Get Clutch, Gearbox, Driveshafts Guide for Citroen Xsara SUV Second Generation (1997-2006)

SAXO - XSARA

FITTING BOSCH INJECTORS

Engine : VJX

[1] Tool to remove/refit injectors (2)

7007-T

Fitting an injector

[2]

7008-T Tool kit 4123-T

The copper seal (1) and the

fire seal washer (2) are to be

replaced each time they are

removed.

NOTE : Fitting parts of diffe-

rent makes is PROHIBITED.

WARNING : Ensure that the fire

seal washer (2) is fitted the right

way round.

Tighten the injector holder

on the cylinder head to :

VJZ

7 m.daN

All Types

9 m.daN

(3) Tighten lightly to avoid distortion.

Tighten to 7 m.daN.

B1HP0YNC B1HP0YPC

B1HP0YGC

166

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XSARA - XSARA PICASSO

FITTING BOSCH INJECTORS

Engine : RHY

Evolution : Classification of diesel injector carriers

Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection

duct diameters (flow of diesel fuel).

16/11/98 #

Identification.

The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel fuel

return aperture :

Mark 1 = BLUE paint mark = Injector class 1.

Mark 2 = GREEN paint mark = Injector class 2.

Identification marking:

a : Supplier identification.

b : PSA identification no.

c : Identification of class.

After Sales operations.

ESSENTIAL : When changing a diesel injector carrier, order a component of the same class.

# 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier.

B1HP16PC

167

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ALL TYPES

SPARKING PLUGS

Electrode

gap setting

Tightening

torque

Vehicles – Models

BOSCH

CHAMPION

Engine type

SAGEM

1.1i

HDZ/HDY

KFX

1.4i

SAXO

FR7DE

RC8YCL

RFN58LZ

1.6i

NFZ

2.5 mdaN

0.9 mm

1.6i 16v

1.4i

NFX

KFW

NFU

FR7DE

FR7ME

FR8ME

FR6DE

RC8YCL

1.6i 16v

2.0i 16v

XSARA

RFN

REC9YCL

RFN52HZ

RFN62LZ

1 mm

0.9 mm

1 mm

2.7 mdaN

RFS

16i

NFV

6FZ

FR7DE

FR8ME

RC8YCL

RFN58LZ

RFN52HZ

2.5 mdaN

2.7 mdaN

XSARA PICASSO

1.8i 16v

REC9YCL

1.1i

HDZ

HFX

FR7DE

FR7KDC

FR7DE

FR7ME

FR7DE

RC8YCL

2.5 mdaN

2.7 mdaN

BERLINGO

1.4i

KFX/KFW

NFU

RC8YCL

RFN58LZ

0.9 mm

1.6i 16v

1.8i

LFX

RC8YCL

168

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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 :

VR < VL < 1.10 VR + 4 Km/h

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.

169

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CLUTCH SPECIFICATIONS

ALL TYPES

1.4i

1.6i 16V

NFX NFU

1.5D

VJX

1.1i

1.6i

Engine type

Gearbox

Make

HDZ

HFX

KFX

KFW

NFT

NFV

MA/4 - MA/5

VALEO

LUK

180 CPO

3400

Mechanism/Type

Clutch disc

180 CP 3400

2200 CPR 3800

180 P 3000

180 XJF

73 C

181 XJ (E73) 11 R 10 X

200X(D95) 11A12X

80D

Ext./Int. lining Ø

Disc lining type

180/127

F 408

200/137

F 410

180/135

F 410

F 808

170

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CLUTCH SPECIFICATIONS

ALL TYPES

2.0i 16V

1.8i 16V

6FZ

1.9TD

2.0 HDi

1.8i

Engine type

Gearbox

Make

LFX

RFN

RFS

WJZ

WJY

DHY

RHY

BE4/5

VALEO

LUK

200 CP

4250

215 DT 5250

Mechanism/Type

Clutch disc

230 DNG 4700

200 P 3700

230 P 4700

200 B

(D73) 33AX

215 F D95

215/147

215 F (D 93) 22 BX

200/134

228

Ext./Int. lining Ø

Disc lining type

200/137

F 408

228/155

F 808

F408

171

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SAXO - XSARA

CLUTCH : CHECKS AND ADJUSTMENTS

Mechanically operated push-action clutch (adjustable)

