COUV-C6-2005 6/01/06 16:30 Page 1 VERY IMPORTANT As the booklet is constantly re-edited, this one only covers vehicles for this particular model year. It is therefore necessary to order a new booklet each year and RETAIN THE OLD ONES.
6/01/06 16:30 Page 2 PRIVATE CARS COUV-C6-2005 AC/DTAV/MMCB/MMEC Méthodes Mécaniques 쏘 «The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden».
Angl-C6-Index-2005 4/02/05 17:10 Page I PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into groups representing the main functions: GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - HYDRAULICS - AIR CONDITIONING.
Angl-C6-Index-2005 4/02/05 17:10 Page II IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example: - INSUFFICIENT INFORMATION. - SUPERFLUOUS INFORMATION. - NEED FOR MORE DETAILS. Please send your comments and suggestions to: CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.
Angl-C6-Index-2005 4/02/05 17:10 Page III CONTENTS GENERAL Auxiliary equipment drive belt 45 IGNITION Vehicle identification 1-4 Checking and setting the valve timing 50 Sparking plugs General specifications: dimensions 5-6 Exhaust line specifications 68 - 72 Cooling system specifications 73 - 75 General specifications: weights 7 Operations to be performed before and after a disconnection of the battery 8 Towing specifications Lifting and supporting the vehicle Checking the oil press
Angl-C6-Index-2005 4/02/05 17:10 Page IV CONTENTS AXLES - SUSPENSION - STEERING Wheels and tyres Checking and adjusting the vehicle height Values for checking and adjusting the axle geometries Front axle Front axle tightening torques Rear axle Rear axle tightening torques Active suspension with variable damping Suspension tightening torques Draining-filling-bleeding the hydraulic steering/suspension circuit Power steering specifications Power steering tightening torques Checking the steering assistance
Angl-C6-page001-21-2005 4/02/05 17:12 Page 1 IDENTIFICATION OF VEHICLES A - Chassis stamp (cold stamp on suspension leg). B - Chassis stamp (cold stamp on bodywork below rear screen). D - AS/RP No. and RP paint code (label on front pillar close to driver's door). E - Inflation pressures and tyre references (label on front pillar close to driver's door). F - Serial no. on bodywork. G - Gearbox reference - Factory serial no. H - Engine legislation type - Factory serial no.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 2 IDENTIFICATION OF VEHICLES Petrol Diesel ES 9 A 3.0i 24 S DT 17 BTED4 2.7 24V HDi Emission standard GENERAL Type code E4 TD XFVJ TD UHZJ Engine type XFV UHZ Cubic capacity (cc) 2946 2720 15 13 Fiscal rating (hp) Gearbox type Gearbox ident.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 3 IDENTIFICATION OF VEHICLES Manufacturer's plate The manufacturer's plate carries the following information: (a) Type approval number (*) (c) Gross vehicle weight (*) (d) Gross vehicle weight (*) (e) Maximum weight on front axle (*) (f) Maximum weight on rear axle (*) (g) Manufacturer identification (*) = according to marketing country.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 4 IDENTIFICATION OF VEHICLES Type approval Structure TD XFVJ Version (4) T Family (1) D Bodywork (2) L3 Depollution levels XFV Engine (3) W3 J Version (4) A GENERAL Family (1) T C6 Bodywork (2) D Saloon 4-door 3-box US Other XFV 3.0i 24 S 2.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 5 GENERAL SPECIFICATION: DIMENSIONS GENERAL Exterior dimensions E1AP13KD 5
Angl-C6-page001-21-2005 4/02/05 17:12 Page 6 GENERAL SPECIFICATION: DIMENSIONS Exterior dimensions (mm) GENERAL Vehicles Wheelbase Front overhang Rear overhang Length overall Front track at ground level Width overall Rear track at ground level Track width Height overall ODM ODM = Vehicle in running order (vehicle empty, All types 2900 1124 884 4908 1586 2081 1558 1860 1464 A B C D E F G H J levels topped up).
Angl-C6-page001-21-2005 4/02/05 17:12 Page 7 GENERAL SPECIFICATION: WEIGHTS Versions Engine type Gearbox type Payload Weight empty in running order Gross Vehicle weight Gross Train weight Max. trailer weight with brakes Incline 12 % Incline 10 % Incline 8 % Max. trailer weight without brakes Maximum nose weight Maximum weight on roof bars ES9A DT17BTED4 3.0i 24S XFV 2.7HDi 24V UHZ 464 1871 2335 3671 1400 1500 1700 1400 750 70 80 NOTE: Maximum nose weight = Vertical load at the tow hook (CVA).
Angl-C6-page001-21-2005 4/02/05 17:12 Page 8 OPERATIONS TO BE CARRIED OUT BEFORE AND AFTER A DISCONNECTION OF THE BATTERY GENERAL Before reconnecting the battery. Doors and tailgate. WARNING: Before disconnecting the battery, partially open the door windows. Automatic gearbox. If the vehicle has to remain stationary: Pplace the gear lever in the parking position "P". If the vehicle has to be moved: Place the gear lever in the neutral position "N". Electric parking brake.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 9 GENERAL SPECIFICATION: TOWING THE VEHICLE Front towing WARNING: When the engine is not running, steering and braking are no longer power-assisted. Towing eye. The towing eye (1) is to be found in the vehicle toolkit (2) stowed in the spare wheel. E2AP02SD Front of the vehicle. Rear towing Open the flap (3). Screw in the towing eye (1). Rear of the vehicle. Open the flap (4). Screw in the towing eye (1). E2AP02RD E2AP02TD 9 GENERAL Open the boot.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 10 GENERAL SPECIFICATION: TOWING THE VEHICLE Vehicle with automatic gearbox. IMPERATIVE: Never tow the vehicle with the wheels hanging (towing by the wheels). Towing: GENERAL - It is necessary to raise the front of the vehicle, in order to tow it. If it is not possible to raise the front of the vehicle. It is essential to place the selection lever in position "N". Do not add any oil.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 11 LIFTING AND SUPPORTING THE VEHICLE IMPERATIVE: Respect the safety and cleanliness requirements. Lifting. ATTENTION: Lifting the vehicle by the front can only be done one side at a time. E2AP016C IMPERATIVE: Do not lift the vehicle by taking weight under the front subframe. Do not place blocks under the front subframe. IMPERATIVE: Never take weight on the front panel support and the front part of the engine subframe.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 12 LIFTING AND SUPPORTING THE VEHICLE Rear of the vehicle. IMPERATIVE: Do not lift under the spare wheel (risk of deformation of the floor). Do not lift under the rear axle crossmember. Use lateral lifting as for the front of the vehicle, or rear lifting (see diagrams). GENERAL IMPERATIVE: Do not place a block between the jack and the strengthener «b». E2AP02MD Place the jack under the strengthener «b». Lateral lifting.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 13 LIFTING AND SUPPORTING THE VEHICLE Lifting by vehicle jack. NOTE: the vehicle jack, with the extension and handle, is to be found in the toolkit stowed in the spare wheel. Correct position for the vehicle jack (1). E2AP02ND Rear of the vehicle. Correct position for the vehicle jack (1). E2AP02QD 13 GENERAL Front of the vehicle.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 14 LIFTING AND SUPPORTING THE VEHICLE Supporting the vehicle. Incorrect positioning of the axle stand. GENERAL E2AP018C IMPERATIVE: Do not place the axle stands under the lugs of the jacking points. Correct positioning of the axle stand.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 15 LIFTING AND SUPPORTING THE VEHICLE Raising the vehicle on a lift, supported from the jacking points. Equipment involved: - Two-column lift. - Auxiliary lift with blocks. Tooling required. [1] Safety straps E5AP2DNC Using the safety straps. WARNING: Check the condition of the safety straps before using them, do not use worn safety straps. WARNING: Do not use straps that show any signs of oil or grease (risk of soiling the carpets and/or seats).
Angl-C6-page001-21-2005 4/02/05 17:12 Page 16 CAPACITIES (in litres) Draining methods Oil capacities are defined according to the following methods Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension). Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension). The engine should be hot (oil temperature 80°C).
Angl-C6-page001-21-2005 4/02/05 17:12 Page 17 CAPACITIES (in litres) Diesel 3.0i 24S 2.7 24V BVA BVA XFV UHZ Engine type Engine with filter cartridge 5,25 Max. after draining and change of filter (by suction) 5,75 Max. after draining and change of filter (by gravity) 5,55 Dry sump 5,95 Between min. and max.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 18 LUBRICANTS - TOTAL recommended oils Engine oil specifications TOTAL ACTIVA or TOTAL ACTIVA QUARTZ Commercial description S.A.E.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 19 LUBRICANTS - TOTAL recommended oils Gearbox oil AM6 automatic gearbox All countries JWS 3309 (ESSO) Power steering oil Power-assisted steering All countries LDS TOTAL H50126 Engine coolant All countries CITROËN fluid Protection: -35C° GLYSANTIN G33 REVKOGEL 2000 2 Litres 9979 70 9979 72 5 Litres 9979 71 9979 73 20 Litres 9979 76 9979 74 210 Litres 9979 77 9979 75 Synthetic brake fluid Packs All countries CITROËN fluid All countries
Angl-C6-page001-21-2005 4/02/05 17:12 Page 20 LUBRICANTS - TOTAL recommended oils Screen wash fluid CITROËN references Packs All countries Concentrate: 250 ml 9980 33 ZC 9875 953U Fluid ready to use 1 Litre 9980 06 ZC 9875 784U 5 Litres 9980 05 ZC 9885 077U GENERAL Greasing General use All countries TOTAL MULTIS 2 TOTAL PETITES MECANISMES Nota : NLGI = National Lubrificating Grease Institude.
Angl-C6-page001-21-2005 4/02/05 17:12 Page 21 ENGINE OIL CONSUMPTION - Oil consumption depends on: - The engine type. - How run-in or worn it is. - The type of oil used. - The driving conditions. II - An engine can be considered RUN-IN after: - 3 000 miles (5 000 km) for a PETROL engine. - 6 000 miles (10 000 km) for a DIESEL engine. III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine. - 0.5 litres per 600 miles (1 000 km) for a PETROL engine.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 22 ENGINE ENGINE SPECIFICATIONS Engines: ES9A - DT17TED4 Petrol Diesel 3.0i 24S 2,7 24V Engine type XFV UHZ Cubic capacity (cc) 2946 2720 Bore/stroke 87/82,6 81x88 Compression ratio 10,9/1 17,3/1 Power ISO or EEC (KW - rpm) 155-6000 150-4000 Torque ISO or EEC (m.
