Citroen C6
Citroen C6
Citroen C6
CITROËN C6
2005
PRIVATE CARS
«The technical information contained in this document is intended for the exclusive use of the trained personnel
of the motor vehicle repair trade. In some instances, this information could concern the security and safety of
the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they
alone would assume full responsibility to the exclusion of that of the manufacturer».
«The technical information appearing in this brochure is subject to updating as the characteristics of each
model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for
further information and to obtain any possible updates».
AC/DTAV/MMCB/MMEC 쏘 «The intellectual property rights relating to the technical information contained in this document belong
Méthodes Mécaniques exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior
written authorisation from the manufacturer is forbidden».
2005 CAR 000 023
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.
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.
CONTENTS
GENERAL Auxiliary equipment drive belt 45 IGNITION
Vehicle identification 1-4 Checking and setting the valve timing 50 Sparking plugs 100
General specifications: dimensions 5-6 Exhaust line specifications 68 - 72
CLUTCH - GEARBOX - TRANSMISSION
General specifications: weights 7 Cooling system specifications 73 - 75
Checking the oil pressure 76 Speedometer 101
Operations to be performed before and
8 AM6 automatic gearbox specifications
after a disconnection of the battery Valve clearances 77 102
Towing specifications 9 - 10 Drain-fill-bleed the engine cooling circuit 78 - 82 Procedure before operations 103
Lifting and supporting the vehicle 11 - 15 INJECTION Precautions: AM6 gearbox 104
Capacities 18 BOSCH 7.4.7 injection system 83 - 89 AM6 gearbox specifications 105
Lubricants 18 - 20 Prohibited operations: SIEMENS HDi Tightening torques: AM6 gearbox 106 - 107
90 - 91 AM6 gearbox control specifications 108 - 110
ENGINE direct injection
Engine specifications 22 Safety requirements: HDi direct injection 92 Shift lock function 111
Engine suspension tightening torques: ES9A 23 Checking the low pressure fuel Initialisation of the AM6 gearbox 112 - 113
93 - 94
supply circuit Draining-filling-topping up
Tightening torques: ES9A engine 24 - 28
Turbo pressure checks 95 - 97 the AM6 gearbox 114 - 116
Suspension tightening torques: DT17 29 - 31
Air supply circuit specifications 98 Oil pressure checks: AM6 gearbox 117 - 119
Adjustment of torque reaction rod 32
Checking the air supply circuit 99 Transmission 120
Tightening torques: DT17 engines 33 - 41
Cylinder head tightening 42 - 43
Angl-C6-Index-2005 4/02/05 17:10 Page IV
CONTENTS
AXLES - SUSPENSION - STEERING BRAKES AIR CONDITIONING
Wheels and tyres 121 - 124 Brake specifications 170 Quantities: aircon system R134.a 203
Checking and adjusting the vehicle height 125 - 128 Special features: air conditioning circuit 204 - 205
Braking system: general specifications 171 - 173
Values for checking and adjusting Pollen filter 206
129 - 133 Braking system: tightening torques 174 - 177
the axle geometries
Values for checking and adjusting Checking the compressor oil level 207 - 208
Front axle 134 - 135 178
the braking system Checking the efficiency of
Front axle tightening torques 136 - 139 209 - 215
General feataures of the air conditioning circuit
Rear axle 140 - 141 179 - 189
the electric parking brake Air conditioning circuit: ES9A 216
Rear axle tightening torques 142 - 143
Brake fluid checks 190 Air conditioning circuit: DT17 217
Active suspension with variable damping 144 - 149
Drain-fill-bleed the braking system 191 - 194
Suspension tightening torques 150 - 154
Draining-filling-bleeding HYDRAULICS
155 - 158
the hydraulic steering/suspension circuit Safety requirements:
195 - 197
Power steering specifications 159 - 162 active suspension with variable damping
Power steering tightening torques 163 - 164 Suspension spheres: general specifications 198
Checking the steering assistance Suspension spheres:
165 - 168 199 - 200
pressure (ES9A engine) specification - identification
Bleeding the hydraulic steering Depressurising the hydraulic
169 201 - 202
assistance circuit suspension circuit
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).
GENERAL
D - AS/RP No. and RP paint code
(label on front pillar close to driver's door).
E1AP13LD
Angl-C6-page001-21-2005 4/02/05 17:12 Page 2
IDENTIFICATION OF VEHICLES
Petrol Diesel
ES DT
9 17
A BTED4
3.0i 24 S 2.7 24V HDi
Emission standard E4
Type code TD XFVJ TD UHZJ
GENERAL
2
Angl-C6-page001-21-2005 4/02/05 17:12 Page 3
IDENTIFICATION OF VEHICLES
Manufacturer's plate
GENERAL
(d) Gross vehicle weight (*)
E1AP09JC
3
Angl-C6-page001-21-2005 4/02/05 17:12 Page 4
IDENTIFICATION OF VEHICLES
Type approval
Structure Version (4)
T Family (1) Depollution levels
Family (1) G H S X 3
T C6 D J N U
Bodywork (2) K L T Y 7 0 4
D Saloon 4-door 3-box M
Z
Engine (3)
XFV 3.0i 24 S ES9A
UHZ 2.7 24V HDi DT17BTED4
4
Angl-C6-page001-21-2005 4/02/05 17:12 Page 5
GENERAL
E1AP13KD
5
Angl-C6-page001-21-2005 4/02/05 17:12 Page 6
6
Angl-C6-page001-21-2005 4/02/05 17:12 Page 7
ES9A DT17BTED4
Versions 3.0i 24S 2.7HDi 24V
Engine type XFV UHZ
Gearbox type AM6
Payload 455 464
Weight empty in running order 1816 1871
Gross Vehicle weight 2271 2335
GENERAL
Gross Train weight 3671
Max. trailer weight with brakes
Incline 12 % 1400
Incline 10 % 1500 1400
Incline 8 % 1700
Max. trailer weight without brakes 750
Maximum nose weight 70
Maximum weight on roof bars 80
NOTE: Maximum nose weight = Vertical load at the tow hook (CVA).
7
Angl-C6-page001-21-2005 4/02/05 17:12 Page 8
If the vehicle has to remain stationary: Activate the electric parking brake. Keep the sun roof switch pressed until the end of the sun roof opening
If the vehicle has to be moved: Deactivate the electric parking brake. sequence.
Features of the vehicle's electrical supply. Multifunction screen.
When the boot is closed and the battery is disconnected, it is possible to It is necessary to adjust the date, time and outside temperature.
supply the vehicle by connecting another battery or a 12V exterior supply. Adjust the display language of the multifunction screen if necessary.
Operations to be performed: NOTE: The default display language of the multifunction screen is French.
- Link the earth of the exterior supply to the vehicle earth. Reconfigure the personalisation menu of the multifunction screen.
- Link the 12V of the exterior supply to the positive terminal of the battery +
unit, in the front left hand side of the engine compartment. Radio.
Reprogramme the radio stations.
After reconnecting the battery. Telematic control unit (RT3 radiotelephone).
Antiscanning function. Reprogramme the radio stations.
It is necessary to wait 1 minute after reconnecting the battery in order to be Navigation.
able to restart the vehicle. Warning: the vehicle has to be out in the open (when you switch on
Electric windows. the ignition, the navigation ECU searches for satellites).
It may be necessary to re-initialise the sequential and anti-pinch functions. Reprogramme the customer parameters.
8
Angl-C6-page001-21-2005 4/02/05 17:12 Page 9
Towing eye.
The towing eye (1) is to be found in the vehicle
toolkit (2) stowed in the spare wheel.
GENERAL
Front of the vehicle. E2AP02SD
Rear towing
Open the flap (3).
Screw in the towing eye (1).
E2AP02RD E2AP02TD
9
Angl-C6-page001-21-2005 4/02/05 17:12 Page 10
IMPERATIVE: Never tow the vehicle with the wheels hanging (towing by the wheels).
Towing:
Driving:
- Never drive with the ignition switched off.
NOTE: The automatic gearbox is only lubricated when the engine is running.
Never push the vehicle to attempt to start it (impossible with an automatic gearbox).
10
Angl-C6-page001-21-2005 4/02/05 17:12 Page 11
Lifting.
ATTENTION: Lifting the vehicle by the front can only be done one side at a time.
GENERAL
IMPERATIVE: Do not lift the vehicle by taking weight under the front subframe. Do not place blocks under
E2AP016C the front subframe.
IMPERATIVE: Never take weight on the front panel support and the front part of the engine subframe.
IMPERATIVE: Place the jack under the centre pillar, inserting an elastomer shim at «a».
E2AP02LD
11
Angl-C6-page001-21-2005 4/02/05 17:12 Page 12
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».
Lateral lifting.
E2AP017C
12
Angl-C6-page001-21-2005 4/02/05 17:12 Page 13
NOTE: the vehicle jack, with the extension and handle, is to be found in the toolkit stowed in the spare wheel.
GENERAL
Correct position for the vehicle jack (1).
E2AP02QD
13
Angl-C6-page001-21-2005 4/02/05 17:12 Page 14
E2AP018C
IMPERATIVE: Do not place the axle stands under the lugs of the jacking points.
E2AP02PD
14
Angl-C6-page001-21-2005 4/02/05 17:12 Page 15
Equipment involved:
- Two-column lift.
- Auxiliary lift with blocks.
IMPERATIVE: Position the safety straps, if placing the vehicle on a lift supported from the jacking points
(risk of the vehicle overbalancing when a heavy component is removed).
Tooling required.
GENERAL
[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).
Place protections on the front seats and on the fragile parts of the vehicle.
Example:
- Two-column lift.
- Place the safety straps [1] under the arm of the lift and criss-crossing the vehicle.
E2AP02FC
15
Angl-C6-page001-21-2005 4/02/05 17:12 Page 16
Place the vehicle on horizontal ground (in the high position if Place the vehicle on horizontal ground (in the high position if
hydropneumatic suspension). hydropneumatic suspension).
The engine should be hot (oil temperature 80°C). The engine should be hot (oil temperature 80°C).
Remove the oil by suction through the dipstick tube.