HFX-KFW-NFT-NFX-VJX

KFW-NFU

SAXO

Adjustable

Engines

MA/5

Gearbox

XSARA

Non-adjustable*

(*) See page 175)

ESSENTIAL : If the clutch control is new, squeeze the cable sheath before adjusting by declutching

successively a minimum of 20 times.

Checks

NOTE : Adjustable steering wheels should be put into the low position

- Record the measurement ‘‘X’’ between positions L1, pedal at rest, and L2, pedal fully depressed.

- Measurement ‘‘X’’ should be : (Pedal travel).

SAXO

135 ± 5 mm

Adjustments.

- If the measurement is incorrect, adjust the clutch pedal travel "X".

- Loosen the lock nuts (1).

- To adjust the travel to conform with the measurements indicated above, either loosen or tighten the nut (2)

(Tighten the nut to increase the travel, and loosen it to decrease the travel.)

- Tighten the lock nut (1).

B2BP023C

B2BP00GC

172

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XSARA

CLUTCH : CHECKS AND ADJUSTMENTS

Push-action clutch with automatic adjustment (non-adjustable) ( )

*

BE3/5 – BE4/5

Engines

LFX - WJZ - WJY

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 176 to 177.).

*

B2BP03CD

173

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XSARA - XSARA PICASSO

CLUTCH : CHECKS AND ADJUSTMENTS

Pull-action clutch with automatic adjustment (non-adjustable) ( )

*

BE4/5

Engines

RFS – RFN – RHY - RHY

Gearbox

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 176 to 177.).

*

B2BP03DD

174

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CLUTCH : CHECKS AND ADJUSTMENTS

XSARA - XSARA PICASSO

Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)

Engines : LFX - RFN - RFS - WJX - 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

175

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CLUTCH : CHECKS AND ADJUSTMENTS

XSARA - XSARA PICASSO

Engines : LFX - RFN - RFS - WJX - 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 cable sleeve.

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 - Hooking yoke.

176

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CLUTCH : CHECKS AND ADJUSTMENTS

XSARA - XSARA PICASSO

Engines : LFX - RFN - RFS - WJX - RHY - RHZ

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.

177

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SAXO - All Types

GEARBOX AND TYRE SPECIFICATIONS

Petrol

1.4i

1.1i

1.6i

1.6i 16V

Automatic

Engine type

HFX

KFW

155/70 R 13 – 1.67 m

MA/5

NFT

NFX

Tyres-Rolling circumference

Gearbox type

165/65 R14 1.725m

185/55 R14 1.7 m

MB3

312

MA/4 – MA/5

20 CN 03 – 20 CN 05

17x61 16x63

Gearbox ident. plate

20 CF 03

20 CF 12

Reduction box torque

Speedometer ratio

14x60

19x17

17x64

19x17

17x56

21x19

19x17

Diesel

1.5D

VJX

Engine type

Tyres-Rolling circumference

Gearbox type

165/65 R14 – 1.725 m

MA/5

Gearbox ident. plate

20 CF 02 29/08/200 ꢀ

Reduction box torque

Speedometer ratio

17x64

19x17

178

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GEARBOX AND TYRE SPECIFICATIONS