4/02/05 17:19 Page 23 ENGINE Angl-C6-page022-82-2005 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: ES9A Torque reaction rod - lower RH engine support 1 6 ± 0,5 2 1 ± 0,1 3 6,5 ± 0,5 LH engine support 4 3 ± 0,3 5 6,5 ± 0,6 6 5 ± 0,5 7 5,5 ± 0,5 Upper RH engine support 8-9 6 ± 0,6 10 4,5 ± 0,5 11 6 ± 0,5 12 6 ± 0,5 B1BP32YP 23
Angl-C6-page022-82-2005 4/02/05 17:19 Page 24 ENGINE ENGINE TIGHTENING TORQUES Engine: ES9A 1 2 3 4 Pencil-type ignition coil Sparking plugs Pre-tightening Angular tightening Valve cover Pre-tightening Tightening Camshaft bearing cap cover Pre-tightening Tightening Cylinder head Pre-tightening Slackening Tightening Angular tightening B1BP27DP 24 0,8 ± 0,3 1 ± 0,1 90° ± 5° 0,5 ± 0,1 1 ± 0,1 0,2 ± 0,1 1 ± 0,1 2 ± 0,2 yes 1,5 ± 0,1 225° ± 5°
4/02/05 17:19 Page 25 ENGINE Angl-C6-page022-82-2005 ENGINE TIGHTENING TORQUES Engine: ES9A 5 6 7 Exhaust manifold (equipped with a new gasket) Pre-tightening (order from 1 to 10) Tightening (order from 1 to 10) Con rod caps Pre-tightening Angular tightening Engine flywheel Pre-tightening Angular tightening B1JP02LD 25 1 ± 0,1 3 ± 0,3 2 ± 0,2 74° ± 5° 2 ± 0,2 60° ± 5°
Angl-C6-page022-82-2005 4/02/05 17:19 Page 26 ENGINE ENGINE TIGHTENING TORQUES Engine: ES9A 8 Crankshaft bearing NOTE: Maximum length under heads for M11 = 131,5 mm. NOTE: Maximum length under heads for M8 = 119 mm. Perform the following operations: - Brush the screw threads. - Refit the screws having first pre-coated them with «MOLYKOTE G RAPID PLUS» grease on the threads and under heads.
4/02/05 17:19 Page 27 ENGINE Angl-C6-page022-82-2005 ENGINE TIGHTENING TORQUES Engine: ES9A 9 10 11 12 Sump Pre-tightening (sequence from 1 to 20) Tightening (sequence from 1 to 20) Crankshaft pinion Pre-tightening Angular tightening Crankshaft pulley Inlet distributor (with new seals) Pre-tightening Tightening Air inlet manifold Pre-tightening Tightening B1BP1GZD 27 0,5 ± 0,1 0,8 ± 0,1 4 ± 0,4 80° 2,5 ± 0,2 0,4 ± 0,1 0,8 ± 0,1 13 0,4 ± 0,1 0,8 ± 0,1
Angl-C6-page022-82-2005 4/02/05 17:19 Page 28 ENGINE ENGINE TIGHTENING TORQUES Engine: ES9A 14 15 16 17 B1BP2D3D 18 20 21 22 19 Camshaft hubs Pre-tightening Angular tightening Cap Guide roller Camshaft pulley Pre-tightening Angular tightening Camshaft pulleys Timing belt tensioner roller Plate for the dynamic tensioner roller Coolant pump Pre-tightening Tightening Oil pump Pre-tightening Tightening B1FP04KC 28 2 ± 0,2 57° 1,5 ± 0,1 8 ± 0,8 2 ± 0,2 115° 1 ± 0,1 2,5 ± 0,2 2,5 ± 0,2 0,5 ± 0,1 0,8 ±
4/02/05 17:19 Page 29 ENGINE Angl-C6-page022-82-2005 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: DT17BTED4 RH engine support 1 2 3 4 5 Screws Screws Screws Nut Screws 6 7 8 9 Screws Screws Screws Screws 8,2 ± 1,25 6 ± 0,6 2,8 ± 0,4 6,5 ± 0,6 6 ± 0,6 Front piloted torque reaction rods B1BP3EPD 6 ± 0,6 4,3 ± 0,4 6 ± 0,6 B1BP3EQD 29
Angl-C6-page022-82-2005 4/02/05 17:19 Page 30 ENGINE TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: DT17BTED4 Rear piloted torque reaction rods 10 11 12 13 Screws Screws Screws Screws 14 15 16 17 Screws Screws Screws Screws 6 ± 0,6 LH gearbox support B1BP3ERD 6 ± 0,6 5,5 ± 0,8 6 ± 0,6 5,5 ± 0,8 B2CP45CD 30
4/02/05 17:19 Page 31 ENGINE Angl-C6-page022-82-2005 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: DT17BTED4 Gearbox impact absorber 18 Screws 19 Screws 4 ± 0,6 B2CP45DC Driveshaft bearing 6 ± 0,6 B2CP45EC 31
Angl-C6-page022-82-2005 4/02/05 17:19 Page 32 ENGINE ADJUSTMENT OF PILOTED TORQUE REACTION ROD Engine: DT17BTED4 IMPERATIVE: Respect the safety and cleanliness requirements. IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engines. Additional operations. NOTE: The piloted torque reaction rods have to be adjusted in the event of removing the fixing yoke of the front piloted torque reaction rod (1).
4/02/05 17:19 Page 33 ENGINE Angl-C6-page022-82-2005 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 1 2 3 4 5 6 7 8 9 B1DP1LZD Cylinder head Butterfly housing Inlet valve cover screws (*) Inlet valve cover studs (*) Coolant outlet housing Cylinder heads Pre-tightening Tightening Tightening Angular tightening EGR (exhaust gas recycling) electrovalve Exhaust manifold nuts Exhaust manifold studs Turbocharger nuts Turbocharger studs Pre-catalysers Vacuum pump (*) Respect the sequence of tightening.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 34 ENGINE ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Order of tightening of screws (2) (2) Camshaft bearing cover screws (from 1 to 13) (2) Camshaft bearing cover studs (from 1 to 13) B1DP1M1C Order of tightening of bolts (4) (from 1 to 8) (4) Cylinder head bolts B1DP1M2C 34
4/02/05 17:19 Page 35 ENGINE Angl-C6-page022-82-2005 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 11 12 13 14 15 16 17 18 B1DP1M3P Cylinder block Coolant pump Con rod screws Pre-tightening Angular pre-tightening Angular tightening Starter gearwheel carrier Pre-tightening Angular pre-tightening Angular tightening Lower engine block screw (*) Lower engine block screw (*) Bearing cap fixing screws (*) Pre-tightening Tightening Angular tightening Crankshaft bearing cap cover Pre-tightening Tightening Ang
Angl-C6-page022-82-2005 4/02/05 17:19 Page 36 ENGINE ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Order of tightening for screws (14) and (15) (14) Lower engine block screw (screw M6) (15) Lower engine block screw (screw M8) Method of tightening: - Tighten the 10 screws (15) (from 1 to 10) to - Tighten the 8 screws (14) (from 1 to 18) to : 2,3 ± 0,3 : 0,9 ± 0,1 B1DP1M4D Order of tightening for screws (16) and (17) (16) Bearing cap fixing screw (screw M9) (17) Crankshaft bearing cap cover screw (screw
4/02/05 17:19 Page 37 ENGINE Angl-C6-page022-82-2005 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Lubrication 19 20 21 22 23 24 25 26 27 28 29 30 31 Oil filter cover Oil filter support Oil/coolant heat exchanger Oil pressure switch Oil pump assembly Oil gauge Oil level sensor Oil sump Drain plug Oil suction strainer Piston skirt spray jets Turbocharger lubrication pipe Turbocharger lubrication pipe B1DP1M6P 37 2,3 ± 0,3 0,9 ± 0,2 1,3 ± 0,2 0,9 ± 0,2 2,3 ± 0,3 2,7 ± 0,5 0,9 ± 0,2 2,3 ± 0,3 0,9 ± 0,1
Angl-C6-page022-82-2005 4/02/05 17:19 Page 38 ENGINE ENGINE TIGHTENING TORQUES Engine: DT17BTED4 32 33 34 35 36 37 38 39 40 Valve timing Camshaft pulley hub screw Tightening Angular tightening Camshaft pulley screw Camshaft bearing caps (*) Tightening Pre-tightening Tensioner roller for the fuel high pressure pump drive belt Fuel high pressure pump drive pulley Tightening Angular tightening Camshaft timing chain tensioner Timing belt guide roller Timing pinion on crankshaft Tightening Angular tighten
4/02/05 17:19 Page 39 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 IMPERATIVE: The camshaft bearing caps are marked at "a" with a letter on the front cylinder head and with a number on the rear cylinder head.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 40 ENGINE ENGINE TIGHTENING TORQUES Engine: DT17BTED4 42 43 44 45 46 47 48 49 50 51 Injection circuit Diesel fuel/cooolant exchanger Diesel injection pump on support Diesel injection pump pinion Diesel injector fixing flange screw Union on diesel injector Pre-tightening Tightening Fuel high pressure common injection rail on engine block Pre-tightening Tightening Unions on fuel high pressure common injection rail Pre-tightening Tightening Fuel filter suppor
4/02/05 17:19 Page 41 ENGINE Angl-C6-page022-82-2005 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 52 53 54 55 56 57 58 59 60 Accessories Screw M8 for automatic tensioner roller (accessories drive belt) Screw M10 for dynamic tensioner roller (accessories drive belt) Guide roller Accessories support Multifunction support Power steering pump pulley Power steering pump Alternator screw Alternator power circuit Aircon compressor screw B1BP3C0D 41 2,2 ± 0,3 4,7 ± 0,7 4,7 ± 0,7 2,3 ± 0,3 2,3 ± 0,3 2,3 ± 0,
Angl-C6-page022-82-2005 4/02/05 17:19 Page 42 ENGINE SPECIAL FEATURES: CYLINDER HEAD TIGHTENING Engine: ES9A Cleaning to be carried out just prior to refitting the cylinder head WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
4/02/05 17:19 Page 43 ENGINE Angl-C6-page022-82-2005 SPECIAL FEATURES: CYLINDER HEAD TIGHTENING Engine: DT17BTED4 Cleaning to be carried out just prior to refitting the cylinder head WARNING: Clean the contact faces with the approved CITROËN cleaning product. Do not use abrasives or cutting tools on the contact faces. The contact faces must not bear any traces of impact or scratching. Insert a tap in the threads of the holes in the cylinder block receiving the cylinder head bolts.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 44 4099-T (C.TRONIC.105) Tools 44 ! ! ! ENGINE BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE 4122-T (C.TRONIC.105.
4/02/05 17:19 Page 45 AUXILIARY EQUIPMENT DRIVE BELT Petrol Diesel 3.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 46 ENGINE AUXILIARY EQUIPMENT DRIVE BELT Engines : all types Petrol and Diesel Tools. Belt tension measuring instrument : 4122-T.(C.TRONIC 105.5). WARNING: If using tool 4099-T (C.TRONIC 105). Essential. Before refitting the auxiliary equipment drive belt, check that: - 1 / The roller(s) rotate freely (no play or stiffness). - 2 / The belt is correctly engaged in the grooves of the various pulleys.
4/02/05 17:19 Page 47 ENGINE Angl-C6-page022-82-2005 AUXILIARY EQUIPMENT DRIVE BELT Engine: ES9A Tools. [1] Ratchet spanner S.171 FACOM (1/2 square) [2] Reduction box S.230 FACOM (1/2 - 3/8) : S 171 : S 230 Removing. Remove the engine cover. Pivot the tensioner roller bracket (1) clockwise, until it locks, using tools [1] and [2] at «a». Remove the auxiliary equipment drive belt. ESSENTIAL: Check that the guide rollers are turning freely (no play and no tightness). Refitting.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 48 ENGINE AUXILIARY EQUIPMENT DRIVE BELT Engine: ES9A B1BP3BSD Tool. [1] 2 mm diameter peg : (-).0188-Q1 Removing. Remove: - The under-engine sound-deadening. - The front RH wheel. - The RH splash-shield. - The air duct (linking the air distributor heat exchanger). Compress the dynamic tensioner roller (1) to free the pegging hole at "a". Peg the dynamic tensioner roller at "a", using tool [1].