GENERAL
Stop the engine (allow to stabilise for 5 minutes). WARNING: Remove the suction container before starting the engine.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
16
Angl-C6-page001-21-2005 4/02/05 17:12 Page 17
BVA BVA
GENERAL
Max. after draining and change of filter (by gravity) 5,55
Dry sump 5,95
Between min. and max. 2
Dry automatic gearbox 7
Volume of oil remaining after draining 4
Quantity of oil to be put back in after draining 3
Hydraulic circuit 6,3
Cooling circuit 11,3 13,2
Fuel tank 65
17
Angl-C6-page001-21-2005 4/02/05 17:12 Page 18
Petrol engines
API: SJ API: SL
ACEA: B5 ACEA: B3 or B4 ACEA: B3
Diesel engines (*) (**)
Prohibited API: CF
Prohibited FAP
(*) In the winter season, on HDi engines, it is recommended to use 5W40 oil instead of 10W40 oil, this to enhance starting from cold.
(**) Do not use 5W30 oil on HDi engines with particle filter (FAP).
18
Angl-C6-page001-21-2005 4/02/05 17:12 Page 19
GENERAL
GLYSANTIN G33 REVKOGEL 2000
2 Litres 9979 70 9979 72
CITROËN fluid 5 Litres 9979 71 9979 73
All countries Protection: -35C°
20 Litres 9979 76 9979 74
210 Litres 9979 77 9979 75
19
Angl-C6-page001-21-2005 4/02/05 17:12 Page 20
Greasing
General use
NLGI norms
TOTAL MULTIS 2 2
All countries
TOTAL PETITES MECANISMES
20
Angl-C6-page001-21-2005 4/02/05 17:12 Page 21
GENERAL
- 6 000 miles (10 000 km) for a DIESEL engine.
IV - OIL LEVEL: The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil.
- This excess oil will be used up rapidly.
- It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.
21
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
22
Angl-C6-page022-82-2005 4/02/05 17:19 Page 23
ENGINE
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 Pencil-type ignition coil 0,8 ± 0,3
Sparking plugs
Pre-tightening 1 ± 0,1
Angular tightening 90° ± 5°
Valve cover
2 Pre-tightening 0,5 ± 0,1
Tightening 1 ± 0,1
Camshaft bearing cap cover
3 Pre-tightening 0,2 ± 0,1
Tightening 1 ± 0,1
Cylinder head
Pre-tightening 2 ± 0,2
4 Slackening yes
Tightening 1,5 ± 0,1
Angular tightening 225° ± 5°
B1BP27DP
24
Angl-C6-page022-82-2005 4/02/05 17:19 Page 25
ENGINE
ENGINE TIGHTENING TORQUES
Engine: ES9A
Exhaust manifold (equipped with a new gasket)
5 Pre-tightening (order from 1 to 10) 1 ± 0,1
Tightening (order from 1 to 10) 3 ± 0,3
Con rod caps
6 Pre-tightening 2 ± 0,2
Angular tightening 74° ± 5°
Engine flywheel
7 Pre-tightening 2 ± 0,2
Angular tightening 60° ± 5°
B1JP02LD
25
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.
Check the presence of the eight centring pins
Pre-tighten the screws M11 (sequence from 1 to 8) 3 ± 0,3
Pre-tighten the screws M8 (sequence from A to H) 1 ± 0,1
Tighten the screws M6 (sequence from a to 1) 1 ± 0,1
Slacken the screws screws M11 and M8 Yes
Proceeding screw by screw
Tighten the screws M11 (sequence from 1 to 8) 3 ± 0,3
Angular tightening 180°
Tighten the screws M8 (sequence from A to H) 1 ± 0,1
Angular tightening 180°
B1BP2D3D
26
Angl-C6-page022-82-2005 4/02/05 17:19 Page 27
ENGINE
ENGINE TIGHTENING TORQUES
Engine: ES9A
Sump
9 Pre-tightening (sequence from 1 to 20) 0,5 ± 0,1
Tightening (sequence from 1 to 20) 0,8 ± 0,1
Crankshaft pinion
10 Pre-tightening 4 ± 0,4
Angular tightening 80°
11 Crankshaft pulley 2,5 ± 0,2
Inlet distributor (with new seals)
12 Pre-tightening 0,4 ± 0,1
Tightening 0,8 ± 0,1
Air inlet manifold 13
Pre-tightening 0,4 ± 0,1
Tightening 0,8 ± 0,1
B1BP1GZD
27
Angl-C6-page022-82-2005 4/02/05 17:19 Page 28
ENGINE
ENGINE TIGHTENING TORQUES
Engine: ES9A
Camshaft hubs
14 Pre-tightening 2 ± 0,2
Angular tightening 57°
15 Cap 1,5 ± 0,1
16 Guide roller 8 ± 0,8
Camshaft pulley
17 Pre-tightening 2 ± 0,2
Angular tightening 115°
18 Camshaft pulleys 1 ± 0,1
B1BP2D3D
20 Timing belt tensioner roller 2,5 ± 0,2
21 Plate for the dynamic tensioner roller 2,5 ± 0,2
Coolant pump
22 Pre-tightening 0,5 ± 0,1
Tightening 0,8 ± 0,1
Oil pump
19 Pre-tightening 0,5 ± 0,1
Tightening 0,8 ± 0,1
B1FP04KC
28
Angl-C6-page022-82-2005 4/02/05 17:19 Page 29
ENGINE
TIGHTENING TORQUES: POWER UNIT SUSPENSION
Engine: DT17BTED4
RH engine support
1 Screws 8,2 ± 1,25
2 Screws 6 ± 0,6
3 Screws 2,8 ± 0,4
4 Nut 6,5 ± 0,6
5 Screws 6 ± 0,6
Front piloted torque reaction rods
6 Screws
B1BP3EPD 6 ± 0,6
7 Screws
8 Screws 4,3 ± 0,4
9 Screws 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 Screws
11 Screws
6 ± 0,6
12 Screws
13 Screws
LH gearbox support
14 Screws 6 ± 0,6
15 Screws 5,5 ± 0,8
B1BP3ERD
16 Screws 6 ± 0,6
17 Screws 5,5 ± 0,8
B2CP45CD
30
Angl-C6-page022-82-2005 4/02/05 17:19 Page 31
ENGINE
TIGHTENING TORQUES: POWER UNIT SUSPENSION
Engine: DT17BTED4
Gearbox impact absorber
18 Screws 4 ± 0,6
B2CP45DC
Driveshaft bearing
19 Screws 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).
B1BP3E9D WARNING: Tighten the supports of the engine/gearbox assembly prior to adjusting the rods.
B1BP3EBD
32
Angl-C6-page022-82-2005 4/02/05 17:19 Page 33
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Cylinder head
1 Butterfly housing
Inlet valve cover screws (*)
2 0,9 ± 0,2
Inlet valve cover studs (*)
3 Coolant outlet housing
Cylinder heads
Pre-tightening 2 ± 0,2
4 Tightening 4 ± 0,5
Tightening 8 ± 0,5
Angular tightening 180 ± 5°
5 EGR (exhaust gas recycling) electrovalve 0,9 ± 0,2
Exhaust manifold nuts 2,3 ± 0,3
6
Exhaust manifold studs 1,3 ± 0,2
Turbocharger nuts 2,3 ± 0,3
7
Turbocharger studs 1,3 ± 0,2
8 Pre-catalysers 2 ± 0,1
9 Vacuum pump 2,3 ± 0,3
33
Angl-C6-page022-82-2005 4/02/05 17:19 Page 34
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
B1DP1M1C
B1DP1M2C
34
Angl-C6-page022-82-2005 4/02/05 17:19 Page 35
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Cylinder block
11 Coolant pump 0,9 ± 0,2
Con rod screws
Pre-tightening 2 ± 0,1
12 Angular pre-tightening 45 ± 5°
Angular tightening 45 ± 5°
Starter gearwheel carrier
Pre-tightening 5 ± 0,5
13 Angular pre-tightening 45 ± 5°
Angular tightening 45 ± 5°
14 Lower engine block screw (*) 0,9 ± 0,2
15 Lower engine block screw (*) 2,3 ± 0,3
Bearing cap fixing screws (*)
Pre-tightening 6 ± 0,6
16 Tightening 14,5 ± 1,4
Angular tightening 90 ± 20°
Crankshaft bearing cap cover
Pre-tightening 1,5 ± 0,1
17 Tightening 3,3 ± 0,9
Angular tightening 47 ± 20°
18 Accessories drive pulley 2,5 ± 0,2
35
Angl-C6-page022-82-2005 4/02/05 17:19 Page 36
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Method of tightening:
- Tighten the 10 screws (15) (from 1 to 10) to : 2,3 ± 0,3
- Tighten the 8 screws (14) (from 1 to 18) to : 0,9 ± 0,1
B1DP1M4D
Method of tightening:
- Pre-tighten the 16 screws (16) (from 1 to 16) to : 6 ± 0,6
- Pre-tighten the 8 screws (17) (from 17 to 24) to : 1,5 ± 0,1
- Pre-tighten the 16 screws (16) (from 1 to 16) to : 14,5 ± 2
- Tighten the screws (16) (from 1 to 16) : 90° ± 20°
- Tighten the 8 screws (17) (from 17 to 24) to : 3,3 ± 0,3
- Tighten the screws (17) (from 17 to 24) : 47° ± 20°
B1DP1M5D
36
Angl-C6-page022-82-2005 4/02/05 17:19 Page 37
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Lubrication
19 Oil filter cover 2,3 ± 0,3
20 Oil filter support
0,9 ± 0,2
21 Oil/coolant heat exchanger
22 Oil pressure switch 1,3 ± 0,2
23 Oil pump assembly 0,9 ± 0,2
24 Oil gauge 2,3 ± 0,3
25 Oil level sensor 2,7 ± 0,5
26 Oil sump 0,9 ± 0,2
27 Drain plug 2,3 ± 0,3
28 Oil suction strainer 0,9 ± 0,1
29 Piston skirt spray jets 1 ± 0,1
30 Turbocharger lubrication pipe 0,9 ± 0,2
31 Turbocharger lubrication pipe 1,3 ± 0,3
B1DP1M6P
37
Angl-C6-page022-82-2005 4/02/05 17:19 Page 38
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Valve timing
Camshaft pulley hub screw
32 Tightening 8 ± 0,8
Angular tightening 90° ± 5°
33 Camshaft pulley screw 2,3 ± 0,3
Camshaft bearing caps (*)
34 Tightening 0,5 ± 0,1
Pre-tightening 0,9 ± 0,1
35 Tensioner roller for the fuel high pressure pump drive belt 2,5 ± 0,2
Fuel high pressure pump drive pulley
36 Tightening 8 ± 0,8
Angular tightening 90° ± 5°
37 Camshaft timing chain tensioner 0,9 ± 0,1
38 Timing belt guide roller 4,5 ± 0,3
Timing pinion on crankshaft
39 Tightening 10 ± 1
Angular tightening 90° ± 5°
40 Timing belt tensioner roller 2,6 ± 0,2
38
Angl-C6-page022-82-2005 4/02/05 17:19 Page 39
ENGINE
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.
