C3 Clutch
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Date
April 16, 2015
Clutch
General procedures
It is possible that the procedures included in these instructions require the use of
tools and equipment considered 'standard workshop equipment'. For example:
Vehicle lifts, engine cranes, transmission jacks, and support beams
of engines/transmissions. It is essential that the personnel carrying out these
procedures are properly trained to use the equipment and ensure that
observe the regulations on safety and hygiene.
If the pressure plate is going to be reused, mark it to ensure it is reassembled in the same position.
the original position on the flywheel.
Mark the installation direction of the clutch disc to be able to install it correctly.
Disconnect the ground cable from the battery.
If it has a guide bearing, check its condition. Replace if necessary.
Make sure that the grooves of the primary shaft of the gearbox are clean and that the
clutch disc can slide freely.
Lubricate the splines of the primary shaft with the specified lubricant (if one is mentioned)
from the gearbox and the clutch release bearing mechanism.
The screws should NOT be loosened or tightened with an impact wrench.
If necessary, bleed the clutch hydraulic system after installing it. Use the
specified brake fluid.
Special tools
Manufacturer's diagnosis equipment or equivalent (automated manual change).
Clutch actuator adjustment tool (automated manual transmission) - Citroen no.
Clutch alignment tool - Citroen no.
Left axle oil seal installation tool - Citroen no.
Right axle oil seal mounting tool - Citroen nº.
Lubricants and fluids
Vehicle data:
Enrollment: Model: Citroen C3 I/II/First/Classic KFV (TU3JP)
Year of construction:
1/6
Lubricant/liquid Specification
Gearbox oil Refer to the Technical Data module
Brake fluid Refer to the Technical Data module
Automatic manual transmission hydraulic fluid Refer to the Technical Data module
Disassembly of the gearbox
Remove the gearbox from underneath the vehicle.
Components to disassemble:
Battery and battery tray.
Air filter box and air intake pipe(s).
Motor control module.
Steering control module.
Pallets.
Torque reaction arm.
1.4D HDi
Remove the catalytic converter.
Disassemble the cooling fan.
Automated manual transmission:
Give the contact.
Move the gear lever to the neutral position.
Make sure that the gear shift indicator "N" on the dashboard is
illuminated.
Set the gear shift actuator of the transmission to the inspection position
Fig. 1The gear shift actuator of the gearbox can only be put on
in the review position with a manufacturer diagnosis team or equivalent.
Remove the contact.
Wait at least 60 seconds.
Dismantle the gear shift actuator of the gearbox.
Dismantle the clutch actuator.
Dismantle the control module of the gearbox.
Clutch replacement
Type of clutch
Except for automated manual shift: This range of models features a mechanism of
Vehicle data:
Registration: Model: Citroen C3 I/II/First/Classic KFV (TU3JP)
Year of construction:
2/6
conventional clutch.
Automated manual transmission: This range of models features a mechanism of
automated clutch.
Pressure plate
This range of models has a conventional pressure plate.
No special procedure is specified.
Assembly of the gearbox
The current industry code of good practices recommends replacing all screws,
nuts and fasteners related to safety.
Assemble the components in reverse order of disassembly.
Install a new oil seal for the left shaft. Tool number 7114-TW.
Install a new oil seal for the right drive shaft. Tool no. 7114-TX.
Purge the hydraulic system of the clutch.
Type 1Fig. 1[2] :
Fill the brake fluid reservoir to the MAX mark.
Connect a tube to the purge nozzle of the clutch receiver cylinder and immerse the
extreme in a container with clean clutch fluidFig. 1[2] .
Press and hold the clutch pedal.
Open the purge nozzle of the clutch release cylinder.
When no more liquid flows, close the purge nozzle.
Lift the clutch pedal.
Repeat the procedure until the clutch fluid contains no air.
Make sure the clutch is working correctly.
Disconnect the tube from the purge nozzle.
Fill the brake fluid reservoir to the MAX mark.
Type 2Fig. 1[3] :
Fill the brake fluid reservoir to the MAX mark.
Connect a tube to the purge nozzle of the clutch receiver cylinder and submerge the
extreme in a container with clean clutch fluidFig. 1[3] .
Press and keep the clutch pedal pressed.
Open the purge nozzle of the clutch receiver cylinder by turning it 90° in the direction
counterclockwise.
When no more liquid flows, close the purge nozzle.
Lift the clutch pedal.
Repeat the procedure until the clutch fluid does not contain air.
Make sure the clutch is working properly.
vehicleData
Enrollment: Model: Citroen C3 I/II/First/Classic KFV (TU3JP)
Year of construction:
3/6
Disconnect the tube from the purge nozzle.
Fill the brake fluid reservoir to the MAX mark.
Type 3Fig. 1[4] :
Fill the brake fluid reservoir to the MAX mark.
Connect a tube to the purge nozzle of the clutch receiver cylinder and immerse it
extreme in a container with clean clutch fluidFig. 1[4] .
Press and hold the clutch pedal.
Release the locking clip and remove the clutch hydraulic line from the cylinder.
clutch pedal to the purge position (first notch)Fig. 1yFig. 1[6]
.
When no more liquid flows, push the clutch hydraulic line into position.
original.
Lift the clutch pedal.
Repeat the procedure until the clutch fluid is free of air.
Hook the clutch hydraulic pipe fixing clipFig. 1[5] .
Ensure that the clutch is working properly.
Disconnect the tube from the purge nozzle.
Fill the brake fluid reservoir up to the MAX mark.
Automated manual transmission:
Mount the clutch actuator. Do not fully tighten the screws.
Install the clutch actuator adjustment toolFig. 1Tool No.
G-0317-T.
Tighten the screw of the clutch actuator adjustment tool until the
the clutch actuator rod makes contact with the clutch leverFig. 1
[8] .
Tighten the adjustment screw of the clutch actuator 3 turnsFig. 1[9]
Make sure that the clutch actuator moves 3 mm.
Tighten the screws of the clutch actuator.
Dismantle the clutch actuator adjustment tool.
Reassemble the gear shift actuator of the gearbox.
Warning: The replacement clutch actuator of the
manufacturer is supplied pre-adjusted in the position of
review.
Adjustment of the gearshift lever
Unspecified.
Clutch adjustment
Self-adjustable. No adjustment needed.
Additional operations
Vehicle Data
Enrollment: Model: Citroen C3 I/II/First/Classic Engine code: KFV (TU3JP)
Year of construction:
4/6
Automated manual transmission:
Program the automated manual transmission system. The manual transmission system
automated can only be programmed with a manufacturer's diagnostic equipment or
equivalent.
Fig. 1
Fig. 1
Vehicle data:
Enrollment: Model: Citroen C3 I/II/First/Classic Engine code: KFV (TU3JP)
Year of construction:
5/6
vehicleData
Matrícula Model: Citroen C3 I/II/First/Classic Engine code: KFV (TU3JP)
Year of construction:
6/6