4/02/05 17:19 Page 49 AUXILIARY EQUIPMENT DRIVE BELT Engine: DT17BTED4 Refitting. WARNING: If re-using the auxiliary equipment drive belt, refit it respecting its direction of fitting. Fit the auxiliary equipment drive belt. ESSENTIAL: Make sure that the auxiliaries drive belt is correctly positioned in the grooves of the various pulleys. Refit: - The dynamic tensioner roller (1) by engaging the belt on the roller. - The screws (2) and (4). Tighten: - Screw (2) : 5 ± 0,5. - Screw (4) : 2,3 ± 0,2.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 50 ENGINE CHECKING AND SETTING THE VALVE TIMING Petrol Diesel 3.
4/02/05 17:19 Page 51 ENGINE Angl-C6-page022-82-2005 CHECKING THE VALVE TIMING Engine: ES9A Tools. [1] [2] [3] [4] [5] [6] [7] Camshaft setting pegs Crankshaft setting peg Fuel pressure take-off union Belt retaining pin Exhaust camshaft hubs immobilising tool Inlet camshaft hubs immobilising tool SEEM belt tension measuring equipment Remove components as necessary for this operation. Remove the auxiliaries drive belt (see corresponding operation). Checking the valve timing.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 52 ENGINE CHECKING THE VALVE TIMING Engine: ES9A Checking the valve timing (continued). Peg the crankshaft, using tool [1]. Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys. Remove the tools [1] and [2]. B1EP08TC Refit: - The lower timing cover (13). - The upper timing covers (9) and (10). - The crankshaft pulley (12). - The roller/dynamic tensioner assembly (11). - The power steering pulley.
4/02/05 17:19 Page 53 CHECKING AND SETTING THE VALVE TIMING Engine: ES9A Setting the valve timing. Remove the components as necessary for the operation. Remove the screws (19) and the plate (20). Peg the crankshaft, using tool [2]. NOTE: Damp the rotation of the camshafts (15) and (17), using tool [6]. Untighten the camshaft pulley screws (15) and (17). NOTE: Damp the rotation of the camshafts (14) and (18), using tool [5]. Untighten the camshaft pulley screws (14) and (18).
Angl-C6-page022-82-2005 4/02/05 17:19 Page 54 ENGINE CHECKING AND SETTING THE VALVE TIMING Engine: ES9A B1EP15VD Setting the valve timing (continued). Refitting. Check that the camshafts and the crankshaft are correctly pegged. Check that the rollers and the coolant pump pulley are turning freely (no tightness). Loosen the camshaft pulley screws by a 1/4 turn. Make sure that the pulleys are turning freely on the camshaft hub. Turn the camshaft pulleys in a clockwise direction, to end of slots.
4/02/05 17:19 Page 55 ENGINE Angl-C6-page022-82-2005 CHECKING AND SETTING THE VALVE TIMING Engine: ES9A Setting the valve timing (continued). Adjusting the timing belt tension. Preliminary operations. Pivot the plate (25) of the tensioner roller (24), using a spanner (type FACOM S.161). Engage the screw (21) on the plate (25). Tighten the screws (21) and (22), tighten to 2,5 ± 0,1 m.daN. Act on the tensioner roller (24) so as to tension the belt, using a spanner (type FACOM R 161).
Angl-C6-page022-82-2005 4/02/05 17:19 Page 56 ENGINE CHECKING AND SETTING THE VALVE TIMING Engine: ES9A Tighten the nut (23) of the tensioner roller (24), tighten to 1 ± 0,1 m.daN. Check that the exhaust camshaft pulley screws are not at the end of slots (by loosening one screw). WARNING: Otherwise, restart the operation for positioning the timing belt. Tighten at least 2 screws per exhaust camshaft pulley to 1 ± 0,1 m.daN. Remove the tools [1], [2] and [4].
4/02/05 17:19 Page 57 CHECKING AND SETTING THE VALVE TIMING Engine: ES9A Tensioning the timing belt. Act on the tensioner roller (24) so as to align the marks «c» and «d», without detensioning the timing belt (failing this, restart the operation of adjusting the belt tension). Hold the tensioner roller (24). Tighten the nut (23), tighten to 1 ± 0,1 m.daN. Check the position of the tensioner roller (the alignment of the marks «c» and «d» should be correct). Remove the tools [1], [2] and [4].
Angl-C6-page022-82-2005 4/02/05 17:19 Page 58 ENGINE CHECKING THE VALVE TIMING Engine: DT17BTED4 Tools. [1] Set of plugs [2] Flywheel setting peg (double flywheel) [3] Camshaft setting pegs : (-).0188-T : (-).0195.K : (-).0195.H Toolkit 0188-T Toolkit 0188-T Checks. IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engines. Remove the engine cover. Disconnect the battery negative terminal. Raise and support the front of the vehicle.
4/02/05 17:19 Page 59 CHECKING THE VALVE TIMING Engine: DT17BTED4 Remove: - The auxiliary drive belt (5) (see corresponding operation). - The upper timing covers (6). B1EP1J9D Position the camshaft pegging holes "a" and "b" at "c" and "d", 30° ± 5° forward of their pegging holes "e" and "f". NOTE: Turn the crankshaft in the normal direction of rotation, by means of the crankshaft pinion screw.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 60 ENGINE CHECKING THE VALVE TIMING Engine: DT17BTED4 Remove the plug from the pegging hole on the cylinder block. NOTE: Removing the particle filter and catalytic converter flexible pipe assembly facilitates removal of the plug from the pegging hole and the positioning of the tool [2]. NOTE: Turn the crankshaft in the normal direction of rotation, by means of the crankshaft pinion screw. Peg the crankshaft, using tool [2]. Peg the camshafts, using tools [3].
4/02/05 17:19 Page 61 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Tools. [1] [2] [3] [4] [5] [6] Kit of plugs Flywheel setting peg (double damping flywheel) Camshaft setting pegs Belt compressure spring Coolant pump pulley peg Lifting bracket : : : : : : (-).0188-T (-).0195.K (-).0195.H (-).0188.K (-).0195.C (-).0195.N Toolkit 0188-T Toolkit 0188-T IMPERATIVE: Respect the safety and cleanliness requirements. WARNING: Before disconnectng the battery, partially open the door windows.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 62 ENGINE CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 B1BP3C2D Remove: - The air duct between the air/air exchanger and the air inlet housing (6). - The air inlet housing (6). Uncouple, plug and move aside the pipes (2) and (3) using tool [1]. Detach and move aside the electrical harness. Remove: - The header tank fixing (1). - The "Swirl" electrovalve fixings (7). Move aside: - The "Swirl" electrovalve (7) with its support.
4/02/05 17:19 Page 63 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Position the camshaft pegging holes "c" and "e" at "d" and "f", 30° ± 5° in front of the pegging holes "h" and "g". NOTE: Turn the crankshaft in the normal direction of rotation, by means of the crankshaft pinion screw. Remove the plug from the pegging hole on the cylinder block. B1EP1JED NOTE: Turn the engine by means of the crankshaft pinion screw to bring it to the pegging position (following the arrow).
Angl-C6-page022-82-2005 4/02/05 17:19 Page 64 ENGINE CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Peg the camshafts, using tools [3] at "h" and "g". Slacken: - The 3 screws (15) of the camshaft pulley (23). - The 3 screws (17) of the camshaft pulley (18). - The screw (21) of the tensioner roller (20). Remove the timing belt (22). Checks. B1EP1JFD IMPERATIVE: Just before refitting, carry out the checks below.
4/02/05 17:19 Page 65 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Reposition the timimg belt, strip «j» well tensioned, in the following order: - Guide roller (19). - Camshaft pulley (18). - Guide roller (16). - Camshaft pulley (23). - Tensioner roller (20). B1EP1JHD NOTE: If necessary, turn the pulleys (23) and (18) slightly anti-clockwise (the offset must not be more than one tooth). Remove the tool [4]. Using a hexagonal spanner, rotate the tensioner roller (20) anti-clockwise.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 66 ENGINE CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Tighten the screws (15) and (17) : 2,2 ± 0,2. Remove tools [2] and [3]. Rotate the crankshaft 8 times in the normal direction of rotation. Fit the tool [2]. Peg the camshafts using tools [3], at "h" and "g".
4/02/05 17:19 Page 67 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Remove tools [2] and [3]. Refit: The lower timing cover (10), the upper timing covers (11), the crankshaft pulley (9), the engine support (12), the coolant pump pulley (13), the accessories drive belt (8) (see corresponding operation), the engine support (4) on the chassis member, the upper RH engine support (5) and the upper RH engine support tie bar. Take away the workshop hoist. B1EP1JHD Remove the tool [6].
Angl-C6-page022-82-2005 4/02/05 17:19 Page 68 ENGINE EXHAUST SPECIFICATIONS Engine: ES9A 1 2 3 4 5 6 7 8 9 10 Upstream oxygen sensor (rear) Downstream oxygen sensor (rear) Downstream oxygen (front) Upstream oxygen sensor (front) Precatalyser (rear) Precatalyser (front) Resonator Catalytic converter Rear silencer Clips B1JP08AD 68 4,7 ± 0,5 3,5 ± 0,5 2,6 ± 0,3
4/02/05 17:19 Page 69 EXHAUST SPECIFICATIONS Engine: ES9A Repair. Respect the precautions to be taken prior to any operation: - The front flexible pipe must be protected against any external mechanical damage. - The front flexible pipe must not come into contact with corrosive products. - Do not deform the front flexible pipe more than 20° angular (X), 20 mm axial, 25 mm shearing (Y) (front flexible pipe removed).
Angl-C6-page022-82-2005 4/02/05 17:19 Page 70 ENGINE EXHAUST SPECIFICATIONS Engine: DT17BTED4 B1JP07QD Engine versions UHZ (1) Clip (2) Particle filter (3) Intermediate pipe (4) Exhaust silencer (5) Rear precatalyser (6) Front precatalyser TR PSA F016 TR PSA K330 PSA 4234 TR PSA K311 TR PSA K310 70
4/02/05 17:19 Page 71 EXHAUST SPECIFICATIONS Engine: DT17BTED4 Repair. Respect the precautions to be taken prior to any operation: - The front flexible pipe must be protected against any external mechanical damage. - The front flexible pipe must not come into contact with corrosive products. - Do not deform the front flexible pipe more than 20° angular (X), 20 mm axial, 25 mm shearing (Y) (front flexible pipe removed).
