CITROEN 2002 BERLINGO - Automatic Gearbox

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196

CLUTCH

GEARBOX

DRIVESHAFTS

AUTOMATIC GEARBOX - AL 4

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.

Engines : NFU - RFN - RHZ

B2CP30ZD

XSARA

Main Page

Presentation2
Identification of Vehicles4
Capacities27
Draining Method27
TOTAL Recommended Oils32
S.A.E. Norm - Table for Selection of Engine Oil Grade32
ACEA Norms34
API Norms34
Blended Oils for All Engines36
Oils Specifically for Petrol and Dual-Fuel Petrol / LPG Engines36
Oils Specifically for Diesel Engines36
Engine Oil Consumption47
Engine Specifications48
Special Features - Tightening Torques52
All Types52
Cylinder Head54
Identification of the Cylinder Head Gasket58
Cylinder Head Bolts59
Cylinder Head Tightening (M.dan)64
Belt Tension/Seem Units Correspondence Table65
Auxiliary Equipment Drive Belt 200266
Auxiliary Equipment Drive Belt67
Alternator70
Power-Assisted Steering70
Plyers for Removing Plastic Peg76
Without Power-Assisted Steering77
Belt Tension Measuring Instrument77
Without Power-Assisted Steering, with Air Conditioning78
Power-Assisted Steering, Without Air Conditioning79
Power-Assisted Steering, with Air Conditioning81
Without Air Conditioning83
No Re-Use of Belt83
Checking the Valve Timing89
Setting the Valve Timing89
Refitting the Timing Belt90
Pre-Tensioning the Timing Belt90
Adjusting the Belt Fitting Tension91
Checking the Belt Tension91
Checking the Valve Timing.101
Timing Belt Tension103
Adjusting the Tension103
Positioning of the Crankshaft104
Repositioning the Flange105
Checking the Setting106
Setting the Valve Timing.107
Pretensioning the Timing Belt108
Tensioning the Timing Belt109
Camshaft Hub Identification121
Special Features of the Timing121
Valve Clearance Settings122
Possible Procedures122
Checking the Oil Pressure123
Engine Oil Pressure Switch124
Oil Filters126
Filling and Bleeding the Cooling Circuit127
Idling - Anti-Pollution128
Petrol Injection131
Petrol Injection132
Emission Standards134
Anti-Pollution Technical Checks (France)142
Fuel Supply Circuit143
Electric Circuit143
High Pressure Fuel Pump143
Identification Markings144
Safety Requirements145
Cleanliness Requirements146
Preliminary Operations146
Checks : Low Pressure Fuel Supply Circuit147
Checks: Air Supply Circuit149
Manual Vacuum Pump149
Vacuum Pump149
Pressure Regulator Valve149
Checks: Turbo Pressure150
Checks: Exhaust Gases Recycling Circuit152
Exhaust Gas Reycling (EGR) Electrovalve152
Specifications of the Siemens Injection Pump153
Specifications of the Delphi Diesel Injection Pump156
Old Assembly157
Checking and Setting the Delphi Mechanical Injection Pump158
Impossible to Peg the Camshaft159
Adjusting the Delphi Mechanical Injection Pump Controls160
Adjusting the Fast Idle160
Checking the Thermostatic Sensor160
Adjusting the Accelerator Control160
Adjusting the Anti-Stall (Residual Output)161
Adjusting the Idle Speed161
Checking the Engine Deceleration161
Fitting Delphi Diesel Injectors162
Fitting an Injector162
Bosch Injection Pump Specifications163
Checking and Setting the Bosch Mechanical Injection Pump165
Setting the Injection Pump165
Adjusting the Fast Idle Speed166
Engine Cold166
Engine Hot166
Anti-Stall Adjustment168
Checking the Engine Deceleration.e168
Fitting Bosch Injectors169
Sparking Plugs171
Speedometer172
Clutch Specifications173
Clutch: Checks and Adjustments175
Mechanically Operated Push-Action Clutch (Adjustable)175