Refit the camshaft bearing caps according to the plan below:
Refit: The camshaft bearing caps (34) 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G and F ; the screws (41)
Tightening of the screws (41):
Pre-tighten the screws (41) of the camshaft bearing caps (34) by hand in the following sequence
9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G and F.
Pre-tighten the screws (41) of the camshaft bearing caps (34) to 0,5 ± 0,1 m.daN in the following
sequence 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G and F.
Tighten the screws (41) of the camshaft bearing caps (34) to 1 ± 0,1 m.daN in the following
sequence 9, 8, 7, 6, 4, 3, 2, D, C, B, A, J, G and F.
Apply sealing product LOCTITE 518 on the camshaft bearing caps (15) K, 5, E and J (see procedure:
remove/refit camshaft).
Refit: the camshaft bearing caps K, 5, E and J.
Tightening of the screws (41):
- Pre-tighten the screws (41) of the camshaft bearing caps (34) by hand in the following sequence
K, 5, E and J.
- Pre-tighten the screws (41) of the camshaft bearing caps (34) to 0,5 ± 0,1 m.daN in the following
sequence K, 5, E and J.
- Tighten the screws (41) of the camshaft bearing caps (34) to 1 ± 0,1 m.daN in the following sequence
K, 5, E and J.
B1DP1MQD
39
Angl-C6-page022-82-2005 4/02/05 17:19 Page 40
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Injection circuit
42 Diesel fuel/cooolant exchanger 2,2 ± 0,3
43 Diesel injection pump on support 2,3 ± 0,3
44 Diesel injection pump pinion 5 ± 0,2
45 Diesel injector fixing flange screw 0,9 ± 0,1
Union on diesel injector
46 Pre-tightening 1,5 ± 0,3
Tightening 2,3 ± 0,3
Fuel high pressure common injection rail on engine block
47 Pre-tightening 1,5 ± 0,3
Tightening 3 ± 0,3
Unions on fuel high pressure common injection rail
48 Pre-tightening 1,5 ± 0,3
Tightening 3 ± 0,3
49 Fuel filter support 2,3 ± 0,3
Union on diesel fuel high pressure pump
50 Pre-tightening 1,5 ± 0,3
Tightening 3 ± 0,3
Fuel high pressure common injection intermediate rail
51 Pre-tightening 1,5 ± 0,3
Tightening 3 ± 0,3
B1HP246D
40
Angl-C6-page022-82-2005 4/02/05 17:19 Page 41
ENGINE
ENGINE TIGHTENING TORQUES
Engine: DT17BTED4
Accessories
52 Screw M8 for automatic tensioner roller (accessories drive belt) 2,2 ± 0,3
Screw M10 for dynamic tensioner roller (accessories drive belt) 4,7 ± 0,7
53 Guide roller 4,7 ± 0,7
54 Accessories support 2,3 ± 0,3
55 Multifunction support 2,3 ± 0,3
56 Power steering pump pulley 2,3 ± 0,3
57 Power steering pump 2,3 ± 0,3
58 Alternator screw 5 ± 0,3
59 Alternator power circuit 1,4 ± 0,2
60 Aircon compressor screw 2,3 ± 0,3
B1BP3C0D
41
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.
Brush the threads of the cylinder head bolts.
Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.
Front cylinder head Engine Tightening (from 1 to 8) X = MAX. re-usable length
Pre-tightening 2 ± 0,2
Slackening yes
ES9A 149,5 mm
Tightening 1,5 ± 0,1
Angular tightening 225° ± 5°
B1DP1KEC
B1DP1KHC
42
Angl-C6-page022-82-2005 4/02/05 17:19 Page 43
ENGINE
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.
Brush the threads of the cylinder head bolts.
Oil the threads and under the heads of the bolts, using MOLYKOTE G RAPID PLUS.
Front cylinder head Engine Tightening (from 1 to 8) NOT re-usable
Pre-tightening 2 ± 0,2
Tightening 4 ± 0,4
DT17BTED4 New screws
Tightening 8 ± 0,8
Angular tightening 180° ± 5°
B1DP1MDD
B1DP1MLC
43
Angl-C6-page022-82-2005 4/02/05 17:19 Page 44
ENGINE
BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE
Tools !
!
!
!
4099-T (C.TRONIC.105) 4122-T (C.TRONIC.105.5)
44
Angl-C6-page022-82-2005 4/02/05 17:19 Page 45
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Petrol Diesel
C6 X X
See pages: 47 to 48 49
45
Angl-C6-page022-82-2005 4/02/05 17:19 Page 46
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Engines : all types Petrol and Diesel
Tools.
Essential.
46
Angl-C6-page022-82-2005 4/02/05 17:19 Page 47
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Engine: ES9A
Tools.
[1] Ratchet spanner S.171 FACOM (1/2 square) : S 171
[2] Reduction box S.230 FACOM (1/2 - 3/8) : 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.
Refit the auxiliary equipment drive belt.
Respect the following order of assembly:
- The crankshaft pulley (2).
- The tensioner roller (3).
Release the tensioner roller bracket (1), by turning it anti-clockwise,
using tools [1] and [2].
ESSENTIAL: Make sure that the belt is correctly positioned in
the grooves of the various pulleys.
B1BP27EC B1BP27FC
47
Angl-C6-page022-82-2005 4/02/05 17:19 Page 48
ENGINE
AUXILIARY EQUIPMENT DRIVE BELT
Engine: ES9A
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].
WARNING: Do not compress the dynamic tensioner roller completely (risk
of damage).
WARNING: Mark the direction of fitting of the auxiliary equipment drive belt
if for re-use.
Disengage the auxiliary equipment drive belt from the various pulleys, commencing
at "b" (coolant pump pulley).
Remove:
- The screws (2) and (4).
- The dynamic tensioner roller (1).
- The auxiliary equipment drive belt (3).
ESSENTIAL: Check that the tensioner and guide rollers as well as the
coolant pump can turn freely (without play, without tight spots and without
projections of grease).
B1BP3BSD
48
Angl-C6-page022-82-2005 4/02/05 17:19 Page 49
ENGINE
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.
Compress the dynamic tensioner roller.
Remove tool [1].
ESSENTIAL: Make sure that the auxiliaries drive belt is correctly positioned in the
grooves of the various pulleys.
Refit:
- The air duct (linking the air distributor heat exchanger).
- The RH splash-shield.
- The front RH wheel.
- The under-engine sound-deadening.
B1BP3BVC
49
Angl-C6-page022-82-2005 4/02/05 17:19 Page 50
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Petrol Diesel
C6 X X
See pages: 51 to 57 58 to 67
50
Angl-C6-page022-82-2005 4/02/05 17:19 Page 51
ENGINE
CHECKING THE VALVE TIMING
Engine: ES9A
Tools.
Remove:
- The power steering pulley.
- The roller/dynamic tensioner assembly (11).
- The crankshaft pulley (12).
- The upper timing covers (9) and (10).
- The lower timing cover (13).
B1BP2BKC
51
Angl-C6-page022-82-2005 4/02/05 17:19 Page 52
ENGINE
CHECKING THE VALVE TIMING
Engine: ES9A
Refit:
B1EP08TC - 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.
B1EP15UD
52
Angl-C6-page022-82-2005 4/02/05 17:19 Page 53
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: ES9A
Setting the valve timing.
WARNING: Mark the direction of fitting of the timing belt, in case the belt is to be reused.
B1EP15VD
53
Angl-C6-page022-82-2005 4/02/05 17:19 Page 54
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: ES9A
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.
WARNING: Respect the direction of fitting of the belt: Facing the timing, the inscriptions on
the belt should be readable the correct way up.
B1EP15VD Fit the timing belt on the crankshaft pinion.
Position the tool [6].
Position the timing belt in the following sequence (belt well tensioned):
- The roller (26), the pulley (18), the pulley (17).
WARNING: Keep the timing belt well tensioned.
- Refit the guide roller (16), tighten to 8 ± 0,8 m.daN.
Position the timing in the following sequence:
- The camshaft pulleys (15) and (14), the tensioner roller (24), the coolant pump pulley and the
guide roller (27).
NOTE: When positioning the belt on the camshaft pulleys, turn these clockwise so as to engage the
next tooth. The angular displacement of the pulleys should not be more than the equivalent of one
tooth.
B1BP2BLC
54
Angl-C6-page022-82-2005 4/02/05 17:19 Page 55
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: ES9A
Setting the valve timing (continued).
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).
NOTE: The check of the belt tension is done on the longest belt section between the crankshaft
pinion and the guide roller.
B1EP15WC
55
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.
B1EP15XC
56
Angl-C6-page022-82-2005 4/02/05 17:19 Page 57
ENGINE
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].
Turn the crankshaft 2 rotations clockwise.
IMPERATIVE: Never turn it back.
Peg the crankshaft, using tool [2].
Check the position of the tensioner roller (the alignment of the marks «c» and «d» should be correct).
Peg the camshaft pulleys, using tool [1].
If the peg [1] goes in: Loosen the exhaust camshaft pulley screws by 45°.
If the peg [1] does not go in: Slacken the exhaust camshaft pulley screws by 45°.
Bring the exhaust camshaft hub to the pegging position (5), using tool [5].
WARNING: Check that the exhaust camshaft pulleys are not at the end of slots. Otherwise, restart
the operation to position the timing belt.
Tighten the exhaust camshaft pulley screws to 1 ± 0,1 m.daN.
Remove tools [1] and [2].
Complete the refitting.
Initialise the injection ECU (see corresponding operation).
B1EP15XC
57
Angl-C6-page022-82-2005 4/02/05 17:19 Page 58
ENGINE
CHECKING THE VALVE TIMING
Engine: DT17BTED4
Tools.
[1] Set of plugs : (-).0188-T
[2] Flywheel setting peg (double flywheel) : (-).0195.K Toolkit 0188-T
[3] Camshaft setting pegs : (-).0195.H 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.
Remove:
- The under-engine sound-deadening.
- The front RH wheel.
- The front RH splash-shield (see corresponding operation).
Remove:
- The air duct between the air/air exchanger and the air inlet housing (4).
- The air inlet housing (4).
Uncouple, plug and move aside the pipes (2) and (3), using tools [1].
Unclip and move aside the electrical harness.
Remove the venting chamber fixing (1).
Move aside the venting chamber (1).
