CLUTCH-GEARBOX-DRIVESHAFTS for Your Citroen Xantia 4 Door Second Generation (1993-2002)

SPEEDOMETER  
ALL TYPES  
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 Kph the speed displayed by the speedometer may be between 100 and 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.  
165  
manuals search engine  
ALL TYPES  
CLUTCH SPECIFICATIONS  
XU  
7
5
10  
JP  
JB  
JP4  
J4R  
All Types  
XM Saloon  
2.0i 16V  
1.6i  
1.8i  
1.8i 16V  
LFY  
Engine type  
BFZ  
LFX  
RFV  
ME/5  
Gearbox type  
Make  
BE3/5  
LUK  
LUK  
VALEO  
VALEO  
LUK  
VALEO  
Mechanism/Type  
200 P 4100  
200 CP 4250  
200 P 4100  
200 CP 4250  
200 P 4100  
215 DT5250  
200 B (D73)  
33 AX  
200 B (D73)  
33 AX  
215 F (D93)  
22 BX  
Clutch disc  
200  
200  
200  
Ext./Int. lining Ø  
Disc lining type  
200/134  
200/137  
200/134  
F 408  
200/137  
200/134  
215/147  
F 808  
166  
manuals search engine  
CLUTCH SPECIFICATIONS  
ALL TYPES  
EW  
XU  
ES  
9
10  
J4  
J4R  
J2TE  
XM  
J4  
Synergie  
XM Estate  
2.0i 16V  
Synergie  
Xantia  
Synergie  
All Types  
3.0i V6  
2.0i Turbo CT  
Engine type  
Gearbox type  
Make  
RFN  
RFV  
RGX  
XFZ  
BE3/5  
ME/5 – ML/5  
VALEO  
ML/5  
LUK  
ME/5 – ML/5  
VALEO  
235 CP 5650  
ML/5  
230 DING  
4700  
Mécanisme/Type  
Clutch disc  
235 CP 5650  
235 T 5700  
242 DT 6500  
228 D 73  
228 SH  
228 D 62  
32 BX  
242 SH (D31)  
11 A 15 X  
228 D  
12 R 14 X  
11 A 15X  
Ext./Int. lining Ø  
Disc lining type  
235/155  
228/155  
242/162  
F 808  
F 808 DS  
F 202  
167  
manuals search engine  
ALL TYPES  
CLUTCH SPECIFICATIONS  
XUD  
11  
DW  
10  
DK  
5
BTF  
TD  
ATED  
RHZ  
ATE  
XM- Synergie  
RHD  
XM  
LHD  
All  
Types  
All  
Types  
Xantia  
Synergie  
2.1 TD  
P8C  
2.0 HDi  
2.5 TDi  
Engine type  
Gearbox type  
Make  
RHY  
THY  
MG/5  
ME/5-ML/5  
ME/5  
BE3/5  
BE3/5-ML/5  
LUK  
ML/5  
VALEO  
VALEO  
225 T 5700  
Mechanism/Type  
Clutch disc  
235 CP 5650  
230 P 4700  
228  
235 T 5700  
228D  
242 DT 6500  
(1)  
228 SH  
228 F (D95)  
32 AX  
242 SH (D95)  
31 Q  
225  
11 A 15X  
Ext./Int. lining Ø  
Disc lining type  
235/155  
F 202  
230/  
235/155  
F 202  
225/  
242/162  
F 206  
F 408  
F 808  
(1) DVA = Damped double flywheel.  
168  
manuals search engine  
CLUTCH : CHECKS AND ADJUSTMENTS  
XANTIA - SYNERGIE  
Push-action clutch with automatic adjustment (Non-adjustable) (*)  
Engines  
BE3/5  
Gearbox  
BFZ - LFX - LFY – RFN – RHY  
Refitting the clutch cable.  
- Set the pedal to the high position (contact at A).  
- Attach the cable end-piece to the pedal.  
- Refit a new clip (3) to the pedal.  
- Fit the end-piece (4) to the bulkhead (G6 grease).  
- Clip the end-piece (5) to the gearbox.  
- Refit the cable to the lever (1).  
- Depress the clutch cable several times to set the assembly  
in place.  
- Check that the end-piece (4) is properly fitted to the bulkhead.  
- Check the operation of the automatic adjusting device.  
1) - Pull the lever (in direction F), the lever must move when  
pulled by hand.  