Angl-C6-page022-82-2005 4/02/05 17:19 Page 72 ENGINE TIGHTENING TORQUES - EXHAUST LINE Engine: DT17BTED4 1 2 3 4 5 6 Clip Particle filter hangers Intermediate pipe hangers Silencer hangers Rear precatalyser screw Front precatalyser screw B1JP07ZD 72 2,6 ± 0,4 0,8 ± 0,1 2 ± 0,3 2 ± 0,3
4/02/05 17:19 Page 73 COOLING SYSTEM SPECIFICATIONS Engines: ES9A - DTE17BTED4 Engine type Capacity Radiator surface Pressurisation Opening of thermostatic regulator Cooling fan 1st speed 2nd speed 3rd speed Air con cut-off Alert Post cooling Marking Information Sensor Colour of connector Tightening (m.daN) 3.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 74 ENGINE COOLING SYSTEM SPECIFICATIONS Engine: ES9A (1) Heater matrix (2) Bleed screw (3) Coolant outlet housing (4) Coolant inlet housing (5) Thermostat (6) Coolant temperature sensor (7) Coolant/oil heat exchanger (engine) (8) Cooling radiator drain plug (9) Coolant/oil heat exchanger (automatic gearbox) (10) Engine cooling radiator (11) Coolant level sensor (12) Header tank (13) Venting chamber B1GP0CXP 74
4/02/05 17:19 Page 75 COOLING SYSTEM SPECIFICATIONS Engine: DT17BTED4 (1) Header tank (2) Coolant outlet housing (3) Coolant/oil heat exchanger (4) Coolant/EGR heat exchanger (rear cylinder bank) (5) Bleed screw (6) Heater matrix (7) Additional heating unit (8) Engine cooling radiator (9) Engine cooling radiator drain tap (10) Coolant/EGR heat exchanger (front cylinder bank) B1GP0D4P 75 ENGINE Angl-C6-page022-82-2005
Angl-C6-page022-82-2005 4/02/05 17:19 Page 76 ENGINE CHECKING THE OIL PRESSURE Engine Temperature (°C) Pressure (bars) Rpm Pressure (bars) Rpm Pressure (bars) Rpm 2279-T.Bis 4103-T (-).1503.K 4202-T ES9A DT17BTED4 80°C 2 900 5 3000 1 to 4 2500 X X X X NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
4/02/05 17:19 Page 77 ENGINE Angl-C6-page022-82-2005 VALVE CLEARANCES ● Inlet All types Exhaust Hydraulic adjustment 77
Angl-C6-page022-82-2005 4/02/05 17:19 Page 78 ENGINE DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine: ES9A Tools. [1] Filling cylinder [2] Adaptor for filling cylinder [3] Control rod for filling cylinder : 4520-T : 4222-T : 4370-T IMPERATIVE: Respect the safety and cleanliness requirements. B1GP0BPC The draining and refilling operations can be carried out using coolant fluid replacement equipment. It is essential to follow the instructions as stated for that equipment. Draining.
4/02/05 17:19 Page 79 DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine: ES9A Open the plug (3) to drain the second bank of cylinders. Remove the drain plugs (2) and (3). Filling and bleeding the circuit. Prior to any filling, rinse the cooling with fresh water. WARNING: Check the sealing of the cooling circuit. B1GP08TC Open the bleed screws of the following components: - Heater matrix outlet. - Coolant outlet housing. - Radiator. Close the drain screw (1) of the radiator.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 80 ENGINE DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine: ES9A Reclose the bleed screw when the fluid flows out clear and without air bubbles. Start the engine. Maintain an engine speed of 1500/2500 rpm, up to the first cooling cycle (starting and stopping of the cooling fan). Block the filling cylinder [1] using the control rod [3]. Remove the filling cylinder assembly [1], [3] and [2]. Refit the header tank cap.
4/02/05 17:19 Page 81 DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine: DT17BTED4 Tools. [1] Filling cylinder [2] Adaptor for filling cylinder [3] Control rod for filling cylinder : 4520-T : 4222-T : 4370-T IMPERATIVE: Respect the safety and cleanliness requirements. The draining and refilling operations can be carried out using coolant fluid replacement equipment. It is essential to follow the instructions as stated for that equipment. Draining. Remove the header tank cap.
Angl-C6-page022-82-2005 4/02/05 17:19 Page 82 ENGINE DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine: DT17BTED4 B1GP0CPC B1GP0CQC Filling and bleeding. Open the bleed screw (2) on the heater matrix hose. Open the bleed screw (3) of the engine cooling radiator. Refit the drain screw (1) with a new seal. Tighten the screw (1) : 3 ± 0,1. Fit the filling cylinder [1], control rod [3] and adaptor [2] assembly on the filler aperture. Fill the engine cooling circuit.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 83 BOSCH ME 7.4.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 84 BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Synopsis.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 85 BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Synopsis. INJECTION (30) Pulse damper (31) Sparking plugs (x6) (32) Fuel tank (33) Canister reservoir (34) Discharge valve (35) Exhaust line Specifications. Cylindrical capacity (cc) : 2946. Idling speed (rpm) non-adjustable : 700 ± 50. Cut-off at maximum engine speed (rpm) : 6520.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 86 BOSCH ME 7.4.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 87 BOSCH ME 7.4.7 INJECTION SYSTEM Component Location Integrated pressure sensor 25 Motorised butterfly housing 14 Accelerator pedal position sensor 26 Ignition injection ECU 29 Supplier BOSCH BOSCH Air circuit Reference DS-S2 0 261 260 140 DVE5 0 280 750 041 14 43 33 Electrical circuit ME 7.4.7.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 88 BOSCH ME 7.4.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 89 BOSCH ME 7.4.7 INJECTION SYSTEM Component Location Sparking plugs 31 Pencil type ignition coils 17 Upstream oxygen sensor 21 Supplier BOSCH FGR8MQPE NGK PFR6E 10 SAGEM BAC 1 2526140 Exhaust circuit 258 040 232 BOSCH Downstream oxygen sensor 20 258 006 185 89 Observations Electrode gap: 1 mm Tightening torque Tighten to: 1 ± 0,1 m.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 90 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engine: DT17BTED4 Cleaning. The use of high pressure cleaners is prohibited. Do not use compressed air. INJECTION Fuel supply circuit. Required fuel: Diesel. WARNING: Do not use other fuels. Electrical circuit. Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. It is forbidden to supply a diesel injector with 12 volts.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 91 PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engine: DT17BTED4 Diesel injectors. Do not separate the diesel injector carrier (2) from the following components: - Diesel injector (g) (no replacement parts). - The fuel flow actuator (e) (destruction). B1HP23HC Do not move the nut (f) (will cause a malfunction). Do not separate the union (h) from a diesel injector. It is forbidden to clean the carbon deposits from the diesel injector nozzle.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 92 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM INJECTION Safety requirements. Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations: - Competent health authorities. - Accident prevention. - Environmental protection. After the engine has stopped, wait 30 seconds before any intervention.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 93 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: DT17BTED4 Ø 10 mm low pressure connector Ø 8 mm low pressure connector Pressure gauge for testing boost pressure Extension : : : : 4215-T 4218-T 4073-T 4251-T Kit 4073-T Checks. IMPERATIVE : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Connect the tool [1] between the booster pump and the fuel filter (white mark on the fuel supply pipe).
Angl-C6-page83-100-2005 4/02/05 17:22 Page 94 CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: DT17BTED4 Checks on pressure: static. Switch on the ignition. INJECTION For 3 seconds (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 1.1 ± 0.4 bar. - Fuel return pressure shown by the pressure gauge [3] = 2 ± 0.5 bar. Abnormal functioning: Fuel supply pressure Fuel return pressure Checks Between 2 and 3 bar 0.8 ± 0.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 95 CHECKS: TURBO PRESSURE Tools. [1] Pressure gauge for checking the pressure [2] Tool for checking the inlet air pressure/vacuum [3] LEXIA diagnostic tool [4] PROXIA diagnostic tool : : : : 7073-T.A (-).0171.G3 4171-T 4165-T Checks. IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. Preliminary operations.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 96 CHECKS: TURBO PRESSURE Engine: DT17BTED4 INJECTION Connect: - The tool [2a] in place of the turbo pressure sensor (1). - The turbo pressure sensor (1) on the tool [2b]. - Tool [1] on tool [2], at "b". Connect the diagnostic tool [3] or [4] to the vehicle's diagnostic socket: - Put the diagnostic tool [3] or [4] in parameter measures. Start the engine. Accelerate to 2500 rpm.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 97 CHECKS: TURBO PRESSURE Engine: DT17BTED4 - Stop the engine. Remove the air filter with the two flowmeters. Mark the flowmeters "d" and "c". Remove both flowmeters. Refit: - Flowmeter "d" in place of flowmeter "c". - Flowmeter "c" in place of flowmeter "d". Start the engine. Accelerate to 2500 rpm. Compare the air flows (mg/stroke) from the two turbochargers: - If the difference in air flow has changed turbochargers, replace the flowmeter that is faulty.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 98 CHECKING THE AIR SUPPLY CIRCUIT SPECIFICATIONS Engine: DT17BTED4 (1) Air filter: MECAPLAST INJECTION (2) Air/air heat exchanger: BEHR (3) Front turbocharger: GARETT (4) Air butterfly housing: MAN HUMEL (5) Rear turbocharger: GARETT (6) Flowmeters: SIEMENS VDO B1HP26UD 98
Angl-C6-page83-100-2005 4/02/05 17:22 Page 99 CHECKING THE AIR SUPPLY CIRCUIT Engine: DT17BTED4 Tool. : FACOM DA 16 INJECTION [1] Manual pressure-vacuum pump Checks. IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. B1HP26DC Checking the vacuum source (vacuum pump). Connect the tool [1] on the take-off "a" of the vacuum pump (1). Start the engine. The value should be 0,85 ± 0,2 bar. "Swirl" control electrovalve.
Angl-C6-page83-100-2005 4/02/05 17:22 Page 100 SPARKING PLUGS Vehicles C6 3.0i 24S Engine BOSCH Electrode gap NGK Electrode gap ES9A FGR8MQPE 1 mm PFR6E10 1 mm IGNITION 100 Tightening torque (m.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 101 SPEEDOMETER 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.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 102 AM6 AUTOMATIC GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence ES9A C6 Torque ratio 20 GH 07 AM6 Drive ratio 49 X 52 15 x 53 DT17BTED4 20 GG 07 CLUTCH GEARBOX TRANSMISSION 102 54 X 47
Angl-C6-page101-120-2005 4/02/05 17:25 Page 103 PROCEDURE PRIOR TO OPERATIONS: AM6 AUTOMATIC GEARBOX Engines: ES9A - DT17BTED4 WARNING: In the emergency programme, an impact is felt when changing P/R or N/R. Reception of the customer. Discuss with the customer, to find out all the malfunction symptoms. Oil quality.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 104 PRECAUTIONS TO BE TAKEN : AM6 AUTOMATIC GEARBOX Engines: ES9A - DT17BTED4 Towing. The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised. Precautions to be taken When performing electrical checks: - The battery should be correctly charged. - Never use a voltage source higher than 16V. - Never use a test lamp. IMPERATIVE: - Put gear lever in position «N». - Do not add any oil.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 105 AM6 AUTOMATIC GEARBOX: GENERAL SPECIFICATIONS Engines: ES9A - DT17BTED4 Identification. (1) identification plate (riveted on the casing) "a" Type of automatic gearbox (AISIN) "b" Type of automatic gearbox (PSA) "c" Component marking "d" Serial no. (2) identification label (affixed on the ECU) "e" Date of manufacture "f" Homologation code (PSA) "g" ECU no. (PSA) "h" Bar code (PSA) "j" Gearbox no. (PSA) "k" Bar code (AISIN) "l" Serial no.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 106 AM6 GEARBOX: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 1 2 3 4 B2CP42WD CLUTCH GEARBOX TRANSMISSION 5 6 7 8 9 Automatic gearbox heat exchanger Hydraulic valve block casing Filler plug Torque converter screw [(ES9 3 screw) (DT17 6 screw)] Pre-tightening Slackening Tightening Sleeve stop Gearbox support Engine speed sensor (ES9J4) Fixing of gearbox on cylinder block Closing panel fixing B2CP42XD 106 4,2 ± 0,4 1,5 ± 0,2 4 ± 0,4 2 ± 0,2 100° 6 ± 0,6
Angl-C6-page101-120-2005 4/02/05 17:25 Page 107 AM6 GEARBOX: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 12 11 12 13 14 15 Oil induction cover Hydraulic valve block (in the order indicated) Oil temperature sensor tightening plate ECU screws Oil drain and overflow plug Oil level plug 1 ± 0,1 1 ± 0,1 1 ± 0,1 2,5 ± 0,2 1 ± 0,1 4,8 ± 0,5 CLUTCH GEARBOX TRANSMISSION B2CP42YD B2CP42ZD 107
Angl-C6-page101-120-2005 4/02/05 17:25 Page 108 AM6 GEARBOX CONTROLS Engines: ES9A - DT17BTED4 The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. The gear control has 5 positions: - Position "P": parking (locking and immobilisation of the vehicle). - Position "R": reverse gear. - Position "N": neutral. - Position "D" : drive (for use of the 6 gears in autoadaptive automatic operation).