B1BP3BXD
58
Angl-C6-page022-82-2005 4/02/05 17:19 Page 59
ENGINE
CHECKING THE VALVE TIMING
Engine: DT17BTED4
Remove:
NOTE: Turn the crankshaft in the normal direction of rotation, by means of the crankshaft pinion
screw.
B1EP1JAD
59
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].
IMPERATIVE: If it is not possible to peg the camshafts, restart the setting of the valve timing
B1DP1MOC
(see corresponding operation).
60
Angl-C6-page022-82-2005 4/02/05 17:19 Page 61
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: DT17BTED4
Tools.
[1] Kit of plugs : (-).0188-T
[2] Flywheel setting peg (double damping flywheel) : (-).0195.K Toolkit 0188-T
[3] Camshaft setting pegs : (-).0195.H Toolkit 0188-T
[4] Belt compressure spring : (-).0188.K
[5] Coolant pump pulley peg : (-).0195.C
[6] Lifting bracket : (-).0195.N
WARNING: Before disconnectng the battery, partially open the door windows.
Removing.
IMPERATIVE: Respect the safety and cleanliness requirements specific to High pressure Diesel injection (HDi) engines.
61
Angl-C6-page022-82-2005 4/02/05 17:19 Page 62
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: DT17BTED4
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.
B1BP3C2D - The header tank (1).
Position the lifting bracket [6] at "a".
Support the engine by means of a workshop hoist.
Remove:
- The upper RH engine support tie bar, and the upper RH engine support (5).
- The engine support (4) on the chassis member.
- The accessories drive belt (8) (see corresponding operation).
- The engine support (12), the crankshaft pulley (9), the upper timing covers (11).
- The lower timing cover (10).
Line up one of the three holes "b" on the pulley with the hole on the body of the coolant pump.
Immobilise the coolant pump pulley, using tool [6].
Remove the coolant pump pulley (13).
B1EP1JDD
62
Angl-C6-page022-82-2005 4/02/05 17:19 Page 63
ENGINE
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).
NOTE: Removing the particle filter and catalytic converter flexible pipe assembly facilitates the
removal of the plug from the pegging hole and the positioning of tool [2].
B1DP1MOC
63
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.
B1EP1JGC
64
Angl-C6-page022-82-2005 4/02/05 17:19 Page 65
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: DT17BTED4
Reposition the timimg belt, strip «j» well tensioned, in the following order:
B1EP1JHD NOTE: If necessary, turn the pulleys (23) and (18) slightly anti-clockwise (the offset must not be
more than one tooth).
IMPERATIVE: If the screws (15) and (17) are at the end of slots, restart the operations to refit
the timing belt.
B1EP1JJC
65
Angl-C6-page022-82-2005 4/02/05 17:19 Page 66
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: DT17BTED4
NOTE: If it is not possible to refit the tools [3], slacken the screws (15) and/or (17) of the camshafts
B1EP1JHD and drive the camshafts by means of their central screws (25) and/or (26).
66
Angl-C6-page022-82-2005 4/02/05 17:19 Page 67
ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engine: DT17BTED4
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.
Refit the "Swirl" electrovalve (7) with its support, the header tank (1), the electrical harness.
B1EP1JJC
67
Angl-C6-page022-82-2005 4/02/05 17:19 Page 68
ENGINE
EXHAUST SPECIFICATIONS
Engine: ES9A
1 Upstream oxygen sensor (rear)
2 Downstream oxygen sensor (rear)
4,7 ± 0,5
3 Downstream oxygen (front)
4 Upstream oxygen sensor (front)
5 Precatalyser (rear) 3,5 ± 0,5
6 Precatalyser (front)
7 Resonator
8 Catalytic converter
9 Rear silencer
10 Clips 2,6 ± 0,3
B1JP08AD
68
Angl-C6-page022-82-2005 4/02/05 17:19 Page 69
ENGINE
EXHAUST SPECIFICATIONS
Engine: ES9A
Repair.
- 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).
- Do not deform the front flexible pipe more than 3° angular (X), 0 mm axial, 3 mm shearing (Y)
(front flexible pipe in place).
WARNING: Non-respect of these precautions will shorten the life of the flexible pipe.
It is therefore imperative to disconnect or remove the exhaust line for any operations
necessitating lifting of the engine-gearbox.
B1JP02JC
69
Angl-C6-page022-82-2005 4/02/05 17:19 Page 70
ENGINE
EXHAUST SPECIFICATIONS
Engine: DT17BTED4
B1JP07QD
70
Angl-C6-page022-82-2005 4/02/05 17:19 Page 71
ENGINE
EXHAUST SPECIFICATIONS
Engine: DT17BTED4
Repair.
- 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).
- Do not deform the front flexible pipe more than 3° angular (X), 0 mm axial, 3 mm shearing (Y)
(front flexible pipe in place).
WARNING: Non-respect of these precautions will shorten the life of the flexible pipe.
It is therefore imperative to disconnect or remove the exhaust line for any operations
necessitating lifting of the engine-gearbox.
B1JP02JC
71
Angl-C6-page022-82-2005 4/02/05 17:19 Page 72
ENGINE
TIGHTENING TORQUES - EXHAUST LINE
Engine: DT17BTED4
1 Clip 2,6 ± 0,4
2 Particle filter hangers
3 Intermediate pipe hangers 0,8 ± 0,1
4 Silencer hangers
5 Rear precatalyser screw 2 ± 0,3
6 Front precatalyser screw 2 ± 0,3
B1JP07ZD
72
Angl-C6-page022-82-2005 4/02/05 17:19 Page 73
ENGINE
COOLING SYSTEM SPECIFICATIONS
Engines: ES9A - DTE17BTED4
3.0i 24S 2,7 24V
Engine type XFV UHZ
Capacity 11,3 13,2
Radiator surface 27 dm2
Pressurisation 1,4 bar
Opening of thermostatic regulator 78°C 83°C
Cooling fan 1 x 600 W 2 x 150W
1st speed FRIC function 97°C or aircon in operation
2nd speed 105°C 101°C or 17 bars in the aircon circuit
3rd speed 105° or 30 bars in the aircon circuit
Air con cut-off 115°C or 30 bars in the aircon circuit
Alert 118°C
Post cooling 6 minutes
Marking 11 6
Information Level of coolant Temperature of coolant Temperature, diesel injection, alert, aircon
Sensor Resistance Thermostat Thermostat
Colour of connector Black Blue Grey
Tightening (m.daN) 1,7 ± 0,4
73
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
Angl-C6-page022-82-2005 4/02/05 17:19 Page 75
ENGINE
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
Angl-C6-page022-82-2005 4/02/05 17:19 Page 76
ENGINE
CHECKING THE OIL PRESSURE
Engine ES9A DT17BTED4
Temperature (°C) 80°C
Pressure (bars) 2
Rpm 900
Pressure (bars) 5 1 to 4
Rpm 3000 2500
Pressure (bars)
Rpm
2279-T.Bis X
4103-T X
(-).1503.K X
4202-T X
NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
76
Angl-C6-page022-82-2005 4/02/05 17:19 Page 77
ENGINE
VALVE CLEARANCES
● Inlet Exhaust
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 : 4520-T
[2] Adaptor for filling cylinder : 4222-T
[3] Control rod for filling cylinder : 4370-T
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.
B1GP0BPC
Draining.
Remove the header tank cap with caution (engine cold).
B1BP2BNC
78
Angl-C6-page022-82-2005 4/02/05 17:19 Page 79
ENGINE
DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT
Engine: ES9A
B1GP0BQC
79
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.
Stop the engine and wait for it to cool down.
B1GP08TC
Checks.
B1GP0BQC
80
Angl-C6-page022-82-2005 4/02/05 17:19 Page 81
ENGINE
DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT
Engine: DT17BTED4
Tools.
[1] Filling cylinder : 4520-T
[2] Adaptor for filling cylinder : 4222-T
[3] Control rod for filling cylinder : 4370-T
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.
Open the bleed screw of the engine cooling radiator, located under the radiator on the LH side.
B1GP0CNC
81
Angl-C6-page022-82-2005 4/02/05 17:19 Page 82
ENGINE
DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT
Engine: DT17BTED4
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.
NOTE: Keep the filling cylinder full to the maximum.
Start the engine.
B1GP0CPC
Close each bleed screw as soon as the liquid starts to flow out without air B1GP0CRC
bubbles.
Block the filling cylinder [1], using the control rod [3].
Remove the filling cylinder [1], control rod [3] and adaptor [2] assembly.
Refit the header tank cap.
Stop the engine.
Checks.
Start the engine.
Maintain an engine speed of 1600 rpm, up to the second cooling cycle (starting
and stopping of the cooling fan).
Stop the engine and wait for it to cool down.
Remove the header tank cap.
If necessary, top up the level of the header tank to the maximum mark.
B1GP0CQC Refit the header tank cap.
82
Angl-C6-page83-100-2005 4/02/05 17:22 Page 83
Synopsis.
(1) Fuel consumption information
INJECTION
(2) Ignition injection test warning lamp
(3) Rev counter
(4) Air conditioning ECU
(5) Multifunction screen
(6) Built-in systems interface
(7) Transponder
(8) Automatic gearbox ECU
(9) Fuel pump, filter and pressure regulator (except grande exportation)
(10) Battery
(11) Pressostat
(12) Engine speed sensor
(13) Camshaft position sensor (x2)
(14) Motorised butterfly housing
B1HP1Z9P
83
Angl-C6-page83-100-2005 4/02/05 17:22 Page 84
Synopsis.
(15) Canister purge electrovalve
INJECTION
B1HP1Z9P
84
Angl-C6-page83-100-2005 4/02/05 17:22 Page 85
Synopsis.
(30) Pulse damper
INJECTION
(31) Sparking plugs (x6)
(32) Fuel tank
(33) Canister reservoir
(34) Discharge valve
(35) Exhaust line
Specifications.