XSARA # 09/2000

Petrol

1.6i 16V

2.0i 16V

1.4i

Automatic

Engine type

KFW

NFU

RFN

RFS

Tyres-Rolling circumference

Gearbox type

195/55 R15 - 1.815 m

MA/5

AL4

BE4/5

AL4

BE3/5

20 TP 49

Gearbox ident. plate

Reduction box torque

Speedometer ratio

20 CF 13

20 DL 40

20 TE 47

20 CN 28

20 TP 47

16x65

21x18

21x73

24x21

19x72

22x19

23x73

24x21

14x62

22x19

Diesel

2.0 Hdi

1.9D

Automatic

Engine type

WJY

RHY

RHZ

195/55 R15 – 1.815 m

BE4/5

Tyres-Rolling circumference

AL4

Gearbox type

20 DL 41

19x75

20 DL 42

19x70

20 DM 10

17x61

20 TP 48

Gearbox ident. plate

Reduction box torque

Speedometer ratio

22x19

Right hand drive :

6FZ-RFN = 20 DM 03

WJZ – WJY = 20 DM 05

RHY = 20 DM 07

RHZ = 20 DM 11

179

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GEARBOX AND TYRE SPECIFICATIONS

XSARA PICASSO

Petrol

Diesel

1.6i

1.8i 16 V

2.0 HDi

Engine type

NFV

6FZ

185/65 R15 – 1.895 m

BE4/5

RHY

Tyres-Rolling circumference

Gearbox type

Gearbox ident. plate

Reduction box torque

Speedometer ratio

20 DL 66

15x64

20 DL 68

20 DL 64

19x72

19x77

22x18

Right hand drive :

NFV = 20 DL 67

6FZ = 20 DL 69

RHY = 20 DL 65.

180

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GEARBOX - MA/5

SAXO - XSARA

Engines : HFX - KFW - NFT - NFX - NFU - VJX

Filler screw

Drain screw

B2CP34HP

B2CP20FC

B2CP20GC

181

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SAXO - XSARA

GEARBOX CONTROLS - MA/5

Engines : HFX - KFW - NFT - NFX - NFU - VJX

1 - Gear lever.

2 - Gear control rod.

3 - Gear control rod.

4 - Gear selection rod.

5 - Gear selection rod.

6 - Knuckle joint

A = 11.5 mm.

B = 9.5 mm.

C = 3 mm.

7 - Fixed point on the gearbox.

B2CP16SP

B2CP16TC

182

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GEARBOX – BE4/5

XSARA - XSARA PICASSO

Engines : NFV - 6FZ - RFN - RFS - WJY - RHY - RHZ

(a) = Marking zone (Sequence and serial no.).

(b) = Location of identification label.

B2CP3BNC B2CP3BPD

183

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XSARA - XSARA PICASSO

GEARBOX – BE4/5

Engines : NFV - 6FZ - RFN - RFS - WJY - RHY - RHZ

Identification

(14) 1^st/ 2^ndgear synchroniser

(1) Primary shaft.

(15) Driven gear (1^stgear).

(16) Secondary shaft.

(17) Differential gear.

(18) Satellite gears.

(19) Planet gears.

(2) Clutch bearing guide.

(3) Gearbox casing.

(4) Clutch housing.

(5) Reverse idle.

(6) Drive gear (3^rdgear).

(7) 3^rd/4^thgear synchroniser

(8) Drive gear (4^thgear).

(9) Drive gear (5^thgear).

(10) 5^thgear synchroniser.

(11) Driven gear (5^thgear).

(12) Driven gear (3^rd/ 4^thgear )

(13) Driven gear (2^ndgear).

(20) Differential housing.

(21) Speedometer drive.

(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).

B2CP3BQP

184

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GEARBOX– BE4/5

SAXO - XSARA - XSARA PICASSO

Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ

Tightening torques

Description

End guide

Ref.

1

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

3

13

1

2

Clutch housing

3

Primary shaft nut

4

Secondary shaft nut

Yoke holding screw

Differential gearwheel screw

Reverse gear contact

Differential housing

Breather pipe

1

5

2

6

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

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SAXO - XSARA - XSARA PICASSO

GEARBOX CONTROLS - BE4/5

Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ

(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

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SAXO - XSARA - XSARA PICASSO

BE4/5 GEARBOX – CHECKS AND ADJUSTMENTS

Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ

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.