Angl-C6-page101-120-2005 4/02/05 17:25 Page 109 AM6 GEARBOX CONTROLS Engines: ES9A - DT17BTED4 The switch "a" positioned on the gear control panel allows the driver to choose one of the following 3 driving programmes: - Normal programme: The normal programme operates in the absence of any other selection being made (auto-adaptive mode ; eco law). - Sport programme: The sport programme permits a more dynamic driving style, with greater performances and acceleration.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 110 AM6 GEARBOX CONTROLS Engines: ES9A - DT17BTED4 Gearbox end. The automatic gearbox is controlled by a cable. “b” Push-button in pushed-in position (1) Sleeve stop (2) Control lever with ball-joint (3) Automatic adjustment CLUTCH GEARBOX TRANSMISSION Automatic adjustment: - Pull out button “b” to adjust the control. - Push in button “b” to lock the adjustment of the control.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 111 AM6 GEARBOX CONTROLS: «SHIFT LOCK» FUNCTION Engines: ES9A - DT17BTED4 IMPERATIVE: Respect the safety and cleanliness requirements, with reference to the brochure: «Recommendations-Precautions». 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».
Angl-C6-page101-120-2005 4/02/05 17:25 Page 112 PROCEDURE FOR INITIALISATION OF THE AUTOMATIC GEARBOX ECU NOTE: For all these operations, follow the procedure in the diagnostic tool. Replacement of the automatic gearbox without replacement of the ECU. Carry out the following operations: - Initialisation of the neutral position of the gear selection lever position sensor. - Initialisation of the adaptation of the oil pressure regulators and electrovalves. - Initialisation of the autoadaptatives.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 113 PROCEDURE FOR INITIALISATION OF THE AUTOMATIC GEARBOX ECU Replacement of the automatic gearbox and of the automatic gearbox ECU. Carry out the following operations: - Initialisation of the autoadaptatives. - Resetting the oil usage counter to zero. - Initialisation of the adaptation of the oil pressure regulators and electrovalves. NOTE: If downloading the automatic gearbox ECU, there is no specific operation, follow the procedure in the diagnostic tool.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 114 DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX Tool. [1] Filling cylinder : (-).0340 Respect the safety and cleanliness requirements. Draining. IMPERATIVE: Draining of the gearbox must be done with the oil hot (60°C minimum), in order to ensure that the impurities in suspension in the oil are eliminated. NOTE: Drainage is only partial, as the torque converter cannot be drained totally. Raise the vehicle.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 115 DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX WARNING: Do not take account of the information mentioned on tool [1]. Oil capacity for a dry gearbox: 7 litres (approx.). Type of oil: JWS 3309 ESSO (red in colour). Volume of oil remaining after draining: 4 litres (approx.). Quantity of oil to be added: 3 litres (approx.). B1BP317C Checking the oil level. Prior conditions: - Vehicle in a horizontal position.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 116 DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX Thread of oil, then "drip-drip". Refit the level plug (2). Tighten the plug (2) to : 0.8 ± 0,1 mdaN. "drip-drip" or nothing. Refit the level plug (2). Stop the engine. Add 0.5 litre of extra oil into the gearbox. Repeat the topping-up procedure. B1BP317C NOTE: The level is correct when the thread of oil becomes "drip-drip".
Angl-C6-page101-120-2005 4/02/05 17:25 Page 117 CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX Tools. [1] Flexible pipe and pressure gauge [2] Flexible union : 4601- TF1 : (-).0336.X Toolkit 4601-T Toolkit 8010-T IMPERATIVE: Respect the safety and cleanliness requirements. CLUTCH GEARBOX TRANSMISSION B2CP45FC Preliminary operations. Remove the air filter housing. Move aside the pipe (1). Remove the screw (2). Screw in the tool [2] in place of the screw (2).
Angl-C6-page101-120-2005 4/02/05 17:25 Page 118 CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX WARNING: Clean the flexible pipe of the tool [1] each time before use; the different automatic gearbox oils cannot be intermixed. Fit the tool [1] on the tool [2]. Perform the following operations: - Raise the vehicle, wheels hanging. - Apply the parking brake. - Start the engine. - Check the oil pressure.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 119 CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX Checking the torque converter. WARNING: This check has to be of short duration (2 seconds), as it causes a rapid rise in the temperature of the oil in the automatic gearbox. Gear lever position. Maximum engine speed for ES9A Maximum engine speed for DT17 : D. : 2400 ± 50 rpm. : 2600 ± 50 rpm.
Angl-C6-page101-120-2005 4/02/05 17:25 Page 120 TRANSMISSION Gearbox oil seal mandrels Tightening torques (m.daN) Vehicle Gearbox Engines Driveshaft bearing C6 AM6 ES9A - DT17BTED4 2 ± 0,2 Driveshaft nut 34,5 ± 2 Right Left (-).0336.U (-).0336.V 8010-T (-).0336.W (1) CLUTCH GEARBOX TRANSMISSION (1) Guide for fitting driveshaft seal. Tightening torques (m.
4/02/05 17:31 Page 121 WHEEL AND TYRES 3.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 122 AXLES SUSPENSION STEERING WHEEL AND TYRES Identification of inflation pressures NOTE: The label indicating the recommended tyre pressures is affixed to the front LH door pillar.
4/02/05 17:31 Page 123 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 WHEEL AND TYRES Identification of the wheel bolts (1) Wheel bolt (all rim types) (2) Light alloy wheel (3) Steel aluminium wheel NOTE: If mixed fixing bolts are fitted on steel wheels, the shoulders of the bolts remain free. Tightening torques for the wheel bolts. 9 ± 1 m.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 124 AXLES SUSPENSION STEERING WHEEL AND TYRES Deflation detection system (4) Valve (5) Antenna (6) HF transmitter unit (7) Washer (8) Seal (9) Cap (10) Nut Composition. A SIEMENS HF transmitter module (6) integral to each wheel in the place of the valve, each including a lithium battery. An HF receiver in the communication module under the dashboard. WARNING: Each time a tyre is replaced, it is necessary to replace the valve (4).
4/02/05 17:31 Page 125 CHECKING AND ADJUSTING VEHICLE HEIGHT Reference heights: REFERENCE = Ignition switched on IMPERATIVE: Respect the safety and cleanliness requirements. Tools. [1] [2] [3] [4] Gauge for measuring radius of wheels (5 bolts) Gauge for height under bodyshell LEXIA station PROXIA station : : : : 9801-T 2305-T 4171-T 4165-T Preliminary operations. Check the tyre pressures. Place the vehicle on a 4 column lift. Switch on the ignition. Release the parking brake.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 126 AXLES SUSPENSION STEERING CHECKING AND ADJUSTING VEHICLE HEIGHT Warning: During measurement of reference heights: Do not switch off the ignition Reference heights: REFERENCE = Ignition switched on Measuring the front wheel radiuses B3CP0AQD Place the tool [1] on the wheel fixing bolts. Measure the wheel radiuses using tool [2]. Measuring the front heights B3CP0ASD B3CP0ARD Measure, using tool [2].
4/02/05 17:31 Page 127 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 CHECKING AND ADJUSTING VEHICLE HEIGHT Reference heights: REFERENCE = Ignition switched on Measuring the rear wheel radiuses B3CP06AC Place the tool [1] on the wheel fixing bolts. Measure the wheel radiuses using tool [2]. Measuring the rear heights B3CP0AUD B3CP0ATD Measure, using tool [2]. The rear LH height H3M: Measure between the ground and zone C under the rear axle crossmember.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 128 AXLES SUSPENSION STEERING CHECKING AND ADJUSTING VEHICLE HEIGHT Reference heights: REFERENCE = Ignition switched on Adjusting the heights. Calculate the following values: - Front LH - Front RH - Rear LH - Rear RH Connect the diagnostic tool [3] or [4] to the vehicle's Switch on the ignition. Perform a global test. Go into the menu. : K1M = R1 - H1M. : K2M = R2 - H2M. : K3M = R3 - H3M. : K4M = R4 - H4M. diagnostic socket. Variable damping.
4/02/05 17:31 Page 129 VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES IMPERATIVE: Respect the safety and cleanliness requirements. Tools. [1] Gauge for measuring radius of wheels (5 bolts) [2] Gauge for height under bodyshell : 9801-T : 2305-T WARNING: «Check and adjust the axle geometries at reference height». Conditions for checking and adjusting. Check the tyre pressures. Place the vehicle on a 4 column lift. Check and adjust if necessary the vehicle heights (see corresponding operation).
Angl-C6-page121-169-2005 4/02/05 17:31 Page 130 AXLES SUSPENSION STEERING VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES Rod for adjusting the rear tracking.
4/02/05 17:31 Page 131 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES Reference heights: REFERENCE = Ignition switched on Front axle Rear axle Dissymmetry of lower castor: 0° 30'. Dissymmetry of lower camber: 0° 25'. Dissymmetry of lower camber: 0° 30. IMPERATIVE: Distribute symmetrically, LH / RH wheel, the total tracking value.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 132 AXLES SUSPENSION STEERING VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES Warning: During measuring of PARKING heights: Switch off the ignition PARKING heights: (values given AS A GUIDE only) Front and rear PARKING heights (ignition switched off) Front axle B3CP0ATD B3CP0ARD Front LH: K1 = 175 ± 6 mm Rear axle Front RH: K2 = 175 ± 6 mm Rear LH: K3 = 131 ± 6 mm 132 Rear RH: K4 = 131 ± 6 mm
4/02/05 17:31 Page 133 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES PARKING heights: (values given AS A GUIDE only) Front and rear PARKING heights (ignition switched off) Front axle Rear axle Dissymmetry of lower castor: 0° 30'. Dissymmetry of lower camber: 0° 25'. Dissymmetry of lower camber: 0° 30. IMPERATIVE: Distribute symmetrically, LH / RH wheel, the total tracking value.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 134 AXLES SUSPENSION STEERING FRONT AXLE ES9A Front subframe. Front subframe in cast aluminium alloy. NOTE: Subframe positioned by indexing on body. Front subframe frame with screwed-in subframe extensions (UHZ engine). (1) Front subframe frame crossmember B3CP09BD (2) Subframe extensions DT17BTED4 (3) Front subframe Front subframe frame with welded subframe extensions (XFV engine).