B1HP1ZAD
85
Angl-C6-page83-100-2005 4/02/05 17:22 Page 86
86
Angl-C6-page83-100-2005 4/02/05 17:22 Page 87
INJECTION
DVE5 6-way black connector
Motorised butterfly housing 14
BOSCH 0 280 750 041 Fixing, on the inlet manifold
14 43 33 6-way black connector
Accelerator pedal
26 Supply, 5 volts
position sensor
Fixing, on the accelerator
Electrical circuit
ME 7.4.7. 128-way connector
Ignition injection 0 261 B00 736 Sequential injection
29 BOSCH
ECU "Flash" type Eprom (reprogrammable eprom)
Installation, in the electronic ECU compartment
280 911 2-way blue connector
Opening of contact at 20 bars
Power steering pressure For ECU information
sensor 24 BITRON (steering on full lock)
Marking mauve ring seal
Fixing : on the power steering high pressure
pump outlet pipe
87
Angl-C6-page83-100-2005 4/02/05 17:22 Page 88
88
Angl-C6-page83-100-2005 4/02/05 17:22 Page 89
INJECTION
Tightening torque
Sparking plugs 31
Tighten to: 1 ± 0,1 m.daN
NGK PFR6E 10
Angular tightening: 90°
Pencil type ignition 17 SAGEM BAC 1 4-way black connector
coils 2526140 Twin-static type ignition
Exhaust circuit
4-way green connector
Upstream oxygen sensor 21 258 040 232 Front fixing: on the exhaust manifold
Rear fixing: on the pre-catalyser
4-way blue connector
BOSCH
Front fixing: on the pre-catalyser
Downstream oxygen sensor 20 258 006 185 Rear fixing: on the pre-catalyser
Tightening torque
Tighten to: 4,7 ± 0,1 m.daN
89
Angl-C6-page83-100-2005 4/02/05 17:22 Page 90
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.
Do not disconnect a diesel injector when the engine is running.
B1HP23GC
90
Angl-C6-page83-100-2005 4/02/05 17:22 Page 91
INJECTION
Do not separate the diesel injector carrier (2) from the following components:
It is forbidden to clean the carbon deposits from the diesel injector nozzle.
Do not separate the fuel high pressure sensor (j) from the central fuel high pressure injection rail (3).
B1HP23JC
91
Angl-C6-page83-100-2005 4/02/05 17:22 Page 92
- Accident prevention.
- Environmental protection. Preliminary operations.
WARNING: Repairs must be carried out by specialised personnel IMPERATIVE: The technician should wear clean overall.
informed of the safety requirements and of the precautions to be
taken. Before working on the injection system, it may be necessary to
clean the apertures of the following sensitive componen (refer to
Safety requirements. corresponding procedures):
- Fuel filter.
IMPERATIVE: Take into account the very high pressures in the high - Fuel high pressure pump.
pressure fuel circuit (1600 bars), and respect the requirements - Fuel high pressure common injection rail.
below: - Fuel high pressure pipes
- No smoking in proximity to the high pressure circuit when work is being - Diesel injector carriers.
carried out.
- Avoid working close to flame or sparks. IMPERATIVE: After dismantling, immediately block the apertures of
Engine running: sensitive components with plugs, to avoid the entry of impurities.
- Do not work on the high pressure fuel circuit. Work area:
- Always stay clear of the trajectory of any possible jet of fuel, which could - The work area must be clean and free of clutter.
cause serious injuries. - Components being worked on must be protected from dust.
- Do not place your hand close to any leak in the high pressure fuel circuit.
92
Angl-C6-page83-100-2005 4/02/05 17:22 Page 93
INJECTION
[4] Extension : 4251-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).
Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel pump and
the fuel filter green mark on the fuel return pipe.
Connect the tool [3] on tool [1] or on tool [2].
NOTE: To check the pressures while the vehicle is being driven, insert the extension [4] between
B1BP3CRD tool [3] and tools [1] or [2].
93
Angl-C6-page83-100-2005 4/02/05 17:22 Page 94
- 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 Fuel return
Checks
pressure pressure
Between 2 and 3 bar 0.8 ± 0.4 bar Check the condition of the diesel fuel filter
More than 3 bar More than 0.8 bar Check the fuel return circuit (pipe pinched)
Between Check the fuel suppy circuit :
Less than 0.8 bar
0.3 and 0.5 bar Booster pump (low pressure), piping
Impossible to start the engine:
- Fuel supply pressure less than 0.3 bar.
B1BP3CRD
94
Angl-C6-page83-100-2005 4/02/05 17:22 Page 95
Tools.
[1] Pressure gauge for checking the pressure : 7073-T.A
[2] Tool for checking the inlet air pressure/vacuum : (-).0171.G3
INJECTION
[3] LEXIA diagnostic tool : 4171-T
[4] PROXIA diagnostic tool : 4165-T
Checks.
IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection
engines.
Preliminary operations.
WARNING: Prior to any intervention, check the connections of the turbocharger pressure
regulation actuators.
NOTE: If an air flow fault is memorised by the diagnostic tool, refer to the chapter "Air flow from
the turbochargers".
Turbo pressure sensor.
Remove the engine cover.
Disconnect the connector "a".
Remove the turbo pressure sensor (1).
B1BP3CZC
95
Angl-C6-page83-100-2005 4/02/05 17:22 Page 96
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".
INJECTION
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.
Compare the pressure values read on the diagnostic tool and on the pressure gauge [1].
NOTE: If there is a significant difference in pressure, replace the turbo pressure sensor.
Air/air exhanger.
Check the condition of the following components:
- Air inlet pipe.
- Airoutlet pipe.
- Air /air exchanger.
Air flow from the turbochargers.
NOTE: If an air flow fault is memorised by the diagnostic tool, check the air flow from the turbocharger
incriminated.
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.
Compare the air flows (mg/stroke) from the two turbochargers.
B1BP3D0C
96
Angl-C6-page83-100-2005 4/02/05 17:22 Page 97
INJECTION
- Mark the flowmeters "d" and "c".
- Remove both flowmeters.
Refit:
- Flowmeter "d" in place of flowmeter "c".
- Flowmeter "c" in place of flowmeter "d".
- If the difference in air flow has changed turbochargers, replace the flowmeter that is faulty.
- If the difference in air flow is coming from the same turbocharger, check the condition of the air inlet
and outlet pipes of this turbocharger: replace or repair the parts that are faulty.
- If no anomaly is detected on the air inlet and outlet pipes of the turbocharger: replace the turbocharger.
B1HP24TC
97
Angl-C6-page83-100-2005 4/02/05 17:22 Page 98
B1HP26UD
98
Angl-C6-page83-100-2005 4/02/05 17:22 Page 99
INJECTION
IMPERATIVE: Respect the safety and cleanliness specific to high pressure
diesel injection engines.
B1HP26EC
99
Angl-C6-page83-100-2005 4/02/05 17:22 Page 100
SPARKING PLUGS
Electrode Electrode
Vehicles Engine BOSCH NGK Tightening torque (m.daN)
gap gap
Tightening : 1 ± 01
C6 3.0i 24S ES9A FGR8MQPE 1 mm PFR6E10 1 mm
Angular tightening : 90° ± 5°
IGNITION
100
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.
- The speed indicated by a speedometer must never be lower than the actual vehicle speed.
- Between the speed displayed «SD» and the speed travelled «ST», there must always be the following relationship:
Example: For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.
TRANSMISSION
The speed indicated by the speedometer may be influenced by:
GEARBOX
CLUTCH
- The speedometer.
- The tyres fitted to the vehicle.
- The final drive ratio.
- The speedometer drive ratio.
Any of these components can be checked without removing them from the vehicle (see information note N° 78-85 TT of 19 October 1978).
NOTE: Before replacing the speedometer, check the conformity of the following points:
- The tyres fitted to the vehicle.
- The gearbox final drive ratio.
- The speedometer drive ratio.
101
Angl-C6-page101-120-2005 4/02/05 17:25 Page 102
ES9A 20 GH 07 49 X 52
C6 AM6 15 x 53
DT17BTED4 20 GG 07 54 X 47
TRANSMISSION
GEARBOX
CLUTCH
102
Angl-C6-page101-120-2005 4/02/05 17:25 Page 103
If a gearbox malfunction occurs, there are two possible configurations Oil level.
depending on the seriousness of the fault:
- Gearbox in back-up mode with a replacement programme of (the fault Preliminary conditions:
values are taken in substitution).
- Gearbox in back-up mode with an emergency programme (3rd hydraulic). - Vehicle horizontal, parking brake off.
WARNING: In the emergency programme, an impact is felt when - Check that the gearbox is not in back-up mode (using a diagnostic tool).
changing P/R or N/R. - The oil temperature should be 60°C (+8, -2) (using a diagnostic tool).
- Press on the brake pedal, change through all the gears.
Reception of the customer. - Place the gear lever in position P.
Discuss with the customer, to find out all the malfunction symptoms.
With the engine running at idle, without power consumers (aircon,
TRANSMISSION
Oil quality. heating, etc.):
GEARBOX
CLUTCH
If the gearbox has suffered a serious fault resulting in a malfunction or - Remove the oil level plug.
the destruction of a clutch, the oil will overheat and become The oil should flow out, then drip-drip.
contaminated with impurities: the oil is said to be «burnt». Refit the oil level plug (the oil level is correct).
This is characterised by a black colour and the presence of an The oil does not flow out through the oil level plug (see operation: drain
unpleasant smell. fill - bleed the gearbox).
103
Angl-C6-page101-120-2005 4/02/05 17:25 Page 104
Never drive with the ignition switched off. It is imperative that the converter retaining peg should be in place
GEARBOX
104
Angl-C6-page101-120-2005 4/02/05 17:25 Page 105
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)
B2CP3YRC
"e" Date of manufacture
TRANSMISSION
"f" Homologation code (PSA)
GEARBOX
CLUTCH
"g" ECU no. (PSA)
"h" Bar code (PSA)
"j" Gearbox no. (PSA)
"k" Bar code (AISIN)
"l" Serial no.
Specifications
Weight : 93 kg (approx.).
Torque capacity : 33 m.daN.
B2CP3YSC
105
Angl-C6-page101-120-2005 4/02/05 17:25 Page 106
B2CP42XD
106
Angl-C6-page101-120-2005 4/02/05 17:25 Page 107
TRANSMISSION
GEARBOX
CLUTCH
B2CP42ZD
107
Angl-C6-page101-120-2005 4/02/05 17:25 Page 108
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.
In position "M", the selection is enabled by an electronic sensor located close to the gear
selector:
- The variation of flux necessary to affect the sensor cells is obtained by a magnet on the lever
opposite the cells, provoking the changes of status.
- The information on this is transmitted to the gearbox ECU.
B2CP430D
108
Angl-C6-page101-120-2005 4/02/05 17:25 Page 109
NOTE: The vehicle is equipped with «shift lock». It is necessary to switch on the ignition and
press the brake pedal to release the selection lever from position "P".
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.
- Snow programme: The snow programme facilitates moving off and traction on ground that
TRANSMISSION
has limited adhesion.