2) - Press the clutch pedal very lightly and repeat the same  
operation. The lever should not move back.  
( ) See pages : 172 to 173).  
*
B2BP03PD  
169  
manuals search engine  
XANTIA - XM - SYNERGIE  
CLUTCH : CHECKS AND ADJUSTMENTS  
Pull-action clutch with automatic adjustment (Non-adjustable) (*)  
Xantia - XM : RFV - DHX  
XM : RGX  
Synergie : RFV  
BE3/5  
ME/5  
ML/5  
Engines  
Gearboxes  
Refitting the clutch cable.  
- Set the pedal to the high position (contact at A).  
- Attach the cable end-piece to the pedal.  
- Refit a new clip (3) to the pedal.  
- Fit the end-piece (4) to the bulkhead (G6 Grease).  
- Clip the end-piece (5) to the gearbox.  
- Refit the cable to the lever (1).  
- Depress the clutch cable several times to set the  
assembly in place.  
- Check that the end-piece (4) is properly fitted to the  
bulkhead.  
- Check the operation of the automatic adjusting device.  
1) Pull the lever (in direction F), the lever must move  
when pulled by hand.  
2) Press the clutch pedal very lightly and repeat the  
same operation. The lever should not move back.  
( ) See pages : 172 to 173).  
*
B2BP03DD  
170  
manuals search engine  
XANTIA - XM - SYNERGIE  
CLUTCH : CHECKS AND ADJUSTMENTS  
Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)  
Engines : BFZ - LFX - LFY - RFV – RGX - RFN - DHX - RHY - RHZ  
WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the  
pedal position must be adjusted. This position is obtained by the angular displacement of the stop  
supports "a" and "b".  
Procedure  
- Loosen the nut (6) and the screw (7).  
- Using a lever, raise the stop support (8) to its highest position.  
- In this position, there must be a substantial free play in the pedal.  
- Lower the support until there is a free play of 2 ± 1 mm.  
- Tighten the screw (7) and the nut (6).  
- Check that the outer cable slides freely (at rest, the pedal is against its upper stop «A», the outer cable  
length should be variable).  
Characteristics  
- The automatic adjusting device requires no manual adjustment.  
- Pedal travel remains constant for all models 145 ± 5 mm.  
- Automatic adjustment is achieved by modifying the curvature of the outer cable.  
- Take extra care with the routing of the outer cable, and do not add any supplementary fixing points.  
B2BP03EC  
171  
manuals search engine  
CLUTCH : CHECKS AND ADJUSTMENTS  
Engines : BFZ - LFX - LFY - RFV – RGX - RFN - DHX - RHY - RHZ  
B2BP02SC  
NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable.  
DESCRIPTION  
1 - Metallic cable, crimped on both ends.  
2 - Outer cable or telescopic duct.  
5 - Tensioning spring ensuring the maximum length of the outer cable.  
6 - Wear take up device.  
3 - Outer cable stop, bulkhead side (fixed point on the bodyshell).  
4 - Outer cable stop, gearbox side (fixed point on the gearbox).  
7 - Attaching end-piece.  
172  
manuals search engine  
CLUTCH : CHECKS AND ADJUSTMENTS  
XANTIA - XM - SYNERGIE  
Engines : BFZ - LFX - LFY - RFV - RGX - RFN - DHX - RHY - RHZ (Continued)  
B2BP03QD  
Operation  
Clutch disengagement phase  
Engagement / adjustment phase  
For the adjusting device to operate correctly, it  
is necessary that :  
The pedal is at rest (against its upper stop)  
The locking sleeve (1) is slightly compressed,  
the rollers (2) are free, the outer cable (3) length  
may vary.  
As soon as the pedal is applied, the attaching  
end-piece (4) leaves the sleeve (1) which  
moves back. The rollers, pushed by spring (5)  
jam the system. The cable behaves like a  
conventional cable.  
The pedal returns to rest on its upper stop.  
Attaching end-piece (4) pushes sleeve (1)  
which frees the rollers.  
Outer cable (3), kept extended by the spring (6)  
becomes :  
- Shorter if the clutch disc is worn.  
- Longer if the outer cable has been compressed.  