4/02/05 17:31 Page 135 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 FRONT AXLE Front pivot. Front pivot fixed on the pivot support by means of an upper balljoint and a lower balljoint. Front hub bearing: - Diameter 83 mm. - Bearing with double row of balls, with an integral magnetic wheel (48 pairs of poles). Suspension leg: - Front axle with wheels independent, of multi-arm type. - Travel stop: height 60 mm. - Anti-roll bar Anti-roll bar B3CP09CC Engines Diameter (mm) Colour ref.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 136 AXLES SUSPENSION STEERING FRONT AXLE: TIGHTENING TORQUES B3CP09DC 1 2 3 4 5 6 7 8 9 Engines: ES9A - DT17BTED4 Suspension leg Body suspension upper support Front suspension cylinder on Suspension upper support Suspension upper arm on Suspension upper support Suspension upper arm on Pivot support Front anti-roll bar rod on Pivot support Pivot upper balljoint on Pivot support Pivot upper balljoint nut Front anti-roll bar rod on Front anti-roll bar Suspens
4/02/05 17:31 Page 137 FRONT AXLE: TIGHTENING TORQUES 10 11 12 Engines: ES9A - DT17BTED4 Suspension leg Pivot lower balljoint on Pivot support Pivot lower balljoint on Pivot support Steering rack balljoint on Front pivot B3CP09FC 137 6,5 ± 0,9 17 ± 1,7 3,5 ± 0,3 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005
Angl-C6-page121-169-2005 4/02/05 17:31 Page 138 AXLES SUSPENSION STEERING FRONT AXLE: TIGHTENING TORQUES B3CP09GD 13 14 15 16 17 18 19 20 21 22 23 24 Engines: ES9A - DT17BTED4 Front subframe Front subframe frame tie-bar on Body Front subframe frame tie-bar on Front subframe frame Front absorber support tie-bar Front subframe frame on Subframe extension Front subframe frame crossmember Subframe extension on Front subframe Front subframe stabiliser bar Front subframe on Body Suspension lower arm on Fr
4/02/05 17:31 Page 139 FRONT AXLE: TIGHTENING TORQUES 25 26 Engines: ES9A - DT17BTED4 Front subframe Suspension lower arm support on Front subframe Suspension lower arm on Front subframe B3CP09TC 139 6,5 ± 0,9 12,3 ± 1,2 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005
Angl-C6-page121-169-2005 4/02/05 17:31 Page 140 AXLES SUSPENSION STEERING REAR AXLE Rear axle (1) (2) (3) (4) Rear axle crossmember Rear axle crossmember rear rubber bush Rear axle crossmember front rubber bush Suspension longitudinal arm NOTE: Rear axle in cast aluminium alloy, of multi-arm type.
4/02/05 17:31 Page 141 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 REAR AXLE (10) Rear anti-roll bar bearing (11) Rear anti-roll bar bearing half-support (12) Rear anti-roll bar (13) Rear anti-roll bar rod NOTE: The rear anti-roll bar bearings are not separable. Anti-roll bar Engines Diameter (mm) Colour ref. ES9A - DT17BTED4 20,6 Orange Vehicle geometry. NOTE: The geometry specifications are given with the values for checking and adjusting the axle geometries.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 142 AXLES SUSPENSION STEERING REAR AXLE: TIGHTENING TORQUES B3DP0BUD 1 2 3 4 5 6 7 8 9 10 Engines: ES9A - DT17BTED4 Rear axle crossmember on Body Rear anti-roll bar bearing on Body Tracking adjustment rod on Rear pivot Rear suspension cylinder on Rear pivot Suspension longitudinal arm on Rear pivot Suspension lower arm on Rear pivot Suspension lower arm on Rear axle crossmember Tracking adjustment rod on Rear axle crossmember Locking of tracking adjustment
4/02/05 17:31 Page 143 REAR AXLE: TIGHTENING TORQUES 11 12 13 14 15 16 17 Engines: ES9A - DT17BTED4 Suspension upper arm on Rear pivot Suspension upper arm on Rear axle crossmember Rear suspension cylinder on Rear axle crossmember Rear anti-roll bar rod on Rear pivot Rear anti-roll bar rod on Rear anti-roll bar Rear anti-roll bar bearing half support Rear hub-bearing nut B3DP0BWD B3DP0BXD 143 7 ± 0,7 4 ± 0,6 1,8 ± 0,4 25 ± 2 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005
Angl-C6-page121-169-2005 4/02/05 17:31 Page 144 AXLES SUSPENSION STEERING ACTIVE SUSPENSION WITH VARIABLE DAMPING Location of components A: Front suspension B: Rear suspension NOTE: The rear stiffness regulator is equipped with two accumulators.
4/02/05 17:31 Page 145 ACTIVE SUSPENSION WITH VARIABLE DAMPING Rear axle (10) Rear suspension cylinder (11) Rear suspension accumulator (12) Variable damping suspension actuator (13) Suspension pressure sensor (14) Rear stiffness regulator accumulator (15) Rear stiffness regulator (16) Wheel travel sensor Source of pressure. Features. Hydraulic fluid : LDS TOTAL H50126. The LDS fluid orange in colour is 100% synthetic. Capacity of the hydraulic circuit : 6.3 litres.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 146 AXLES SUSPENSION STEERING ACTIVE SUSPENSION WITH VARIABLE DAMPING Built-in Hydro-electronic Interface (BHI) Composition of the Built-in Hydro-electronic Interface: - An electric motor. - A pump with 5 pistons. - 4 electrovalves. - 2 non-return valves. - A pressure limiter. - An anti-pulse accumulator. - A filter. - The suspension ECU. Features of variable damping suspension. Variable damping suspension ECU (CSS).
4/02/05 17:31 Page 147 ACTIVE SUSPENSION WITH VARIABLE DAMPING Wheel travel sensor (9) Front RH wheel travel sensor The wheel travel sensor defines the angular position of the suspension lower arm. Identification of the sensors: - B3BP19ZC Suspension pressure sensor Front RH wheel travel sensor Front LH wheel travel sensor Rear RH wheel travel sensor Rear LH wheel travel sensor : Yellow. : Red. : Green. : Blue.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 148 AXLES SUSPENSION STEERING ACTIVE SUSPENSION WITH VARIABLE DAMPING Variable damping suspension actuator Each suspension cylinder has a variable damping suspension actuator. (1) Variable damping suspension actuators (front) (12) Variable damping suspension actuators (rear) Anti-roll bars: Front anti-roll bar. ES9A : Diameter 23.5 mm Yellow. DT17BTED4 : Diameter 24 mm Pink. Rear anti-roll bar. ES9A and DT17BTED4 B3BP1A0D 148 : Diameter 20.
4/02/05 17:31 Page 149 ACTIVE SUSPENSION WITH VARIABLE DAMPING One-touch control for body height «g» One-touch control to raise body height «h» Sport mode activation/deactivation switch «j» One-touch control to lower body height C5FP0R8C 149 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005
Angl-C6-page121-169-2005 4/02/05 17:31 Page 150 AXLES SUSPENSION STEERING SUSPENSION: TIGHTENING TORQUES B3CP09DC 1 2 3 4 5 6 7 8 9 Front suspension Body suspension upper support Front suspension cylinder on Suspension upper support Suspension upper arm on Suspension upper support Suspension upper arm on Pivot support Suspension upper arm on Pivot support Pivot upper balljoint on Pivot support Pivot upper balljoint nut Front anti-roll bar rod on Front anti-roll bar Suspension lower arm on Pivot supp
4/02/05 17:31 Page 151 SUSPENSION: TIGHTENING TORQUES 10 11 12 13 14 15 Front pivot lower balljoint on Pivot support Front pivot lower balljoint on Pivot support Steering rack balljoint on Front pivot Rear fixing of suspension lower arm on Front subframe Rear fixing of suspension lower arm on Front subframe Fixing of front anti-roll bar bearing on Front subframe B3CP09FC B3CP09WD 151 6,5 ± 0,9 17 ± 1,7 3,5 ± 0,3 11 ± 1,1 6,5 ± 0,6 4,5 ± 0,4 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005
Angl-C6-page121-169-2005 4/02/05 17:31 Page 152 AXLES SUSPENSION STEERING SUSPENSION: TIGHTENING TORQUES 16 17 Fixing of suspension lower arm support on Front subframe Front fixing of suspension lower arm on Front subframe B3CP09XD 152 8 ± 0,8 12,3 ± 1,2
4/02/05 17:31 Page 153 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 SUSPENSION: TIGHTENING TORQUES 18 19 20 21 22 23 24 25 B3DP0CPD 26 27 28 29 Rear suspension Tracking adjustment rod on Rear pivot Lower fixing of rear suspension cylinder on Rear pivot Suspension longitudinal arm on Rear pivot Suspension lower arm on Rear pivot Rear anti-roll bar bearing on Body Suspension lower arm on Rear axle crossmember Tracking adjustment rod on Rear axle crossmember Screw for locking of tracking adjustmen
Angl-C6-page121-169-2005 4/02/05 17:31 Page 154 AXLES SUSPENSION STEERING SUSPENSION: TIGHTENING TORQUES 30 31 32 Rear suspension Upper fixing of rear anti-roll bar rod on Rear pivot Lower fixing of rear anti-roll bar rod on Rear anti-roll bar Fixing of rear anti-roll bar half-bearing B3DP0CRD 154 4 ± 0,6 1,8 ± 0,4
4/02/05 17:31 Page 155 DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Tools. [1] Pliers for clic clips [2] LEXIA diagnostic tool [3] PROXIA diagnostic tool : 4121-T : 4171-T : 4165-T Draining. Start the engine. Place the vehicle in the low position. Stop the engine. Raise and support the vehicle, wheels hanging. WARNING: The LDS fluid reservoir is pressurised. Open the cap of the LDS fluid reservoir. Remove: - The front RH wheel. - The front RH splash-shield.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 156 AXLES SUSPENSION STEERING DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Filling. Couple the hose (2) on the LDS fluid reservoir. Refit: - The clip (1). - The front RH splash-shield. - The front RH wheel. Lower the vehicle. "a" maximum level for the LDS fluid Fill the LDS fluid reservoir up to the maximum level for the LDS fluid "a".
4/02/05 17:31 Page 157 DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Bleeding. Connect tool [2] or [3] to the vehicle's diagnostic socket. Switch on the ignition. Perform a global test. Go into the menu: - Variable damping. - Bleeding the suspension circuit. Follow the instructions on the screen. Apply a pressure of 0.5 bar in the LDS fluid reservoir (using a tool FACOM 920). Start the engine. Wait for the vehicle height to stabilise. Place the vehicle in the high position.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 158 AXLES SUSPENSION STEERING DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Checking and topping up the LDS fluid level. NOTE: Checking the LDS fluid level is done with the vehicle in the forced low position (hydraulic suspension circuit depressurised). "a" Maximum level for the LDS fluid "b" Minimum level for the LDS fluid Open the cap (3). If necessary, add LDS fluid up to the maximum level "a".
4/02/05 17:31 Page 159 POWER STEERING SPECIFICATIONS Top of column (1) Driver's airbag (2) Steering wheel (3) Controls under the steering wheel (4) Steering lock (5) Fixing of steering wheel on the shaft of the steering column C5FP0U2D Steering column (6) Steering column support (7) Fixing of steering cardan on the distributor valve stem B3EP17SD 159 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005
Angl-C6-page121-169-2005 4/02/05 17:31 Page 160 AXLES SUSPENSION STEERING POWER STEERING SPECIFICATIONS Steering mechanism The steering mechanism with integral ram is fixed on the front subframe by two studs. The steering assistance valve has groove technology. The hydraulic supply and return pipes are fixed on the steering assistance valve by means of a flange. The adjustment of the steering push-rod is via a screw plug «a».