GEARBOX
CLUTCH
To revert to the normal programme, you have to press a second time on the sport or snow
switch.
B2CP430D
109
Angl-C6-page101-120-2005 4/02/05 17:25 Page 110
Gearbox end.
Automatic adjustment:
GEARBOX
CLUTCH
B2CP431C
110
Angl-C6-page101-120-2005 4/02/05 17:25 Page 111
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».
Unlocking the «SHIFT LOCK» (with an operating fault).
C5FP0RBC
Should it be impossible to unlock the «shift lock» with the «Normal operation» method.
TRANSMISSION
The fault may originate from one of the following components:
GEARBOX
- «Shift lock».
CLUTCH
- Gear lever position switch.
- Automatic gearbox ECU.
- Electrical harness.
- Battery voltage.
Operations to be performed.
Unclip the cover (1).
Unlock the «shift lock» by pressing at "a" with the aid of a screwdriver (screwdriver with a minimum length of
150 mm).
Move the gear selection lever out of position "P".
C5FP0RCD
111
Angl-C6-page101-120-2005 4/02/05 17:25 Page 112
NOTE: For all these operations, follow the procedure in the diagnostic tool.
112
Angl-C6-page101-120-2005 4/02/05 17:25 Page 113
TRANSMISSION
NOTE: If downloading the automatic gearbox ECU, there is no specific operation, follow the procedure in the diagnostic tool.
GEARBOX
CLUTCH
IMPERATIVE: For a certain time, having carried out an ECU initialisation procedure, one may obtain gear changing quality that is more
or less good (adaptation of the ECU parameters to the gearbox). To improve the quality, it is necessary to perform a road test with
frequent changing through the gears (auto-adaptive laws).
113
Angl-C6-page101-120-2005 4/02/05 17:25 Page 114
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.
B1BP317C
Remove:
TRANSMISSION
Filling.
Fit the drain plug (1) (with a new seal).
Tighten the plug (1) to : 5 ± 1 mdaN.
Remove:
- The air filter housing.
- The oil filler plug (3).
Use tool [1].
B2CP3WZC
114
Angl-C6-page101-120-2005 4/02/05 17:25 Page 115
TRANSMISSION
Checking the oil level.
GEARBOX
CLUTCH
Prior conditions:
- Vehicle in a horizontal position.
- Check that the gearbox is not in back-up mode.
Remove the filler plug (3).
Add 0.5 litre of extra oil into the gearbox.
Press the brake, change through all the gears.
Gear lever in position "P".
Engine running, at idle:
- Oil temperature 60°C (+ 8 ; - 2) (parameter measures with a diagnostic tool).
- Remove the level plug (2).
B2CP3WZC
115
Angl-C6-page101-120-2005 4/02/05 17:25 Page 116
"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".
TRANSMISSION
A level of oil that is too high can have the following consequences: Abnormal overheating of the oil, leaks of oil
causing a level which is too low resulting in destruction of the gearbox.
B2CP3WZC
116
Angl-C6-page101-120-2005 4/02/05 17:25 Page 117
Tools.
[1] Flexible pipe and pressure gauge : 4601- TF1 Toolkit 4601-T
[2] Flexible union : (-).0336.X Toolkit 8010-T
B2CP45FC
TRANSMISSION
Preliminary operations.
GEARBOX
CLUTCH
Remove the air filter housing.
B2CP45GC
117
Angl-C6-page101-120-2005 4/02/05 17:25 Page 118
WARNING: Clean the flexible pipe of the tool [1] each time before use; the different
automatic gearbox oils cannot be intermixed.
WARNING: Wait for the gearbox oil to reach a temperature between 58°C and 68°C.
TRANSMISSION
NOTE: Check the temperature of the oil using the diagnostic tool in parameter measures.
B1BP3END
118
Angl-C6-page101-120-2005 4/02/05 17:25 Page 119
TRANSMISSION
GEARBOX
Diagnosis:
CLUTCH
- If the maximum engine speed obtained is lower than the value indicated, the torque
converter is the cause.
- If the maximum engine speed obtained is higher than the value indicated, the automatic
gearbox is the cause (slipping).
Additional operations.
Remove tools [1] and [2].
Refit the screw (2), with a new seal.
Reposition the pipe (1).
Refit the air filter housing.
B1BP3END
119
Angl-C6-page101-120-2005 4/02/05 17:25 Page 120
TRANSMISSION
Tightening torques (m.daN) Gearbox oil seal mandrels
Driveshaft Driveshaft
Vehicle Gearbox Engines Right Left Tool kit
bearing nut
(-).0336.U (-).0336.V
C6 AM6 ES9A - DT17BTED4 2 ± 0,2 34,5 ± 2 8010-T
(-).0336.W (1)
TRANSMISSION
GEARBOX
ES9Al Steel
CITROËN 9±1
DT17BTED4 Alloy
120
Angl-C6-page121-169-2005 4/02/05 17:31 Page 121
SUSPENSION
STEERING
AXLES
WHEEL AND TYRES
3.0i 24S 2,7 24V
Engine plate XFV UHZ
Tyre/circumference S 225/55 R17 97W/2,071 m 245/45 R18 100W/2,065m 245/45 R18 100W/2,065m
Type Michelin PRIMACY
T
Wheel
A 7 J17-CH5-32 8 J18-CH5-33 8 J18-CH5-33
Name of rim SATURNE SAN MARIN 2 SAN MARIN 2
Normal operating pressure:
front/rear 2,4/2,4 2,4/2,4 2,4/2,4
Pressure for maximum load :
front/rear 2,6/2,6 2,4/2,4 2,6/2,6
Pressure: loaded, high speed:
front/rear 2,4/2,4 2,4/2,4 2,6/2,6
Tyre S 225/55 R17 97W
Spare wheel T 7 J17-5-32
Normal operating pressure 2,6 2,4 2,6
Pressure for maximum load 2,6 2,4 2,6
Pressure: loaded, high speed
S = Standard fitting. T = Steel wheel. A = Alloy wheel.
NOTE: The label indicating the recommended tyre pressures is affixed to the front LH door pillar.
121
Angl-C6-page121-169-2005 4/02/05 17:31 Page 122
SUSPENSION
STEERING
NOTE: The label indicating the recommended tyre pressures is affixed to the front
LH door pillar.
B2GP01FD
122
Angl-C6-page121-169-2005 4/02/05 17:31 Page 123
SUSPENSION
STEERING
AXLES
WHEEL AND TYRES
Identification of the wheel bolts
NOTE: If mixed fixing bolts are fitted on steel wheels, the shoulders of the bolts
remain free.
9 ± 1 m.daN
B2GP00JD
123
Angl-C6-page121-169-2005 4/02/05 17:31 Page 124
SUSPENSION
STEERING
WARNING: Each time a tyre is replaced, it is necessary to replace the valve (4).
B2GP01ND
124
Angl-C6-page121-169-2005 4/02/05 17:31 Page 125
SUSPENSION
STEERING
AXLES
CHECKING AND ADJUSTING VEHICLE HEIGHT
Reference heights: REFERENCE = Ignition switched on
Tools.
[1] Gauge for measuring radius of wheels (5 bolts) : 9801-T
[2] Gauge for height under bodyshell : 2305-T
[3] LEXIA station : 4171-T
[4] PROXIA station : 4165-T
Preliminary operations.
125
Angl-C6-page121-169-2005 4/02/05 17:31 Page 126
SUSPENSION
STEERING
Place the tool [1] on the wheel Measure, using tool [2].
fixing bolts.
Measure the wheel radiuses The front LH height H1M: Measure between the ground and zone A under the front subframe.
using tool [2]. The front RH height H2M: Measure between the ground and zone B under the front subframe.
126
Angl-C6-page121-169-2005 4/02/05 17:31 Page 127
SUSPENSION
STEERING
AXLES
CHECKING AND ADJUSTING VEHICLE HEIGHT
Reference heights: REFERENCE = Ignition switched on
Measuring the rear wheel radiuses Measuring the rear heights
Place the tool [1] on the wheel Measure, using tool [2].
fixing bolts.
Measure the wheel radiuses The rear LH height H3M: Measure between the ground and zone C under the rear axle crossmember.
using tool [2]. The rear RH height H4M: Measure between the ground and zone D under the rear axle crossmember.
127
Angl-C6-page121-169-2005 4/02/05 17:31 Page 128
SUSPENSION
STEERING
128
Angl-C6-page121-169-2005 4/02/05 17:31 Page 129
SUSPENSION
STEERING
AXLES
VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES
IMPERATIVE: Respect the safety and cleanliness requirements. Conditions for checking and adjusting.
Check the tyre pressures.
Tools. Place the vehicle on a 4 column lift.
[1] Gauge for measuring radius of wheels (5 bolts) : 9801-T Check and adjust if necessary the vehicle heights (see corresponding
[2] Gauge for height under bodyshell : 2305-T operation).
Steering rack locked at its zero point (see corresponding operation).
WARNING: «Check and adjust the axle geometries at reference Switch off the ignition before removing the tools from the wheels.
height». Lower the vehicle.
Start the engine.
Put the vehicle in the high position.
Put the vehicle in the normal height position (driving height).
Stop the engine.
Switch on the ignition.
Check and adjust the front and rear axle geometries at reference
height.
WARNING: Do not switch off the ignition during checking and
adusting of the front and rear axle geometries.
SUSPENSION
STEERING
B3BP1BND
130
Angl-C6-page121-169-2005 4/02/05 17:31 Page 131
SUSPENSION
STEERING
AXLES
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.
«Tyres: 225/55 R17»
Front axle Rear axle
Pivot Push
Vehicle Tracking Castor Camber Angle Tracking Camber Angle
Adjustable Non adjustable Adjustable Non adjustable
mm -1±1 4,32 ± 1
C6 5° 30' ± 30' - 0°24' ± 30 8° 40' ± 30' - 1° 27' ± 30' 0° ± 12'
0° - 0°09' ± 0°09' 0° 34' ± 0°09'
«Tyres: 245/45 R18»
Front axle Rear axle
Pivot Push
Vehicle Tracking Castor Camber Angle Tracking Camber Angle
Adjustable Non adjustable Adjustable Non adjustable
mm - 1,1 ± 1 4,58 ± 1
C6 5° 30' ± 30' - 0°24' ± 30 8° 40' ± 30' - 1° 27' ± 30' 0° ± 12'
0° - 0°09' ± 0°09' 0° 34' ± 0°09'
131
Angl-C6-page121-169-2005 4/02/05 17:31 Page 132
SUSPENSION
STEERING
B3CP0ARD B3CP0ATD
Front LH: K1 = 175 ± 6 mm Front RH: K2 = 175 ± 6 mm Rear LH: K3 = 131 ± 6 mm Rear RH: K4 = 131 ± 6 mm
132
Angl-C6-page121-169-2005 4/02/05 17:31 Page 133
SUSPENSION
STEERING
AXLES
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.
