gear synchroniser.

(11) Driven gear (5th gear).

(12) Driven gear (3rd / 4th gear )

(13) Driven gear (2nd gear).

(14) 1st / 2nd gear synchroniser.

(15) Driven gear (1st gear).

(16) Secondary shaft.

(17) Differential gear.

(18) Satellite gears.

(19) Planet gears.

(20) Differential housing.

(21) Speedometer drive.

(22) Extension.

«c» Adjusting shims : 0,7 to 2,4 mm (From 0,10 to 0,10 mm)

«d» Adjusting shims:1,4 to 1,6 mm (From 0,10 to 0,10 mm)

B2CP3BQP

152

BE4/5 GEARBOX

Engines : 8HV - 8HY

Tightening torques (m.daN).

(23) Clutch bearing guide (3 screws)

: 1.25 ± 0.2

: 1.3 ± 0.2

: 7.25 ± 0.5

: 6.5 ± 0.5

: 1.5 ± 0.2

: 6.5 ± 0.5

: 2.5 ± 0.3

: 5 ± 0.5

(24) Clutch housing (13 screws)

(25) Primary shaft nut (1 screw)

(26) Secondary shaft nut (1 screw)

(27) Yoke retaining screw (2 screws)

(28) Differential gearwheel screw (2 screws)

Reverse gear switch (1 screw)

(29) Differential housing (4 screws)

(30) Breather pipe

: 1.7 ± 0.2

: 1.25 ± 0.2

: 2.2 ± 0.2

: 1.25 ± 0.2

: 3.5 ± 0.3

(31) Rear housing cover screws (7 screws)

(32) Top-up plug (1 screw)

(33) Differential housing screws (4 screws)

(34) Drain plug (1 screw)

B2CP3BRD

153

AL 4 AUTOMATIC GEARBOX

Engine : KFV

WARNING : This gearbox benefits from a special CITROEN

semi-synthetic oil which cannot be mixed with any other oil.

The gearbox is lubricated for life.

(a) Part reference.

B2CP3H1D

154

AL 4 AUTOMATIC GEARBOX

Engine : KFV

Tightening torques: (m.daN).

(1) Fixing of electrovalve for modulation of flow of oil into

the exchange (EPDE)

: 1 ± 0.2

: 5 ± 1

(2) Fixing of oil heat exchanger

B2CP3H2D

(3) Fixing of gearbox input speed sensor

(4) Fixing of oil overflow and drainage (X = 81 mm).

(5) Oil top-up plug

: 1 ± 0.2

: 4 ± 0.2

: 2.4 ± 0.4

: 0.8 ± 0.1

(6) Fixing of oil pressure sensor

B2CP3H3D

155

AL 4 AUTOMATIC GEARBOX

Engine : KFV

Tightening torques: (m.daN).

(7) Fixing of plug

: 0.8 ± 0.2

(8) Fixing of converter on the engine diaphragm :

Pre-tightening

Tightening

: 1 ± 0.1

: 3 ± 0.3

(9) Fixing of gearbox on the engine

(12) Fixing of the selection lever position switch

(13) Oil filler cap

: 5.2 ± 1

: 1.5 ± 0.2

: 2.4 ± 0.4

B2CP3H4C B2CP3H5C

156

AL 4 AUTOMATIC GEARBOX

Engine : KFV

Hydraulic valve block fixing.

Centre the hydraulic valve block by means of screws (10) and (11).

Pre-tightening

Slacken

: 0.9

: the screws (9).

Tightening

: 0,75 (respect the order indicated)

NOTE : The screw (11) est collared.

WARNING: Do not slacken the TORX screw (14), risk of dropping

the selection control inside the gearbox.

B2CP3H6C

157

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

PRECAUTIONS TO BE TAKEN

Towing

REMOVING - REFITTING (Automatic gearbox).

The front of the vehicle must be raised in order to be towed.

If the front of the vehicle cannot be raised

WARNING : Never place the gearbox on its lower casing

(risk of deforming the tray and damaging the hydraulic valve block).