NOTE : The pedal gear has a non-adjustable assisting device  
173  
manuals search engine  
XANTIA - XM - SYNERGIE  
CLUTCH : CHECKS AND ADJUSTMENTS  
Hydraulically operated pull-action clutch (Non-adjustable)  
ME/5  
ML/5  
MG/5  
XM  
: RGX -P8C  
Engines  
Gearboxes  
Xantia - XM - Synergie : RGX - XFZ - RHZ  
XM  
: THY  
(1) Quick-fit union Tool 9040-T.H.  
B2BP03RC E5AP14VC B2BP03SC  
174  
manuals search engine  
CLUTCH : CHECKS AND ADJUSTMENTS  
XANTIA - XM - SYNERGIE  
Hydraulically operated pull-action clutch (Non-adjustable)  
Engines : RGX - XFZ – RHZ - P8C - THY  
A / Old assembly, supplied complete and filled with hydraulic  
fluid.  
B / New assembly :  
- The components supplied separately.  
- The circuit is filled with fluid after being fitted to the vehicle.  
(1) Clutch transmitter.  
(2) Clutch receiver.  
(3) Hydraulic clutch control reservoir.  
(4) Link pipe.  
(5) Click-fit union, sealed (after dismantling).  
(6) Click-fit union, non-sealed (after dismantling).  
(7) Bleed screw.  
Le nouveau montage est composé des pièces suivantes :  
The new assembly consists of the the following parts :  
- Clutch transmitter, anchored in place after a 1/4 turn.  
- Clutch receiver, with push-rod.  
- Hydraulic clutch control reservoir, with feed pipe.  
- Link pipe, between clutch transmitter and receiver.  
B2BP03ZD  
175  
manuals search engine  
XANTIA - XM - SYNERGIE  
CLUTCH : CHECKS AND ADJUSTMENTS  
Hydraulically operated pull-action clutch (Non-adjustable)  
Engines : RGX - XFZ – RHZ - P8C - THY  
After fitting on the vehicle, the circuit should be filled with a  
«DOT 4» type brake fluid.  
Clutch control reservoir capacity 120 cc.  
(Bleeding is carried out not under pressure).  
Repair  
The new clutch control components are not compatible with the  
old parts.  
Both the old and the new components are marketed by  
«Replacement Parts».  
Draining-Filling - Top-up  
- Check the level after each repair visit.  
- Fill the circuit (after drainage), using a filling cylinder  
specifically designed for this operation.  
- Use the circuit’s bleed screw (7).  
- The level of fluid inside the clutch control reservoir should be  
between the min. and max. marks.  
NOTE : Wear on the clutch causes a slight increase in the level  
of fluid inside the control reservoir.  
B2BP03ZD  
176  
manuals search engine  
GEARBOX AND TYRE SPECIFICATIONS  
XANTIA  
Petrol  
( ) = Long gearbox.  
1.6i  
1.8i  
1.8i 16V  
2.0i 16V  
*
Auto.  
Auto.  
BFZ  
LFX  
LFY  
RFV  
Engine type  
175/70R14  
1.85 m  
185/65R15  
1.895 m  
AL4  
20 TP 52  
23X73  
205/55R15  
1.85 m  
BE3/5  
20 TB 97  
19X79  
185/65R15  
1.895 m  
AL4  
20 TP 53  
23X73  
185/65 R14 - 1.815 m  
BE3/5  
Tyres-Rolling circumference  
Gearbox type  
Gearbox ident. plate  
Reduction box torque  
Speedometer ratio  
20 TD 00  
15X64  
20 TB 94  
19X75  
20 TB 95  
20 TB 95 (*)  
19X79  
22X18  
28X18  
20X16  
22X18  
20X16  
Petrol  
Diesel  
(1) = Plastic pinion  
1.9 TD  
2.0 HDi  
2.0i  
Turbo CT  
3.0i V6  
XFZ  
Auto.  
Auto.  
DHX  
Engine type  
RGX  
RHY  
RHZ  
Tyres-Rolling circumference  
205/60 R15 - 1.92 m  
ML/5  
205/60R15 - 1.92m  
205/60 R15 - 1.92 m  
Gearbox type  
4 HP 20  
20 HZ XX  
20X69  
AL4  
20 TP 50  
25x71  
BE3/5  
ML/5  
20 LE 84  
16X65  
Gearbox ident. plate  
Reduction box torque  
Speedometer ratio  
20 LE 90  
15X67  
20 LE 89  
16X69  
20 TB 53  
19X75  
25X20 (1)  
20X16  
20x16  
22X18  
25X20 (1)  
177  
manuals search engine  
XM  
GEARBOX AND TYRE SPECIFICATIONS  
Petrol  
2.0i 16V  
3.0i V6  
2.0i Turbo CT  
Auto.  