Fit the ball-joints on the gearbox lever.

possible as long as the locking key is removed.

Unclip at "b", using two small screwdrivers.

Lock the cable lengths with the ball-joint locking

keys.

B2CP3BXC B2CP3BYC

187

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BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS

Engines : NFV - 6FZ - RFN - RFS - WJY – RHY - RHZ

Adjusting the gear controls.

SAXO - XSARA - XSARA PICASSO

TOOLS.

[1] ] Tool for positioning the gear lever

ADJUSTMENTS.

: 9607-T.

CHECKS.

WARNING : Cables should be adjusted each

time the gearbox, gear controls or power unit

are removed.

- Remove the tool [1].

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.

Inside the vehicle.

- Remove the trim under the gear lever.

- Lock the gear lever in neutral position,using tool [1].

- Refit the trim under the gear lever.

- Refit the air filter assembly.

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

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AUTOMATIC GEARBOX - MB3

SAXO

Engine : KFW

Tightening torques m.daN.

- Gearbox to engine fixing

3.5

- Converter to engine fixing

- Converter closing plate fixing

M8

2.5

1.6

2.6

6.5

8.5

1

M10

- Electrical bracket fixing

- Flexible mounting to gearbox fixing

- Speedometer drive

- Heat exchanger fixing

5

NOTE : When fitting a new automatic gearbox, it is

ESSENTIAL that the heat exchanger and the oil be

replaced.

B2CP14ZP

189

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SAXO

RECOMMENDATIONS - PRECAUTIONS (MB3 AUTOMATIC GEARBOX)

Engine : KFW

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).

- Add an extra 2 litres of oil to the automatic gearbox.

- Do not exceed 30 kph over a distance of 50 km.

- Gear lever in position "N".

Driveshafts.

ESSENTIAL : When moving the left driveshaft, ensure it remains

horizontal (risk of losing the tri-axe joint needles).

WARNING : Do not forget to remove the extra oil.

Driving.

Initialising procedure.

Never drive with the ignition switched off.

Never push the vehicle to try to start it (impossible with an automatic

gearbox).

The gearbox should be initialised in the following cases :

- Replacement of the ECU.

- Clearing of faults.

NOTE : The automatic gearbox is only lubricated when the engine is

running.

Wait until the vehicle is completely stationary before engaging the

gear lever in position "P".

- Replacement of the potentiometer.

- Replacement or adjustment of the accelerator cable.

- Incorrect initialisation.

NOTE : The initialisation procedure should be checked using a

diagnostic tool.

190

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RECOMMENDATIONS – PRECAUTIONS (AUTOMATIC GEARBOX - MB3)

SAXO

Engine : KFW

PRE-REPAIR PROCEDURE

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 (prior conditions)

- Oil hot (80°C min.).

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

- Vehicle on a level surface.

- Selection lever in position "P".

- Engine running.

The level should be between the min. markings "A" and "B" on the dipstick.

ESSENTIAL : In no case should the oil level exceed the marking "B".

Top up the automatic gearbox oil level (if necessary).

B2CP16WC

191

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SAXO

RECOMMENDATIONS – PRECAUTIONS (AUTOMATIC GEARBOX - MB3)

Engine : KFW

PRE-REPAIR PROCEDURE (continued)

Negative pressure circuit.

Absence of fault codes

Measure the parameters.

Anomalies present:

- YES : Carry out the necessary repairs.

- NO : Check (adjust the negative pressure capsule).

- Check the negative pressure circuit.

- Carry out the necessary repairs.

Checks using the diagnostic tool.

ESSENTIAL : Initialise the ECU

Perform a road tes

Preliminary checks :

- The adjustment of the gear selection control.

- The adjustment of the accelerator cable.