«Tyres: 225/55 R17»
Front axle Rear axle
Pivot Pivot
Vehicle Tracking Castor Camber Angle Tracking Camber Angle
Adjustable Non adjustable Adjustable Non adjustable
mm - 2,32 ± 1 5,13 ± 1
C6 5° 30' ± 30' - 0°30' ± 30 8° 21' ± 30' - 1° 54' ± 30' 0° ± 12'
0° - 0°18' ± 0°09' 0° 41' ± 0°09'
«Tyres: 245/45 R18»
Front axle Rear axle
Pivot Pivot
Vehicle Tracking Castor Camber Angle Tracking Camber Angle
Adjustable Non adjustable Adjustable Non adjustable
mm - 2,46 ± 1 5,43 ± 1
C6 0° - 0°18' ± 0°09' 5° 30' ± 30' - 0°30' ± 30 8° 21' ± 30' 0° 41' ± 0°09' - 1° 54' ± 30' 0° ± 12'
133
Angl-C6-page121-169-2005 4/02/05 17:31 Page 134
SUSPENSION
STEERING
B3CP09LD
134
Angl-C6-page121-169-2005 4/02/05 17:31 Page 135
SUSPENSION
STEERING
AXLES
FRONT AXLE
Front pivot.
Front pivot fixed on the pivot support by means of an upper balljoint and a lower balljoint.
- Diameter 83 mm.
- Bearing with double row of balls, with an integral magnetic wheel (48 pairs of poles).
Suspension leg:
Anti-roll bar
Engines Diameter (mm) Colour ref.
ES9A 23,5 mm Yellow
DT17BTED4 24 mm Pink
NOTE: The geometry specifications are given with the values for checking and adjusting the
axle geometries.
B3CP09CC
135
Angl-C6-page121-169-2005 4/02/05 17:31 Page 136
SUSPENSION
STEERING
B3CP09EC
136
Angl-C6-page121-169-2005 4/02/05 17:31 Page 137
SUSPENSION
STEERING
AXLES
FRONT AXLE: TIGHTENING TORQUES
Engines: ES9A - DT17BTED4
Suspension leg
10 Pivot lower balljoint on Pivot support 6,5 ± 0,9
11 Pivot lower balljoint on Pivot support 17 ± 1,7
12 Steering rack balljoint on Front pivot 3,5 ± 0,3
B3CP09FC
137
Angl-C6-page121-169-2005 4/02/05 17:31 Page 138
SUSPENSION
STEERING
B3CP09HD
138
Angl-C6-page121-169-2005 4/02/05 17:31 Page 139
SUSPENSION
STEERING
AXLES
FRONT AXLE: TIGHTENING TORQUES
Engines: ES9A - DT17BTED4
Front subframe
25 Suspension lower arm support on Front subframe 6,5 ± 0,9
26 Suspension lower arm on Front subframe 12,3 ± 1,2
B3CP09TC
139
Angl-C6-page121-169-2005 4/02/05 17:31 Page 140
SUSPENSION
STEERING
Stub axle:
- Diameter 32 mm.
- The stub axle, joined onto the rear pivot, is not separable.
140
Angl-C6-page121-169-2005 4/02/05 17:31 Page 141
SUSPENSION
STEERING
AXLES
REAR AXLE
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.
B3BP1AED
141
Angl-C6-page121-169-2005 4/02/05 17:31 Page 142
SUSPENSION
STEERING
B3DP0BVD
142
Angl-C6-page121-169-2005 4/02/05 17:31 Page 143
SUSPENSION
STEERING
AXLES
REAR AXLE: TIGHTENING TORQUES
Engines: ES9A - DT17BTED4
11 Suspension upper arm on Rear pivot
12 Suspension upper arm on Rear axle crossmember 7 ± 0,7
13 Rear suspension cylinder on Rear axle crossmember
14 Rear anti-roll bar rod on Rear pivot
4 ± 0,6
15 Rear anti-roll bar rod on Rear anti-roll bar
16 Rear anti-roll bar bearing half support 1,8 ± 0,4
17 Rear hub-bearing nut 25 ± 2
B3DP0BWD
B3DP0BXD
143
Angl-C6-page121-169-2005 4/02/05 17:31 Page 144
SUSPENSION
STEERING
B3CP09AD
144
Angl-C6-page121-169-2005 4/02/05 17:31 Page 145
SUSPENSION
STEERING
AXLES
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.
B3DP0BSD
Capacity of the hydraulic circuit : 6.3 litres.
LDS fluid reservoir NOTE: LDS: Liquide Direction Suspension (steering/suspension fluid).
«a» LDS fluid reservoir filler (cap)
«b» Suction (BHI) (power steering pump)
«c» Return (stiffness regulators)
«d» Return (power steering pump)
«e» Return (filter)
«f» Suction (filter)
The level of the LDS fluid must be checked with the vehicle in the low position (refer to the
procedure «Depressurisation: suspension circuit»).
B4BP01SD
145
Angl-C6-page121-169-2005 4/02/05 17:31 Page 146
SUSPENSION
STEERING
B3BP1A1C
146
Angl-C6-page121-169-2005 4/02/05 17:31 Page 147
SUSPENSION
STEERING
AXLES
ACTIVE SUSPENSION WITH VARIABLE DAMPING
Wheel travel sensor
The wheel travel sensor defines the angular position of the suspension lower arm.
Suspension pressure sensor IMPERATIVE: Before operating on a wheel travel sensor, uncouple its rod so as not to
go past the maximum angular travel (see corresponding operation).
The suspension pressure sensors (7) informs the suspension ECU (CSS) of the pressure in
the hydraulic high pressure pipes of the front suspension.
The sensor (13) informs the suspension ECU (CSS) of the pressure in the hydraulic high
pressure pipes of the rear suspension.
B3BP19YC
147
Angl-C6-page121-169-2005 4/02/05 17:31 Page 148
SUSPENSION
STEERING
Anti-roll bars:
B3BP1A0D
148
Angl-C6-page121-169-2005 4/02/05 17:31 Page 149
SUSPENSION
STEERING
AXLES
ACTIVE SUSPENSION WITH VARIABLE DAMPING
One-touch control for body height
C5FP0R8C
149
Angl-C6-page121-169-2005 4/02/05 17:31 Page 150
SUSPENSION
STEERING
B3CP09EC
150
Angl-C6-page121-169-2005 4/02/05 17:31 Page 151
SUSPENSION
STEERING
AXLES
SUSPENSION: TIGHTENING TORQUES
10 Front pivot lower balljoint on Pivot support 6,5 ± 0,9
11 Front pivot lower balljoint on Pivot support 17 ± 1,7
12 Steering rack balljoint on Front pivot 3,5 ± 0,3
13 Rear fixing of suspension lower arm on Front subframe 11 ± 1,1
14 Rear fixing of suspension lower arm on Front subframe 6,5 ± 0,6
15 Fixing of front anti-roll bar bearing on Front subframe 4,5 ± 0,4
B3CP09FC
B3CP09WD
151
Angl-C6-page121-169-2005 4/02/05 17:31 Page 152
SUSPENSION
STEERING
B3CP09XD
152
Angl-C6-page121-169-2005 4/02/05 17:31 Page 153
SUSPENSION
STEERING
AXLES
SUSPENSION: TIGHTENING TORQUES
Rear suspension
18 Tracking adjustment rod on Rear pivot
19 Lower fixing of rear suspension cylinder on Rear pivot
7 ± 0,7
20 Suspension longitudinal arm on Rear pivot
21 Suspension lower arm on Rear pivot
22 Rear anti-roll bar bearing on Body 7,5 ± 0,7
23 Suspension lower arm on Rear axle crossmember
7 ± 0,7
24 Tracking adjustment rod on Rear axle crossmember
25 Screw for locking of tracking adjustment rod 1 ± 0,2
B3DP0CPD Suspension longitudinal arm on Body
26 Pre-tightening 3,3 ± 0,3
Angular tightening 150° ± 5°
27 Suspension upper arm on Rear pivot
28 Suspension upper arm on Rear axle crossmember 7 ± 0,7
29 Upper fixing of rear suspension cylinder on Rear axle crossmember
B3DP0CQD
153
Angl-C6-page121-169-2005 4/02/05 17:31 Page 154
SUSPENSION
STEERING
B3DP0CRD
154
Angl-C6-page121-169-2005 4/02/05 17:31 Page 155
SUSPENSION
STEERING
AXLES
DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT
Tools.
[1] Pliers for clic clips : 4121-T
[2] LEXIA diagnostic tool : 4171-T
[3] PROXIA diagnostic tool : 4165-T
Draining.
155
Angl-C6-page121-169-2005 4/02/05 17:31 Page 156
SUSPENSION
STEERING
Filling.
Refit:
Fill the LDS fluid reservoir up to the maximum level for the LDS fluid "a".
B3FP7HFD
156
Angl-C6-page121-169-2005 4/02/05 17:31 Page 157
SUSPENSION
STEERING
AXLES
DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT
Bleeding.
B3FP7HGD
157
Angl-C6-page121-169-2005 4/02/05 17:31 Page 158
SUSPENSION
STEERING
NOTE: Checking the LDS fluid level is done with the vehicle in the forced low position
(hydraulic suspension circuit depressurised).
IMPERATIVE: A container of LDS that has been opened must be sealed and kept in a
clean place. A container of LDS has to be used up within two weeks of opening, after
which any unused LDS fluid must be disposed of.
B3FP7HGD
158
Angl-C6-page121-169-2005 4/02/05 17:31 Page 159
SUSPENSION
STEERING
AXLES
POWER STEERING SPECIFICATIONS
Top of column
C5FP0U2D (5) Fixing of steering wheel on the shaft of the steering column
Steering column
(6) Steering column support
B3EP17SD
159
Angl-C6-page121-169-2005 4/02/05 17:31 Page 160
SUSPENSION
STEERING
The hydraulic supply and return pipes are fixed on the steering assistance valve by means of
a flange.
IMPERATIVE: The toothed washers «b» must be placed between the steering mechanism
and the front subframe.
Engines ES9A/DT17BTED4.