Auto.  
Auto.  
Engine type  
RFV  
195/65R15 - 1.93 m  
XFZ  
RGX  
Tyres-Rolling circumference  
Gearbox type  
205/65R15 - 1.97 m  
BE3/5  
4 HP 18  
ML/5  
4 HP 20  
ME/5  
4 HP 18  
Gearbox ident. plate  
Reduction box torque  
Speedometer ratio  
20 TD 01  
14X6218X77  
22X18  
20 GZ 5G  
20 LE 59  
20 HZ YY  
20 GM 33  
20 GZ 1G  
17X71 0X69  
2
14X59  
20X16  
18X77  
21X26 (1)  
25X20  
25X20  
25X20  
Diesel  
2.1 TD  
2.5 TD  
(1) = Plastic pinion  
Engine type  
Auto.  
P8C  
195/65R15 - 1.93 m  
THY  
Tyres-Rolling circumference  
Gearbox type  
205/65R15 - 1.97 m  
MG/5  
ME/5  
4 HP 18  
20 GZ 5D  
18X77  
Gearbox ident. plate  
Reduction box torque  
Speedometer ratio  
20 GM 31  
15X59  
20 KM 70  
16X65  
21X26 (1)  
25X20  
16X20 (1)  
178  
manuals search engine  
GEARBOX AND TYRE SPECIFICATIONS  
SYNERGIE  
Petrol  
Diesel  
2.0i 16V  
RFN  
2.0 HDi  
Auto.  
Engine type  
RHY  
205/65 R15 - 1.97 m  
Tyres-Rolling circumference  
Gearbox type  
BE4/5  
AL4  
ML/5  
20 DL 26  
20 DL 27  
20 TP 31  
20 LE 91 ( )  
Gearbox ident. plate  
Reduction box torque  
Speedometer ratio  
*
1x73  
1154xx66722  
18x14  
20x16  
25x20  
( ) DVA = Double damped flywheel  
*
179  
manuals search engine  
XANTIA- XM  
BE3/5 GEARBOX  
Engines : BFZ - LFX - LFY - RFV 03 - RHY  
Drain screw  
Filler screw  
Vent hole  
B2CP34JP  
B2CP20HC B2CP20JC  
180  
manuals search engine  
BE3/5 GEARBOX CONTROLS  
XANTIA- XM  
Engines : BFZ - LFX – LFY – RFV - RHY  
Tightening torques m.daN.  
(1) Pinion/subframe fixing  
2.7 ± 0.2  
1 ± 0.1  
(2) Bar /lever fixing  
Adjustment of the control rods  
(3) Length selection rod  
(4) Length engagement rod  
100 ± 1 mm  
245 ± 1 mm  
Note : The adjustment dimensions are the distances  
between ball-joint centres.  
B2BP005D  
181  
manuals search engine  
XANTIA- XM  
BE3/5 GEARBOX CONTROLS  
Engine : RFV  
(1)  
(2)  
(3)  
100 ± 1 mm.  
100 ± 1 mm.  
246 ± 1 mm.  
B2CP34ZD  
182  
manuals search engine  
BE4/5 GEARBOX  
SYNERGIE  
ENGINE : RFN  
(a) = Marking zone (Sequence and serial no.).  
(b) = Location of identification label.  
B2CP3BNC B2CP3BPD  
183  
manuals search engine  
SYNERGIE  
BE4/5 GEARBOX SPECIFICATIONS  
Engines : RFN  
Description (Continued)  
(14) 1st / 2nd gear synchroniser  
(15) Driven gear (1st gear)  
(16) Secondary shaft.  
(17) Differential gear.  
(18) Satellite gears  
(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 (2nd / 4th gear )  
(13) Driven gear (2nd gear).  
(19) Planet gears.  
(20) Boîtier de différentiel.  
(21) Differential housing.  
(22) Extension.  
«d» Adjusting shims : 0.7 to 2.4 mm  
(0.10 mm and increasing by 0.10 mm).  
"c" Adjusting shims : 1.4 to 1.6 mm  
(0.10 mm and increasing by 0.10 mm).  