4/02/05 17:31 Page 161 AXLES SUSPENSION STEERING Angl-C6-page121-169-2005 POWER STEERING SPECIFICATIONS Steering assistance circuit (8) Steering assistance valve (9) Steering mechanism with integral ram (10) Low pressure piping (11) High pressure piping (12) Power steering pump (13) LDS fluid reservoir LDS fluid reservoir. The LDS fluid reservoir supplies the suspension circuit as well as the steering assistance circuit (fluid: LDS TOTAL H50126).
Angl-C6-page121-169-2005 4/02/05 17:31 Page 162 AXLES SUSPENSION STEERING POWER STEERING SPECIFICATIONS Setting the steering rack mid-point. IMPERATIVE: Respect the precautions to be taken prior to any operation (refer to the brochure "Recommendations-precautions"). Preliminary operation. Raise and support the vehicle on 2-column lift. Remove (on the RH side): - The clip (1). - The clip (2). Detach the steering rack protection gaiter. B3EP13UC Setting. Turn the steering wheel to full LH lock.
4/02/05 17:31 Page 163 POWER STEERING: TIGHTENING TORQUES Steering column B3EP17GD Steering mechanism with integral ram 1 2 3 4 5 6 7 8 9 10 11 12 Engines: ES9A - DT17BTED4 Steering wheel bolt Upper nuts Lower nuts Fixing of steering cardan on valve stem Union of hydraulic pipe on ram Fixing of supply pipes bracket on distributor valve Fixing of distributor valve on steering mechanism Steering ball-joint nut Locking nut for adjustment of steering track rods Fixing of steering rack ball-joint Steering
Angl-C6-page121-169-2005 4/02/05 17:31 Page 164 AXLES SUSPENSION STEERING POWER STEERING: TIGHTENING TORQUES Steering assistance pump: ES9A engine 13 14 15 16 Fixation Fixation Fixation Fixation of of of of Engines: ES9A - DT17BTED4 steering assistance pump on support pulley on steering assistance pump pulley on steering assistance pump steering assistance pump on support B3EP17JC Steering assistance pump: DT17BTED4 engine B3EP17KC 164 2,5 ± 0,6 0,8 ± 0,2 2,2 ± 0,3 2 ± 0,3
4/02/05 17:31 Page 165 CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) E5AP2PND Tools. [1] Pipe spanner [2] Set of 2 hose clamps [3] Pressure checking assembly [3a] Pressure gauge [3b] Checking tube: Pressure gauge to tap [3c] Checking tube: High pressure pipe to tap [3d] Checking tube: High pressure pump to tap [3e] 3-way tap [4] Union [5] Union [6] Plug for checking sealing of the steering valve : : : : : : : : : : : FACOM 18.17 4153-T (-).0710.AZ (-).0710.B1 (-).0710.B2 (-).0710.B3 (-).
Angl-C6-page121-169-2005 4/02/05 17:31 Page 166 AXLES SUSPENSION STEERING CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) Attach the tool [3a]. Do up: - The union [5] on the pipe (2). - The union [4] on the steering assistance pump. Connect the assembly [3] to the unions [4] and [5]. B1BP3GQD Tighten all the unions. Remove the tool [2]. Open the tap [3e]. Start the engine and allow it to run for 5 seconds. Stop the engine. Move the steering several times in each direction.
4/02/05 17:31 Page 167 CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) Checking the valve sealing. Remove the exhaust line (3). Move aside the heat shield from the steering mechanism. Slacken the union (6) on the power steering ram. Remove: - The screw (4). - The bracket (7). B1JP08WD Uncouple the two supply pipes (5) from the distributor valve, and move them aside. Fit on the distributor valve the tool [6], tighten the screw to: 0,8 ± 0,1 m.daN.
Angl-C6-page121-169-2005 4/02/05 17:31 Page 168 AXLES SUSPENSION STEERING CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) Remove: - The exhaust line (3). - The tool [6]. Couple the two supply pipes (5) on the distributor valve. B1JP08WD Refit: - The bracket (7). - The screw (4), tighten to 0,8 ± 0,1 m.daN. Retighten the union (6) on the power steering ram; tighten to 1,4 ± 0,35 m.daN. Refit the exhaust line (3). Pinch the pipe at "a", using tool [2]. Remove: - The assembly [3].
4/02/05 17:31 Page 169 BLEEDING THE HYDRAULIC STEERING ASSISTANCE CIRCUIT Precautions to be taken. Proceed with care so as to prevent any entry of polluting particles. IMPERATIVE: Respect the safety and cleanliness requirements. IMPERATIVE: Fill the LDS fluid reservoir with new fluid: TOTAL LDS. Bleeding. Check the level and top up the LDS fluid (see procedure: drain-fill-bleed the suspension circuit). Apply a pressure of 0.5 bar in the LDS fluid reservoir (using tool FACOM 920). Start the engine.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 170 BRAKES BRAKE SPECIFICATIONS 3.0i 24S Engine plate ES9A Master cylinder/diameter/travel 254 / TEVES / AMCT / AFT (2) Supplier/type/piston diameter Disc diameter TRW / C II 40 + 45 WE - 30-12 PE / 40 et 45 Ventilated 330 Disc thickness/min.
4/02/05 17:35 Page 171 BRAKING SYSTEM: GENERAL SPECIFICATIONS Braking system Braking circuit Braking circuit in the form of an X. Disc brakes at the front and at the rear (vehicles all types): - The front brake discs are ventilated. - The rear brake discs are ventilated. Electric parking brake (FSE) acting via cables on the rear wheels. The compensator and main brake limiter functions are assured by the ABS REF systems. ESP is fitted as standard on the entire range.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 172 BRAKES BRAKING SYSTEM: GENERAL SPECIFICATIONS ABS/ESP hydraulic valve block Components Supplier Reference TRW ESP VSC 440 Hydraulic valve block ECU Observations Located on the front LH chassis member: 4 regulation channels 25-way connector Integral to the hydraulic valve block 2-way black connector Front wheel sensor The sensors, of inductive type, are fitted on the pivot SIEMENS VDO Air gap non-adjustable: 0.25 to 1.
4/02/05 17:35 Page 173 BRAKING SYSTEM: GENERAL SPECIFICATIONS Parking brake (1) Electrically-controlled parking brake system (FSE) (2) Parking brake cables (3) Cable for manual unlocking of the electric parking brake (FSE). WARNING: It is forbidden to open the electric parking brake system in After Sales. If a malfunctioning of the electric parking brake is diagnosed, it is necessary to replace it.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 174 BRAKES TIGHTENING TORQUES: BRAKING SYSTEM 1 2 3 4 5 6 7 Front brakes Front brake disc Yoke on brake caliper Unions on brake piping Front brake caliper Hydraulic valve block on intermediate support Intermediate support on support Front wheel sensor 1 ± 0,1 3 ± 0,2 4 ± 0,5 11,5 ± 1 0,8 ± 0,2 0,8 ± 0,1 B3FP7HMD B3FP7HPD B3FP7HND 174
4/02/05 17:35 Page 175 BRAKES Angl-C6-PAGE170-194-2005 TIGHTENING TORQUES: BRAKING SYSTEM 8 9 10 Braking amplifier Braking amplifier on support Support on bulkhead Master-cylinder B3FP7HQD B3FP7HRD 175 2,1 ± 0,3
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 176 BRAKES TIGHTENING TORQUES: BRAKING SYSTEM 11 12 13 14 Rear brakes Rear brake caliper Unions on brake piping Rear brake caliper support Rear wheel sensor B3FP7HSD B3FP7HTD 176 3,5 ± 0,3 1,5 ± 0,1 10,8 ± 1 0,8 ± 0,1
4/02/05 17:35 Page 177 TIGHTENING TORQUES: BRAKING SYSTEM Parking brake 15 16 17 18 Electric parking brake system (FSE) Nut for parking brake cables Gyrometer/accelerometer sensor on support Sensor support on body B3FP7HUD Gyrometer/accelerometer sensor B3FP7HVD 177 0,4 ± 0,06 6 ± 0,6 0,9 ± 0,1 0,4 ± 0,06 BRAKES Angl-C6-PAGE170-194-2005
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 178 BRAKES VALUES FOR CHECKING AND ADJUSTING THE BRAKING SYSTEM Front brakes Engines Rear brakes ES9A - DT17BTED4 Type Ventilated brake discs Engines ES9A - DT17BTED4 Type Ventilated brake discs Diameter (mm) 330 Diameter (mm) Nominal thickness (mm) 30 Nominal thickness (mm) 302 22 Minimum thickness (mm) 28 Minimum thickness (mm) 20 Difference in maximum thickness on same circumference (mm) 0,01 Difference in maximum thickness on same cir
4/02/05 17:35 Page 179 GENERAL FEATURES OF ELECTRIC PARKING BRAKE B3FP7HWD C5FP0W3D Presentation. (6) Electric parking brake control "a" Parking brake warning lamp Functioning of the electric parking brake. To apply the parking brake: Prior conditions: - Vehicle stationary or not. - Ignition switched on. - Engine running or not. Pull and release the control (6).
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 180 BRAKES GENERAL FEATURES OF ELECTRIC PARKING BRAKE Presentation. (1) (2) (3) (4) (5) (6) Handle for manual unlocking of the electric parking brake (FSE) Cable for manual unlocking of the electric parking brake Rear RH cable of the electric parking brake Electric parking brake system (FSE) Rear LH cable of the electric parking brake Electric parking brake control "a" Parking brake warning lamp B3FP7HWD Normal functioning of the electric parking brake.
4/02/05 17:35 Page 181 GENERAL FEATURES OF ELECTRIC PARKING BRAKE NOTE: The parking brake can be activated when the vehicle is moving, at whatever speed, but only if the control (6) is kept pulled, the parking brake being deactivated as soon as the control (6) is released. NOTE: The electric parking brake has an "anti-lock" system for limiting the locking of the wheels and guaranteeing vehicle stability if the parking brake is actioned while the vehicle is moving. Releasing the parking brake.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 182 BRAKES GENERAL FEATURES OF ELECTRIC PARKING BRAKE Releasing of the electric parking brake (with a fault). NOTE: Impossible to release the parking brake with the method "Normal functioning". The fault may be caused by the following components: - Battery voltage. - Malfunctioning of the electric parking brake system. Open the central armrest.
4/02/05 17:35 Page 183 ELECTRIC PARKING BRAKE SYSTEM Removing-refitting the electric parking brake system. IMPERATIVE: Respect the safety and cleanliness requirements. WARNING: Before disconnecting the battery, partially open the door windows. Removing. IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables. C5FP0VVD IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in the central armrest, before operating on the parking brake cables.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 184 BRAKES ELECTRIC PARKING BRAKE SYSTEM Uncouple the parking brake cable (6) from the brake caliper (on each side). Unclip the parking brake cable at "a" (on each side). Detach the brake cables from their attachments on the bodywork. B3FP7HHD Extract the manual unlocking cable of the electric parking brake from its location at "b".