Push-Action Clutch with Automatic Adjustment (Non-Adjustable)176
Refitting the Clutch Cable177
Adjustment of Push and Pull Action Clutch with Automatic Compensation178
Gearbox and Tyre Specifications181
Gearbox - Ma/5184
Gearbox Controls - Ma/5185
Gearbox – Be4/5186
Be4/5 Gearbox – Checks and Adjustments190
Principles of Adjusting the Gear Controls190
Be4/5 Gearbox - Checks and Adjustments191
Adjusting the Gear Controls191
Inside the Vehicle191
Under the Bonnet191
Automatic Gearbox - Mb3192
Recommendations - Precautions (Mb3 Automatic Gearbox)193
Precautions to be Taken193
Recommendations – Precautions (Automatic Gearbox - Mb3)194
Oil Quality194
Oil Level (Prior Conditions)194
Negative Pressure Circuit195
Checks Using the Diagnostic Tool195
Absence of Fault Codes195
Fault Codes Present195
Special Features: Automatic Gearbox - Mb3196
Hydraulic Valve Block196
Fitting the Casing196
Mb3 Automatic Gearbox Controls197
Mb3 Automatic Gearbox Controls - Checks and Adjustments198
Selection Control198
Adjusting the Selection Control198
Automatic Gearbox - al 4199
Recommendations - Precautions (Automatic Gearbox - al 4 )200
Procedure before Repairs201
Reading the Fault Codes203
Presence of Anomalies203
Updating the Gearbox ECU by Downloading204
Updating the Value of the Oil Usage Counter204
Using PROXIA204
Using LEXIA or ELIT204
Shift Lock206
Unlocking the SHIFT LOCK (in Normal Operation)206
Unlocking the SHIFT LOCK (in the Event of a Malfunction)206
Driveshafts - Gearboxes207
Geometry of the Axles at Reference Height208
Axle Geometry209
Normal Suspension210
Raised Suspension210
Axle Geometry210
Front Axle211
Suspension – Front Anti-Roll Bar211
Rear Axle - Suspension213
Steering Specifications214
Manual Steering214
Power Steering System217
Front and Rear Measuring Points219
Reference Heights220
Setting the Reference Height220
Values of the Front and Rear Suspensions, at Reference Height221
Pivot Ball Joint227
Rear Axle231
Adjusting the Rear Dummy Damper232
Manual Steering Specifications233
Steering Wheel - Manual Steering233
Power-Assisted Steering Specifications236
Steering Wheel - Power-Assisted Steering236
Power-Assisted Steering Assembly239
Measurements at Reference Height240
Evolution: Rear Hub Nut245
Height of the Vehicle in Running Order246
Measurements at the Front and Rear Axles, Vehicle in Running Order247
Steering Column Specifications248
Brake Specifications252
Brakes254
Adjusting the Brake Limiter254
Removing the Caliper255
Application from RPO 8973256
Bleeding the Brakes259
Checking the Brake Pressure274
Adjusting the Compensator275
Checking and Adjusting the Handbrake276
Braking System Specifications279
Checking and Adjusting the Load-Sensitive Brake Compensator281
Brake Pressure Checking Tool281
Weight of Fuel in the Fuel Tank281
Determining the Rear Weight of the Vehicle281
Weight of the Options on the Vehicle282
Checking the Braking Pressure286
Adjusting the Load-Sensitive Brake Compensator287
Starter Motors290
Alternators295
Checking the Alternator Output302
Checking the Voltage Regulator302
BEHR Plate Evaporator309
Pollen Filter309
BEHR Condenser with Integral Reservoir (16 Ti)310
Compressor Lubricant313
Checking the Compressor Oil Level313
Checking Temperatures315
Two Thermometers315
Checks on the Air Conditioning Circuit320
Plan of Air Conditioning System321

CITROEN 2002 BERLINGO - Automatic Gearbox - al 4

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