B2CP3
184  
manuals search engine  
BE4/5 GEARBOX  
SYNERGIE  
Engine : RFN  
Tightening torques  
Ref.  
Description  
End guide  
Clutch housing  
Primary shaft nut  
Number of screws  
m.daN  
1.2 ± 0.1  
1.3 ± 0.1  
7.2 ± 0.7  
6.5 ± 0.7  
1.5 ± 0.1  
6.5 ± 0.7  
2.5 ± 0.3  
5 ± 0.5  
1
2
3
4
5
6
3
13  
1
Secondary shaft nut  
Yoke holding screw  
Differential gearwheel screw  
Reverse gear contact  
Differential housing  
Breather pipe  
1
2
2
B2CP3BSP  
1
7
8
4
1
1.7 ± 0.2  
1.2 ± 0.1  
2.2 ± 0.2  
1.2 ± 0.1  
3.5 ± 0.4  
9
Rear housing cover screw  
Top-up plug  
7
10  
11  
12  
1
Differential housing screw  
Drain plug screw  
4
1
B2CP3BTD  
185  
manuals search engine  
SYNERGIE  
BE4/5 GEARBOX CONTROLS  
Engines : RFN  
(1) Gear control lever  
(2) Gear engagement control cable (*)  
(3) Gear selection control cable (*)  
(4) Gear selection ball-joint Ø 10 mm.  
(5) Gear engagement ball-joint Ø 10 mm.  
(6) Flexible insulating grommet through the bulkhead  
(*) = These two cables cannot be separated.  
B2CP3BWD  
186  
manuals search engine  
SYNERGIE  
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS  
Engines : RFN  
Principles of adjusting the gear controls.  
WARNING : Cables should be adjusted each time the gearbox,  
gear controls or power unit are removed.  
Principles.  
WARNING : Do not use any tool to unclip the  
ball-joints.  
Lock the gear lever in neutral position,  
using tool: 9607-T.  
To unlock the ball-joint, press at the centre «a»,  
then pull the ball-joint upwards.  
Place the gearbox in neutral.  
Note : Changing an individual ball-joint is  
Couple the cables on the lever.  
possible as long as the locking key is removed.  
Fit the ball-joints on the gearbox lever.  
Lock the cable lengths with the ball-joint locking keys.  
Unclip at «b», using two small screwdrivers.  
B2CP3BXC B2CP3BYC  
187  
manuals search engine  
SYNERGIE  
BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS  
Engines : RFN  
Adjusting the gear controls.  
TOOL  
[1] Tool for positioning the gear lever  
: 9607-T.  
CHECKS  
- Remove the tool [1].  
ADJUSTMENTS  
WARNING : Cables should be adjusted each  
time the gearbox, gear controls or power unit  
are removed.  
- 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.  
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  
neutral.  
- Lock the cable lengths with the ball-joint locking  
keys.  
B2CP3C6C  
B2CP3C0C  
188  
manuals search engine  
ME/5 GEARBOX  
XM  
Engines : RGX - P8C  
Filler screw  
Drain screw  
B2CP34KP  
B2CP20KC B2CP20LC  
189  
manuals search engine  
ME/5 GEARBOX CONTROLS  
XM  
Engines : RGX - P8C  
(1)  
(2)  
Z
Z
3 ± 2 mm  
3 ± 2 mm  
(3)  
X
Y
8.5 mm  
8.5 mm  
B2CP351D  
190  
manuals search engine  
XANTIA - XM - SYNERGIE  
ML/5 GEARBOX  
Engines : XFZ - RHZ -  
Tightening torque : m.daN.  
- Gearbox casing/clutch bell housing fixing  
- Speedometer cable housing/engine fixing  
- Clutch bell housing/engine fixing :  
• Screws H10 x 150 L 75  
1.8  
1.5  
6
• Screws M12 x 175 L 70  
8.5  
Drain screw  
Filler screw  
B2CP34LC  
191  
manuals search engine  
ML/5 GEARBOX CONTROLS  
XANTIA - XM - SYNERGIE  
Engines : XFZ - RHZ  
B2CP0350P  
192  
manuals search engine  
ML/5 GEARBOX CONTROLS  
XANTIA - SYNERGIE  
Engines : XFZ - RHZ  
B2CP16FP  
193  
manuals search engine  
XM  
MG/5 GEARBOX  
Engine : THY  
Drain screw  
Filler screw  
B2CP34MD  
B2CP34NC  
194  
manuals search engine  
MG/5 GEARBOX CONTROLS  
XM  
Engines : THY  
B2CP16GP  
195  
manuals search engine  
XANTIA - XM  
4 HP 18 AUTOMATIC GEARBOX  
Engines : RFV - RGX - P8C  
Ref.  