Never use the connections as handles for raising, turning, holding or

pushing the gearbox.

IMPERATIVE : - Put gear lever in position «N»..

- Do not add any oil.

- Do not exceed 50 kph over a distance of 50 km.

Driving.

ESSENTIAL :

Never drive with the ignition switched off.

Never push the vehicle to try to start it;

(impossible with an automatic gearbox).

- Fit the converter retaining peg while the gearbox is removed.

- Fit the centring peg to locate the gearbox on the engine:

(remove the converter retaining peg just before locating)

Lubrication

The automatic gearbox is only lubricated when the engine is running.

WARNING : With the safety programme selected, a snatching can be

felt when changing from "P" ꢀ "R" or "N" ꢀ "R".

158

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

Gearbox only

PROCEDURE BEFORE REPAIRS

Oil level AL 4 (prior conditions).

- Vehicle in horizontal position.

- Check gearbox is not in back-up mode.

- Remove the oil filler plug (3).

- Add 0.5 litres extra oil into the gearbox.

- Foot on the brake, change through all the gears.

- Selection lever in position "P".

- Engine running, at idle.

- Oil temperature : 60°C (+8°C; -2°C), measured with the aid of a diagnostic tool.

- Remove the oil level plug (3).

- Thread of oil then "drip-drip": refit plug (3). Tighten 2.4 m.daN.

- "Drip-drip" or nothing : refit the plug (3).

- Stop the engine.

- Add 0.5 litres extra oil into the gearbox.

- Repeat the oil level procedure.

NOTE : The level is correct at the moment the thread of oil becomes drip-drip.

- Refit the oil filler plug (3). Tighten to 2.4 m.daN.

Initialise the oil usage counter (open the diagnostic tool procedure).

NOTE : The dimension X : TU engines = 81 mm

B2CP31FD

159

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

PROCEDURE BEFORE REPAIRS (continued)

When the ECU detects an erroneous or absent value

Reading the fault codes.

on input or output :

Read the fault codes.

- It writes the fault in memory.

Absence of fault codes:

- For each associated context, it writes the context of the oldest

Carry out a measure of parameters.

fault

in memory.

Presence of anomalies:

- It initiates a back-up mode strategy

- YES : Carry out the necessary repairs.

- NO : Read the fault codes – engine ECU

There are two types of back-up modes :

- Carry out a road test.

- The ECU makes replacement values available (relating to comfort,

gear selection quality, loss of functions).

Following an initialisation of the ECU, for a certain period of time there

may be an inconsistent gear selection quality (while ECU parameters

are adapting to the gearbox.

To achieve a consistent standard, it will be necessary to carry out a

road test taking in frequent gear changes (auto-adaptive laws)

- Access to emergency programme (only 3rd gear and reverse are

available)

160

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

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.

A pedal initialisation.

An initialisation of the auto-adaptives.

A recording 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

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.

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.

161

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

ECU : Downloading, Configuration, Initialisation (pedal) (continued)

Downloading.

Pedal initialisation.

ECU downloading procedure :

- Follow the diagnostic tooling procedure.

A pedal initialisation must be carried out in the following cases :

- Replacement of the automatic gearbox ECU.

- Replacement of the automatic gearbox.

A new ECU or downloaded update is always configured

with the following options :

- SHIFT LOCK gear selection lever position.

- OBD outlet (emission standard L4).

- Downloading of the ECU configuration.

If the ECU is to be fitted to a vehicle without one or both

of these options:

- Carry out a configuration which inhibits the diagnosis of the

option(s) concerned.

- Adjustment or replacement of the accelerator cable.

- Replacement of the throttle potentiometer.

IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent gear

selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes

(auto-adaptive laws).

162

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)

Engine : KFV

SHIFT LOCK

The shift lock is a system which locks the gear selection lever in the park position «P».

Unlocking the «shift lock» (normal operation).

Switch on the ignition.