4/02/05 17:35 Page 185 ELECTRIC PARKING BRAKE SYSTEM Slacken the nuts (7). Remove the electric parking brake system assembly. B3FP7HKD Refitting. Refit the electric parking brake system assembly. Tighten the nuts (7) : 0,4 ± 0,1 m.daN. Attach the brake cables on their attachments on the bodywork. Clip the parking brake cable, at "a" (on each side). Couple the parking brake cable (6) on the brake caliper (on each side). IMPERATIVE: Position the shim (8) (thickness 3 mm) at "c" (on each side).
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 186 BRAKES ELECTRIC PARKING BRAKE CABLES Removing-refitting the parking brake cables. IMPERATIVE: Respect the safety and cleanliness requirements. WARNING: Before disconnecting the battery, partially open the door windows. Removing. IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables.
4/02/05 17:35 Page 187 BRAKES Angl-C6-PAGE170-194-2005 ELECTRIC PARKING BRAKE CABLES Connector end. Unclip and push back the ring (4). Uncouple the parking brake cable (5). Manual unlocking cable end. B3FP7JOD B3FP7HYD Do up at «b». Uncouple the parking brake cable.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 188 BRAKES ELECTRIC PARKING BRAKE CABLES Refitting. Connector end. Clip the parking brake cable (5) at «c». Clip the ring (4). NOTE: Align the pin «d» with the notch «e». B3FP7J1D Do up the nut (3). Tighten the nut (3) to : 0,6 ± 0,1 m.daN.
4/02/05 17:35 Page 189 BRAKES Angl-C6-PAGE170-194-2005 ELECTRIC PARKING BRAKE CABLES Manual unlocking cable end. NOTE: Grease the cable worm (6). Engage the parking brake cable (6) into the electric parking brake system. Do up 3 turns anti-clockwise at "b". NOTE: Align the pin "g" with the notch "f". B3FP7JOD Do up the nut (3). Tighten the nut (3) to : 0,6 ± 0,1 m.daN. Refit the electric parking brake system (see corresponding operation). Reconnect the battery.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 190 BRAKES BRAKE FLUID CHECKS IMPERATIVE: Respect the safety and cleanliness requirements. WARNING: Brake fluid is toxic to health. Avoid any contact with your skin or with your eyes. If there is contact with your eyes, rinse immediately with copious amounts of water for several minutes. WARNING: Brake fluid is highly corrosive to paintwork. If there is spillage onto the bodywork, clean the surface immediately.
4/02/05 17:35 Page 191 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Tools. [1] Generic bleeding apparatus [2] LEXIA station [3] PROXIA station : «LURO» or similar : 4171-T : 4165-T NOTE: Bleeding of the secondary braking circuit is done with the help of diagnostic tools [2] or [3]. Draining the brake fluid reservoir. B1BP3G7D Disconnect the battery. Remove the engine cover (1) and the lid (2). Disconnect the connector «a». Take out the filter of the brake fluid reservoir (4).
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 192 BRAKES DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Filling the braking circuit. WARNING: Use only the approved and recommended hydraulic fluids. IMPERATIVE: Only use new brake fluid that has not emulsified; avoid any introduction of impurities into the hydraulic circuit. Fill the brake fluid reservoir (4). Bleeding the primary braking circuit.
4/02/05 17:35 Page 193 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM B3FP7H4D B3FP7H5D Using the bleeding apparatus. Connect the bleeding apparatus [1] on the brake fluid reservoir (4). Adjust the apparatus pressure to 2 bars. For each brake circuit: - Connect a transparent tube onto the bleed screw. - Submerge the other end of the tube in a clean container. - Open the bleed screw. - Wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the bleeding apparatus.
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 194 BRAKES DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Bleeding the secondary braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up. NOTE: Connect the bleeding apparatus [1] on the brake fluid reservoir (4). Use the diagnostic tools [2] or [3]. Select the menu ESP VSC 440. Bleed sequence: Menu ESP. - Front LH wheel. - Front RH wheel. - Rear LH wheel. - Rear RH wheel.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 195 SAFETY REQUIREMENTS: ACTIVE SUSPENSION WITH VARIABLE DAMPING All operations on the hydraulic suspension circuit must be performed in conformity with the following requirements and regulations: WARNING: Operations should be carried out by specialised personnel who have had training in the safety requirements and precautions to be taken. Safety requirements.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 196 SAFETY REQUIREMENTS: ACTIVE SUSPENSION WITH VARIABLE DAMPING During the operation. HYDRAULICS Wait for the pressure in the hydraulic circuit to fall fully before disconnecting the unions on the following components (risk of sudden sinking of the vehicle): - Built-in Hydro-electronic Interface (BHI). - Front suspension cylinder. - Rear suspension cylinder. - Front stiffness regulator. - Rear stiffness regulator. - Suspension pressure sensors.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 197 SAFETY REQUIREMENTS: ACTIVE SUSPENSION WITH VARIABLE DAMPING IMPERATIVE: Do not remain underneath the vehicle during an operation to adjust vehicle heights or during actuator (electrovalve) tests. IMPERATIVE: Any deforming of the wheel travel sensor supports is forbidden. If there is any deformation found, replace the component. Cleanliness requirements. Preliminary operations. The work area must be kept clean and uncluttered.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 198 SUSPENSION SPHERES: GENERAL SPECIFICATION Each suspension sphere is identified at "a", by one number and two letters, marked in bold characters: - The number consists of 2 digits, corresponding to the nitrogen pressure inside the suspension sphere. - The two letters identify the location of the suspension sphere. HYDRAULICS Other information marked on the suspension sphere: - Day of the year of manufacture. - Year of manufacture. - Time of manufacture.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 199 SUSPENSION SPHERES: SPECIFICATION - IDENTIFICATION Specifications. The «slimline» accumulators are grey in colour. NOTE: Recharging the «slimline» accumulators with nitrogen is impossible. Volume of nitrogen : 385 ± 15 cc. Engine version ES9A Suspension sphere marking Pressure rating (bars) GO 50 Suspension sphere marking Pressure rating (bars) KS 40 DT17BTED4 Suspension cylinder accumulators (rear).
Angl-C6-page195-202-2005 4/02/05 17:36 Page 200 SUSPENSION SPHERES: SPECIFICATION - IDENTIFICATION Stiffness regulator accumulators (front). NOTE: The dampers are integral to the hydractive regulator. Engine version Suspension sphere marking Pressure rating (bars) KR 70 Suspension sphere marking Pressure rating (bars) KS 40 ES9A HYDRAULICS DT17BTED4 Stiffness regulator accumulators (rear). NOTE: The dampers are integral to the hydractive regulator.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 201 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT [1] PROXIA station [2] LEXIA station Go into the menu: - Suspension. - De-pressurisation. Follow the instructions displayed on the screen. Wait for the vehicle's suspension to sink completely. NOTE: This operation takes around 3 minutes. Switch off the ignition. Disconnect the battery. : 4165-T : 4171-T De-pressurisation. NOTE: It is possible to de-pressurise the suspension by individual axle.
Angl-C6-page195-202-2005 4/02/05 17:36 Page 202 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT Front suspension: Undo the pressure release screw (1) by one turn. Wait for the pressure in the hydraulic circuit to drop fully. HYDRAULICS Rear suspension: Undo the pressure release screw (2) by one turn. B3BP1BED Wait for the pressure in the hydraulic circuit to drop fully.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 203 AIR CONDITIONING R 134.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 204 SPECIAL FEATURES: AIR CONDITIONING SYSTEM Compressor Condenser The variable capacity air conditioning compressor has external control. The internal pneumatic valve is replaced by an external electrovalve. The condenser has a cylinder incorporating the function of aircon fluid reservoir and with integral filtering cartridge. NOTE: The filtering cartridge is not interchangeable.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 205 SPECIAL FEATURES: AIR CONDITIONING SYSTEM Tightening Requirements for fitting the inlet and outlet brackets: - Aircon compressor. - Aircon condenser. - Aircon pressure reducer valve. IMPERATIVE: Assembly requirement: the bracket(s) «f» must be against their interface(s) before the nut(s) are tightened. C5HP1CWC 205 AIR CONDITIONING IMPERATIVE: Respect the tightening torques.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 206 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter The pollen filter is located on the driver's side under the dashboard to the right of the steering column. IMPERATIVE: Respect the safety and cleanliness requirements. Removing. Remove the trim (1) under the dashboard (driver's side). C5FP0S1C Release the tab at "b". Tilt, lift and remove the cover (2). Remove the pollen filter (3).
Angl-C6-page203-217-2005 4/02/05 17:40 Page 207 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level There are three specific cases: - 1) Repairs to a system without leaks. - 2) Slow leak. - 3) Fast leak. a) - Using draining/recovery equipment not fitted with an oil decanter.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 208 SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Checking the compressor oil level (continued) 2) Slow leak. Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3) Fast leak. This type of leak causes both oil loss as well as allowing air to enter the system. It is therefore necessary to: - Replace the dryer. - Drain as much oil as possible (when replacing the faulty component).
Angl-C6-page203-217-2005 4/02/05 17:40 Page 209 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Equipment: EXXOTest Tooling (tools and Equipment flash). Equipment:VALEO Exxoclim : 2.4.2-1. Clim test 2 : 4372-T. Method of use : See instructions. Method of use : See instructions. E5AP2N4D E5AP2N5D 209 AIR CONDITIONING Tooling.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 210 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Testing procedure. Checking. Position the equipment - Exxoclim or Clim test 2 - (see instructions). Preliminary operations. Close all the front air vents. Start the engine. Open the front air vent. Activate the «air conditioning» control. Position the air distribution control to «frontal flow». Activate the «air recirculation» control.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 211 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Reminder (for information) Under-cooling. The under-cooling represents the difference between the condensation temperature and the aircon fluid temperature at the aircon condenser outlet. The under-cooling gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 212 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Possible causes Aircon compressor clutch Lack of aircon fluid in the aircon circuit The clutch of the aircon compressor does not engage, or disengages suddenly The aircon compressor does not turn or stops suddenly Aircon pressostat Aircon evaporator sensor Electrical circuit (wiring, fuses, etc.
Angl-C6-page203-217-2005 4/02/05 17:40 Page 213 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch The clutch of the aircon compressor remains engaged The aircon compressor makes an abnormal Aircon fluid quantity Aircon compressor defective Lack of aircon fluid in the aircon circuit Aircon compressor valves defective The clutch of the aircon compressor
Angl-C6-page203-217-2005 4/02/05 17:40 Page 214 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Low pressure and high pressure too high Possible causes Aircon pressure reducer defective Duct clogged Low pressure too high and high pressure too low Aircon compressor seal defective Aircon evaporator sensor defective Abnormal levels of pressure Low pressure too low and high pressure too high too high Aircon pressure red
Angl-C6-page203-217-2005 4/02/05 17:40 Page 215 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Low pressure normal and high pressure too high Low pressure normal and high pressure too low Possible causes Presence of air in the aircon circuit Aircon pressostat defective Evaporator sensor defective Abnormal levels of pressure Low pressure too high and high pressure normal Aircon pressure reducer jammed open Low pressu
Angl-C6-page203-217-2005 4/02/05 17:40 Page 216 AIR CONDITIONING SYSTEM R.134.a Engine: ES9A Tightening torques (m.daN).
Angl-C6-page203-217-2005 4/02/05 17:40 Page 217 AIR CONDITIONING SYSTEM R.134.a Engine: DT17BTED4 Tightening torques (m.daN). «a» Compressor front support «b» Compressor rear support C5HP1DRP 217 : : : : : : : : : 0,6 0,6 8005-T.