letter  
Torque  
m.daN  
X (mm) Y (mm)  
Tightening torques m.daN  
120.8  
A
B
C
D
E
80  
80  
75  
65  
60  
(1) Gearbox casing screw  
(2) Oil dipstick tube nut  
(3) Strainer cover  
1 ± 0.1  
4.5± 0.4  
10  
12  
10  
10  
0.6  
0.8  
0.6  
(4) Hydraulic valve block  
0.8  
0.6  
Note : When replacing an automatic gearbox, it is ESSENTIAL to replace the  
heat exchanger, as well as the oil.  
B2CP34UD  
B2CP34SC B2CP34TC  
196  
manuals search engine  
XANTIA- XM  
GEARBOX CONTROLS - 4 HP 18 AUTOMATIC GEARBOX  
Engines : RFV - RGX - P8C  
B2CP35AD  
B2CP35BC  
197  
manuals search engine  
XANTIA - XM  
CHECKS AND ADJUSTMENTS - 4 HP 18 AUTOMATIC GEARBOX  
Engines : RFV - RGX - P8C  
Checks - Adjustments : Kick down cable  
Preliminary conditions :  
- Engine hot.  
- Idling speed correct.  
- Cable routing correct  
Accelerator cable adjustment :  
- Remove the kick down cable from the drum.  
- Pull out the sleeve stop (1) and fit the spring clip (2) so as to obtain a small  
clearance at «a».  
Kick down cable adjustment :  
- Pull out the cable until the start of the kick down command, the lug (3) should be  
at: X = 39 mm from the end of the sleeve.  
- The lug (3) should then be positioned and crimped on the cable.  
- Refit the kick down cable on the drum.  
- Adjust the clearance (B) from 0.5 mm to 1 mm max. by tightening the nuts (4).  
B2CP35DC  
B2CP35CC  
B2CP013C B2CP35EC  
198  
manuals search engine  
RECOMMENDATIONS - PRECAUTIONS : AL 4 and 4 HP 20 AUTOMATIC GEARBOXES  
Engines : LFY - RFV - RFN - XFZ - DHX  
XANTIA - XM - SYNERGIE  
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 :  
- 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)  
- Never drive with the ignition switched off.  
- Never push the vehicle to try to start it;  
(impossible with an automatic gearbox).  
Lubrication  
WARNING :With the safety programme selected, a snatching can be  
felt when changing from ‘‘P’’ ‘‘R’’ or ‘‘N’’ ‘‘R’’.  
The automatic gearbox is only lubricated when the engine is running.  
199  
manuals search engine  
XANTIA - XM - SYNERGIE  
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX  
Engines : LFY - RFV - RFN - DHX  
PROCEDURE BEFORE REPAIRS  
AL 4 gearbox  
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.  
200  
manuals search engine  
XANTIA - XM - SYNERGIE  
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX  
Engines : LFY - RFV - RFN - DHX  
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 (2).  
- 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).  
B2CP31FD  
201  
manuals search engine  
XANTIA - XM  
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX  
Engine : XFZ  
Tools  
[1] Hose clamp pliers  
[2] Filling cylinder  
[3] Specific end-piece  
: 4517-T  
: (-).0341.  
: (-).0341.B.  
Tool kit 4507-T  
Checking the oil level.  
Preliminary conditions  
- Vehicle in horizontal position, handbrake released.  
- Engine idling, without using power (headlamps, heated rear screen etc.).  
- Check absence of gearbox back-up mode; using a diagnostic tool.  
- Apply the brake, change through all the gears.  
- Gear selection lever at position P.  
- The check is to be carried out when the oil has reached a temperature of 55°C ± 1°C; using a diagnostic tool.  
- Remove the oil filler plug (3).  
B1BP202C  
202  
manuals search engine  
XANTIA- XM  
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX  
Engine : XFZ  
Checking the oil level (continued)  
Flowing of oil from the oil filler aperture.  
- As soon as the oil temperature reaches 60°C ± 1°C, refit the oil filler plug (*).  