Apply the brake pedal and keep it pressed.

Using the selection lever, disengage from position «P».

Unlocking the «shift lock» (with a fault).

NOTE : It is impossible to unlock the «shift lock» with the « normal operation» method.

The causes of the fault may arise from the following components :

- «Shift lock».

C5FP0ETC

- Gear lever position switch.

- Automatic gearbox ECU.

- Electrical harnesses.

- Battery voltage.

Remove :

- The gear lever knob (1) by pulling upwards.

- The cover (2) (unclip).

- The top of the central console (3).

Unlock the «shift lock» (4) with aid of a screwdriver.

Using the selection lever, disengage from position «P».

B2CP3GZC

163

MA/5 GEARBOX CONTROLS

Engines : HFX - KFV - NFU - 8HX - 8HW

(1) Gear control lever.

(2) Gear engagement control cable (*)

(3) Gear selection control cable (*)

(*) The two cables cannot be separated.

B2CP3HXD

164

MA/5 GEARBOX CONTROLS

Engines : HFX - KFV - NFU - 8HX - 8HW

(4) Gear engagement ball-joint Ø 10 mm.

(5) Gear selection ball-joint Ø 10 mm.

B2CP3HYC

Length D

Length C

Gear engagement

control cable (2)

1015 mm

790 mm

Length A

Length B

Gear selection

control cable (3)

1093 mm

775 mm

B2CP3HZD

165

MA/5 GEARBOX CONTROLS

Engines : HFX - KFV - NFU - 8HX - 8HW

Adjustment.

WARNING: Do not use any tool to detach the ball-

joints.

The gear selection control and gear engagement control

cables cannot be adjusted.

B2CP3J0D

To unlock the ball-joint, press at «a» then pull the ball-joint

upwards.

To release the sleeve stops, pull the needles «b», in the

direction of the arrow, then disengage the sleeve stops from

their supports.

B2CP3J1D

166

BE4/5 GEARBOX CONTROLS

Engines : 8HV - 8HY

(1) Gear control lever

(2) Gear engagement control cable (*).

(3) Gear selection control cable (*).

(*) These two cables cannot be separated.

B2CP3J3D

167

BE4/5 GEARBOX CONTROLS

Engines : 8HV - 8HY

(4) Gear engagement ball-joint Ø 10 mm.

(5) Gear selection ball-joint Ø 10 mm.

B2CP3J4C

Length A

Length B

Gear

selection

907 mm

645 mm

cable (5)

Length D

Length C

Gear

selection

cable (4)

965 mm

610 mm

B2CP3J5D

168

BE4/5 GEARBOX CONTROLS

Engines : 8HV - 8HY

Adjustment.

The gear selection control and gear engagement

control cables cannot be adjusted.

To release the ball-joint, press at «d» then pull the

ball-joint upwards.

To release sleeve stops:

- Press on the tabs of the clip (6) at «a».

- Disengage the sleeve stops from their supports.

B2CP3J6D

169

AL4 GEARBOX CONTROLS

Engine : KFV

B2CP3H7D

170

AL4 GEARBOX CONTROLS

The gear selection lever is guided by the shape of the stepped grille and by a return spring which holds it to the left.

The gear control has 5 positions:

- "P" Park (locks and immobilises the vehicle).

- "R" Reverse gear.

- "N" Neutral.

- "D" Drive (use of all four gears in automatic and autoactive mode).

- "M" Manual (This position permits the driver to choose his own gears in one-touch mode, by pulling «M» or pushing «M+» on the gear selection lever).

NOTE : Only positions «P» or «N» authorise the engine to be started.

In position «M», selection is made by an electronic sensor located close to the gear lever.

The degree of movement required to actuate the sensor cells is achieved by a magnet located on the lever opposite the cells, this causing the

change of status.

The information is transmitted to the gearbox ECU.

NOTE : On a vehicle equipped with the «shift lock», it is necessary to switch on the ignition and apply the brake pedal in order to release the

selection lever from position «P».