Carry out the necessary operations

Fault codes present

Carry out the necessary repairs.

Clear the fault codes.

Reading the fault codes

Read the fault codes.

ESSENTIAL : Initialise the ECU

Perform a road test.

192

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SPECIAL FEATURES: AUTOMATIC GEARBOX - MB3

SAXO

Engine : KFW

Hydraulic valve block.

Refitting.

WARNING : On refitting the strainer, ensure that the bracket (6) runs under the

washer of the screw (7).

- Refit the strainer without tightening the screws.

- Observe the following tightening sequence :

- Screws 1,2,3,4 and 5 to 0.9 m.daN.

ESSENTIAL : Respect the position of the magnets in the lower casing. Clean

the casing before placing the smooth side of the magnet against the sheet

metal.

Fitting the casing.

WARNING : The fixing brackets (8) of the lower casing have a fitting direction

(small side = lower casing side).

Tightening torque 0.6 m.daN.

B2CP34PC

B2CP13TC

B2CP34QC

193

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SAXO

MB3 AUTOMATIC GEARBOX CONTROLS

Engine : KFW

B2CP352D

194

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SAXO

MB3 AUTOMATIC GEARBOX CONTROLS - CHECKS AND ADJUSTMENTS

Selection control

Adjusting the selection control

WARNING: No part must be forced

while performing these operations

(careful removal).

ESSENTIAL : Put the gearbox side

control in the 1st imposed position;

the 2 markings "a" must be aligned.

Removing the gear lever knob.

- Remove the screws (1).

- Lift the lever knob (2) by about 10 mm.

- Turn backwards by 1/4 turn, and

raise by approximately 7 mm.

- Press and hold down the locking

button (3).

- Fit the ball joint (1).

- Fit the lug (2).

- Lock the outer cable stop by 1/4 turn

(in the direction of the arrow).

- Check that the painted markings "b"

are aligned.

- Turn forwards by 1/4 turn, remove the gear lever knob (2).

Refitting the gear lever knob

- Press and hold down the locking button (3).

- Fit the knob (2) on the lever until it touches its stop (in the direction

shown in the diagram).

- Release the locking button (3).

- Turn forwards by 1/4 turn.

- Refit the screws (1).

ESSENTIAL : Check the passage of all the gears, otherwise adjust

the selection control.

B2CP18YC

B2CP18WC B2CP18XC

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XSARA

AUTOMATIC GEARBOX - AL 4

Engines : NFU - RFN - RHZ

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.

B2CP30ZD

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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

Engines : NFU - RFN - RHZ

XSARA

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).

IMPERATIVE : - Put gear lever in position "N".

- Do not add any oil.

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

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

pushing the gearbox

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

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

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XSARA

RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4)

Engines : NFU – RFN - RHZ

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.

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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4)

XSARA

Engines : NFU - RFN - RHZ

PROCEDURE BEFORE REPAIRS

Oil level AL 4 (prior conditions).

AL 4 gearbox only

- 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 : Dimension X : TU and EW engines = 81 mm DW engines = 77 mm.

B2CP31FD

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XSARA

RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

Engines : NFU – RFN - RHZ

PROCEDURE BEFORE REPAIRS (continued)

When the ECU detects an erroneous or absent valueon input or

output :

Reading the fault codes.

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 fault

in memory.

- Carry out a measure of parameters.

- It initiates a back-up mode strategy.

Presence of anomalies:

There are two types of back-up modes :

- YES : Carry out the necessary repairs.

- NO : Read the fault codes - engine ECU

- 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).

- Access to emergency programme (only 3rd gear 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).

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RECOMMENDATIONS - PRECAUTIONS (AUTOMATIC GEARBOX - AL 4 )

XSARA

Engines : NFU - RFN - RHZ

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 LEXIA or ELIT.

Using PROXIA

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.

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Clutch, Gearbox, Driveshafts for Your Citroen Xsara SUV Second Generation (1997-2006)

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