Note : The oil level is correct.  
No flowing of oil from the oil filler aperture.  
- Refit the oil filler plug (3).  
- Stop the engine.  
- Remove the air vent assembly (1) and (2) from the gearbox; using tool [1].  
- Add 0.5 litre of additional oil into the gearbox; using tool [2].  
- Repeat the procedure of topping up the oil.  
- Remove the tools [2] and [3].  
- Refit the metallic part (1) of the air vent assembly, using a Ø 18 mm drift and a mallet.  
- Clip on the plastic part (2) of the air vent assembly.  
- Refit the air filter housing.  
(*) Note : The method of topping up gearbox oil with an oil gauge remains unchanged.  
B2CP3ACD B2CP3ABC  
203  
manuals search engine  
XANTIA - XM  
RECOMMENDATIONS - PRECAUTIONS : AL 4 and 4 HP 20 AUTOMATIC GEARBOXES  
Engines : LFY - RFV - RFN - XFZ - DHX  
PROCEDURE BEFORE REPAIRS (continued)  
When the ECU detects an erroneous or non-existent value  
on input or output :  
Reading the fault codes.  
- Read the fault codes.  
- It writes the fault in memory.  
- For each associated context, it writes the context of the oldest fault  
in memory.  
No fault codes present :  
Carry out a measure of parameters.  
- It initiates a back-up mode strategy.  
Anomalies present :  
YES : Carry out the necessary repairs.  
NO : Read the fault codes – engine ECU  
There are two types of back-up modes :  
- The ECU makes replacement values available (relating to comfort,  
gear selection quality, loss of functions).  
- Carry out a road test.  
Following an initialisation of the ECU, for a certain period of time  
there may be an inconsistent gear selection quality (while ECU  
parameters are adapted to the gearbox).  
- Access to emergency programme (only 3rd ratio and reverse are  
available).  
To achieve a consistent standard, it will be necessary to carry out a  
road test taking in frequent gear changes (auto-adaptive laws).  
Note : 4 HP 20 : A snatching may be felt when changing :  
P/R - N/R - N/D.  
204  
manuals search engine  
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX  
Engine : XFZ  
XANTIA- XM  
ECU : Downloading, Configuration, Initialisation (Pedal).  
Downloading (4 HP 20)  
Updating the gearbox ECU by downloading :  
- Follow the procedure using the diagnostic equipment  
The operation of downloading is used to update the automatic gearbox ECU or to adapt it to the engine ECU.  
After downloading, carry out the following :  
Following the diagnostic tool procedure.  
- A reinitialisation of the auto adaptor (4 HP 20).  
- A road test (4 HP 20).  
IMPERATIVE : Every update of the automatic gearbox ECU  
must be accompanied by an update of the engine ECU.  
205  
manuals search engine  
XANTIA - XM - SYNERGIE  
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX  
Engines : LFY-RFV-DHX-RFN  
ECU : Downloading  
Updating the gearbox ECU by downloading :  
- SFollow 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 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.  
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.  
206  
manuals search engine  
XANTIA - XM - SYNERGIE  
RECOMMENDATIONS - PRECAUTIONS : AL 4 AUTOMATIC GEARBOX  
Engines : LFY-RFV-DHX-RFN  
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).  
207  
manuals search engine  
SYNERGIE  
RECOMMENDATIONS - PRECAUTIONS : AL4 AUTOMATIC GEARBOX  
Engine : RFN  
Gear control is by a cable linked to the selection lever located on the  
dashboard.  
The gear selection control has 5 positions :  
«P» Park (immobilisation of the vehicle, whatever the slope).  
«R» Reverse gear.  
«N» Neutral.  
«D» Drive (autoadaptative mode, eco-law).  
«M» Manual mode (M+, M-).  
The vehicle can only be started when the selection lever is in position «P»  
or «N».  
Shift-Lock  
The «shift-lock» is a system which locks the gear selection lever in  
position «P».  
To unlock the gear selection lever from position «P», switch on the  
ignition and press the brake pedal.  
During a repair, the shift-lock can be unlocked by pressing the locking  
finger «a» (see corresponding operation).  
B2CP3CFD  
208  
manuals search engine  
RECOMMENDATIONS - PRECAUTIONS : 4 HP 20 AUTOMATIC GEARBOX  
Engine : XFZ  
XANTIA- XM  
SHIFT LOCK  
- The shift lock is a system which locks the selection lever in the park position «P».  