The two switches on the gear control grille permit the driver to choose one of the following three driving programmes:

- «Normal» programme: this applies in the absence of any other selection. (autoactive mode; eco law).

- «a» «Sport» programme: for a more dynamic driving style, favouring performance and overtaking etc.

- «b» «Snow» programme: for easier starting and traction on slippery surfaces.

To return to the «Normal» programme you have only to press a second time on the «sport» or «snow» switch.

171

AL4 GEARBOX CONTROLS

Engine : KFV

Close to the gearbox.

Control of the automatic gearbox is by a cable.

«c» Push button.

(1) Control lever with ball-joint.

(2) Automatic adjustment.

Pull out the button to permit adjustment of the control.

Press in the button to lock the adjustment of the control.

(3) Sleeve stop.

(4) Selection control locking clip (5), on the sleeve stop (3).

B2CP3H8C

172

AL4 GEARBOX CONTROLS

Engine : KFV

Unlocking: «Shift lock» function.

NOTE : The «shift lock» is a system that locks the gear selection lever in position «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» with the «Normal operation» method.

The fault may originate from one of the following components:

- «Shift lock».

- Gear lever position switch.

- Automatic gearbox ECU.

- Electrical harness.

- 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».

C5FP0ETC

B2CP3GZC

173

SPECIFICATION OF DRIVESHAFTS

Engines : HFX - KFV - NFU - 8HX - 8HW - 8HV - 8HY

NOTE : The wheel hubs have bearings with integral magnetic wheels

designed for the ABS system.

Features.

The driveshafts no longer have gearwheels for the ABS system.

This function is performed by the wheel bearings.

The driveshaft gaiters are secured by rings.

Should the driveshafts need repairs, the rings are replaced by clips.

Tightening torques: m.daN.

Driveshaft nuts

Driveshaft bearings

: 24.5 ± 0.5.

: 2 ± 0.2.

B2FP05CP

174

SPECIFICATION OF DRIVESHAFTS

Gearbox

References

Vehicles

1.1i

Engine types

HFX

Type

MA/5N

Differential diameter

68

Wheel end

Gearbox end

Gi 1700i

MA/5N - MA/5L

AC/1700i

1.4i

KFV

AL4

1.6i 16V

1.4 HDi

NFU

MA/5S

AC 2000i

AC 1700i

AC 2000i

8HX-8HW

8HV-8HY

MA/50

77

1.4 HDi 16V

BE4/5L

Gi 2000i

Housing diameter (mm)

Shaft diameter (mm)

Driveshaft gaiters

Wheel end

Gearbox end Diameter LH side Diameter RH side

Wheel end

Gearbox end

1.1i

1.4i

HFX

KFV

72

22.8

75

31

36

TP (1)

C/C (2)

1.6i 16V

1.4 HDi

1.4 HDi 16V

NFU

79

75

79

75

72

75

26.7

22.8

26.7

8HX-8HW

8HV-8HY

(1) = Thermoplastic. - (2) = Rubber.

175

DRIVESHAFTS - GEARBOX

Gearbox oil seal mandrels

Tightening torques (m.daN)

Driveshaft

bearing

Driveshaft

nut

RH side

LH side

7114-T.X

Tool kit

Vehicles

Gearbox

MA/5

Engines

HFX - KFV

8HX - 8HW

None

2 ± 0.2

1 ± 0.1

2 ± 0.2

7114-T.W

7116-T

24.5 ± 0.5

32.5 ± 1.5

NFU

KFV

C3

(-) 0338 J1

+ (-)0338 J3

(-) 0338 H1

(-) 0338 H2

AL4

(-) 0338

7116-T

BE4/5

8HV - 8HY

7114-T.W

7114-T.X

Tightening torques for wheel bolts (m.daN)

Steel

CITROËN C3

9 ± 0.5

Aluminium

176

Clutch, Gearbox, Driveshafts for Your Citroen C3 SUV First Generation (2002-2009)

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