Unlocking the SHIFT LOCK (in normal operation)  
- Switch on the ignition.  
- Press and hold down the brake pedal.  
- Using the selection lever, disengage from position «P».  
NOTE : It is IMPERATIVE to disengage the gear selection lever from position "P" the minute  
you start applying the brake pedal. Otherwise, release pressure on the brake pedal and then  
try again.  
Unlocking the SHIFT LOCK (In the event of a malfunction)  
- Remove the cover (1).  
- Unlock the shift lock (2) using a screwdriver.  
- Using the selection lever, disengage from position «P».  
B2CP268C B2CP269C  
209  
manuals search engine  
XANTIA - XM - SYNERGIE  
AL 4 AUTOMATIC GEARBOX  
Engine : LFY - RFV - RFN - DHX  
WARNING : CITROEN special semi-synthetic oil cannot be mixed with other oils.  
The gearbox is lubricated for life.  
(a) Component reference.  
B2CP30ZD  
210  
manuals search engine  
XANTIA- XM  
4 HP 20 AUTOMATIC GEARBOX  
Engine : XFZ  
(1) Oil/water exchanger.  
(2) Selection lever position switch.  
(3) Torque converter.  
(4) Differential.  
(5) Secondary shaft.  
(6) Clutch.  
(7) Brake.  
B2CP34VP  
211  
manuals search engine  
XANTIA - XM  
GEARBOX CONTROLS - 4 HP 20 AUTOMATIC GEARBOX  
Engines : XFZ  
4 HP 20  
Adjusting the selection mechanism.  
- Put selection lever (5) in position : parking.  
- Untighten nut (2) and the lock nut (4) on either side of the linkage (3)  
so as to connect the ball-joint (1) to the selector.  
- Apply grease G9.  
- Tighten the nut (2) and the lock nut (4) to 1 m.daN.  
B2CP37FD  
212  
manuals search engine  
XANTIA- XM  
GEARBOX CONTROLS - AL 4 and 4 HP 20 AUTOMATIC GEARBOXES  
Engines : LFY - RFV - DHX - XFZ  
Adjusting the selection mechanism  
4 HP 20  
- If the selection mechanism is NEW, pull out the locking key (1) 1/4 of  
a turn.  
If the selection mechanism is OLD and not set correctly, press on  
component (2), without flexing the cable, then release.  
- Check the passage through all the gears.  
B2CP35FD  
AL 4  
Adjusting the selection mechanism.  
- If the selection mechanism is NEW or removed from the vehicle,  
component (1) is locked..  
When fitting the selection mechanism, press on component (2),  
without flexing the cable, then release. (Component (1) unlocks).  
- Check the passage through all the gears.  
B2CP37ED  
213  
manuals search engine  
ALL TYPES  
TRANSMISSION - GEARBOX  
Tightening torque (m.daN)  
Gearbox oil seal mandrels  
Driveshaft  
bearing  
Driveshaft  
nut  
Right  
Left  
Tool kit  
Gearbox  
Engines  
BE3/5  
BFZ-LFX-LFY-RFV-RHY  
RFN  
32.5  
7114-T.X  
9017-TC  
7116-T  
9017-T  
7114-T.W  
9017.T.B  
BE4/5  
ME/5  
34.5  
32.5  
RGX-P8C  
1
RGX-XFZ-RHZ  
5701-T.A  
ML/5  
9017.T.C  
NO  
RFV-RGX  
DHX-RHZ-P8C (Synergie)  
10 + 60°  
34.5  
MG/5  
1.9  
THY  
5708-T.J  
5708-T.H  
5708-T  
4 HP 18  
RGX - RFV - P8C  
Seal extractor  
Right/Left (-) 0338 C  
AL 4  
LFY - RFV - DHX  
(-) 0338  
8010-T  
(-) 0338 H1  
(-) 0338 J1  
1
32.5  
+ (-) 0338 H2  
+ (-) 0338 J2  
8010-T.K2 +  
8010-T.J.  
Rep. : rouge  
8010-T.K1 +  
8010-T.J.  
Rep. : noir  
4 HP 2 0  
XFZ  
Tightening torque (m da.N) of the wheel bolts : XANTIA - XM = 9  
-
SYNERGIE = 10.  
214  
manuals search engine