B3EP17TD
160
Angl-C6-page121-169-2005 4/02/05 17:31 Page 161
SUSPENSION
STEERING
AXLES
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
B3EP17UD
161
Angl-C6-page121-169-2005 4/02/05 17:31 Page 162
SUSPENSION
STEERING
Additional operation.
Refit:
- The protection gaiter.
- The clip (2).
- The clip (1) (new).
B3EP13VD
162
Angl-C6-page121-169-2005 4/02/05 17:31 Page 163
SUSPENSION
STEERING
AXLES
POWER STEERING: TIGHTENING TORQUES
Steering column Engines: ES9A - DT17BTED4
1 Steering wheel bolt 3,3 ± 0,5
2 Upper nuts 2 ± 0,3
3 Lower nuts 2 ± 0,3
4 Fixing of steering cardan on valve stem 2 ± 0,3
5 Union of hydraulic pipe on ram 1,4 ± 0,35
6 Fixing of supply pipes bracket on distributor valve 0,8 ± 0,1
7 Fixing of distributor valve on steering mechanism 2 ± 0,2
8 Steering ball-joint nut 3,5 ± 1
B3EP17GD 9 Locking nut for adjustment of steering track rods 5,3 ± 0,8
10 Fixing of steering rack ball-joint 9,0 ± 0,9
Steering mechanism with integral ram
11 Steering mechanism stud 0,9 ± 0,2
12 Steering mechanism nut 14 ± 1,4
B3EP17HD
163
Angl-C6-page121-169-2005 4/02/05 17:31 Page 164
SUSPENSION
STEERING
B3EP17JC
B3EP17KC
164
Angl-C6-page121-169-2005 4/02/05 17:31 Page 165
SUSPENSION
STEERING
AXLES
CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE)
Tools.
[1] Pipe spanner : FACOM 18.17
[2] Set of 2 hose clamps : 4153-T
[3] Pressure checking assembly :
[3a] Pressure gauge : (-).0710.AZ
[3b] Checking tube: Pressure gauge to tap : (-).0710.B1
[3c] Checking tube: High pressure pipe to tap : (-).0710.B2
[3d] Checking tube: High pressure pump to tap : (-).0710.B3
[3e] 3-way tap : (-).0710.C
[4] Union : (-).0710.E1Z
[5] Union : (-).0710.E2Z
[6] Plug for checking sealing of the steering valve : (-).0410.N
E5AP2PND
Precautions to be taken.
Work with care to avoid entry of polluting particles.
NOTE: Correct operation of the system requires the LDS fluid and the hydraulic components
to be perfectly clean.
Check:
- The level of the LDS fluid (see procedure: drain-fill-bleed the suspension circuit).
- The condition of the piping and unions.
Using the tools.
Prepare the checking assembly [3], [4] and [5].
Remove the bracket (1).
Clamp the pipe at "a", using tool [2].
B1BP3GPD
Uncouple and move aside the piping (2), using tool [1].
165
Angl-C6-page121-169-2005 4/02/05 17:31 Page 166
SUSPENSION
STEERING
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].
B1BP3GRD
166
Angl-C6-page121-169-2005 4/02/05 17:31 Page 167
SUSPENSION
STEERING
AXLES
CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE)
Remove:
- The screw (4).
- The bracket (7).
Uncouple the two supply pipes (5) from the distributor valve, and move them aside.
B1JP08WD Fit on the distributor valve the tool [6], tighten the screw to: 0,8 ± 0,1 m.daN.
Couple two pipes at the outlets of the pipes (5).
Move the steering slowly from lock to lock, to drain the ram.
Collect the LDS fluid in a tray.
Refit the exhaust line (3).
Open the tap [3e].
Start the engine.
Hold the engine speed between 1200 and 1500 rpm.
Hold the steering at full lock to the right, then at full lock to the left.
The pressure should adjust to : 115 ± 5 bars.
B3EP185D
167
Angl-C6-page121-169-2005 4/02/05 17:31 Page 168
SUSPENSION
STEERING
Remove:
- The exhaust line (3).
- The tool [6].
Couple the two supply pipes (5) on the distributor valve.
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].
B1JP08WD Remove:
- The assembly [3].
- The union [5] on the pipe (2).
- The union [4] on the steering assistance pump.
Couple the pipe (2), using tool [1].
Tighten the pipe (2) to 2 ± 0,2 m.daN.
Refit the bracket (1).
Bleed the hydraulic steering assistance circuit (see corresponding operation).
Top up the level of the LDS fluid (see procedure: drain-fill-bleed the suspension circuit).
B3EP185D
168
Angl-C6-page121-169-2005 4/02/05 17:31 Page 169
SUSPENSION
STEERING
AXLES
BLEEDING THE HYDRAULIC STEERING ASSISTANCE CIRCUIT
Precautions to be taken.
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).
Check the level and top up the LDS fluid (see procedure: drain-fill-bleed the suspension circuit).
169
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 170
BRAKES
BRAKE SPECIFICATIONS
3.0i 24S 2,7 24S
170
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 171
BRAKES
BRAKING SYSTEM: GENERAL SPECIFICATIONS
Braking circuit Braking system
B3FP7GED
171
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 Observations
Located on the front LH chassis member:
Hydraulic valve block ESP 4 regulation channels
TRW VSC 440 25-way connector
ECU
Integral to the hydraulic valve block
2-way black connector
Front wheel sensor The sensors, of inductive type, are fitted on the pivot
SIEMENS Air gap non-adjustable: 0.25 to 1.65 mm
VDO 2-way black connector
Rear wheel sensor The sensors, of inductive type, are fitted on the pivot
Air gap non-adjustable: 0.23 to 1.35 mm
The hub has a bearing with integral magnetic wheel
Front pivot bearing (48 pairs of poles)
NSK
The rear hub-bearing has a radial ABS target
Rear hub bearing (48 pairs of poles)
B3FP7GFC
172
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 173
BRAKES
BRAKING SYSTEM: GENERAL SPECIFICATIONS
Parking brake
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.
Changing of the parking brake cables does not necessitate opening of the electric parking
brake system (see corresponding operation).
B3FP7GDD
(4) Handle for manual unlocking of the electric parking brake (FSE)
If it is impossible to release the electric parking brake, a handle (4) located in the front central
armrest will mechanically unlock the electric parking brake.
C5FP0T8C
173
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 174
BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
Front brakes
1 Front brake disc 1 ± 0,1
2 Yoke on brake caliper 3 ± 0,2
3 Unions on brake piping 4 ± 0,5
4 Front brake caliper 11,5 ± 1
5 Hydraulic valve block on intermediate support
0,8 ± 0,2
6 Intermediate support on support
7 Front wheel sensor 0,8 ± 0,1
B3FP7HMD
B3FP7HND B3FP7HPD
174
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 175
BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
Braking amplifier
8 Braking amplifier on support
9 Support on bulkhead 2,1 ± 0,3
10 Master-cylinder
B3FP7HQD
B3FP7HRD
175
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 176
BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
Rear brakes
11 Rear brake caliper 3,5 ± 0,3
12 Unions on brake piping 1,5 ± 0,1
13 Rear brake caliper support 10,8 ± 1
14 Rear wheel sensor 0,8 ± 0,1
B3FP7HSD
B3FP7HTD
176
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 177
BRAKES
TIGHTENING TORQUES: BRAKING SYSTEM
Parking brake
15 Electric parking brake system (FSE) 0,4 ± 0,06
16 Nut for parking brake cables 6 ± 0,6
17 Gyrometer/accelerometer sensor on support 0,9 ± 0,1
18 Sensor support on body 0,4 ± 0,06
B3FP7HUD
Gyrometer/accelerometer sensor
B3FP7HVD
177
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 178
BRAKES
VALUES FOR CHECKING AND ADJUSTING THE BRAKING SYSTEM
Front brake pads (engines all types) Rear brake pads (engines all types)
Nominal thickness (mm) 13 Nominal thickness (mm) 11,15
Minimum thickness (mm) 3 Minimum thickness (mm) 2
178
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 179
BRAKES
GENERAL FEATURES OF ELECTRIC PARKING BRAKE
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).
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)
B3FP7HWD 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.
To release the parking brake:
Prior conditions:
- Vehicle stationary.
- Gear lever in position P.
- Ignition switched on.
- Engine running.
Press on the brake pedal.
Pull and release the control (6).
Parking brake warning lamp:
Condition for the warning lamp "a" coming on:
- Electric parking brake activated or incorrectly deactivated.
C5FP0W3D - Malfunctioning of the electric parking brake.
179
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 180
BRAKES
GENERAL FEATURES OF ELECTRIC PARKING BRAKE
Presentation.
(1) Handle for manual unlocking of the electric parking brake (FSE)
(2) Cable for manual unlocking of the electric parking brake
(3) Rear RH cable of the electric parking brake
(4) Electric parking brake system (FSE)
(5) Rear LH cable of the electric parking brake
(6) Electric parking brake control
Prior conditions:
- Vehicle stationary or not.
- Ignition switched on.
- Engine running or not.
Pull and release the control (6).
C5FP0W3D
180
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 181
BRAKES
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.
Prior conditions:
- Vehicle stationary.
- Gear lever in position P.
- Ignition switched on.
B3FP7HWD
- Engine running.
Press on the brake pedal.
Pull and release the control (6).
C5FP0W3D
181
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 182
BRAKES
GENERAL FEATURES OF ELECTRIC PARKING BRAKE
NOTE: Impossible to release the parking brake with the method "Normal functioning".
Pull on the handle (7) located on the plastic part of the central armrest in order to release the parking
brake mechanically.
WARNING: This control does not permit application of the parking brake.
C5FP0W4D
182
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 183
BRAKES
ELECTRIC PARKING BRAKE SYSTEM
Removing-refitting the electric parking brake system.
WARNING: Before disconnecting the battery, partially open the door windows.
Removing.
IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables.
IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in
C5FP0VVD the central armrest, before operating on the parking brake cables.
B1JP08XD
183
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).
Extract the manual unlocking cable of the electric parking brake from its location at "b".
B3FP7HJD
184
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 185
BRAKES
ELECTRIC PARKING BRAKE SYSTEM
Slacken the nuts (7).
Remove the electric parking brake system assembly.
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).
Engage the manual unlocking cable of the electric parking brake in its location at "b".
B3FP7HKD Couple the handle (2) to the parking brake cable.
Refit the central console (1) (see corresponding operation).
Refit:
- The protections (5) and (3).
- The exhaust line (4) (ES9A engine).
Reconnect the battery.
Apply and release the electric parking brake.
Check the functioning of the electric parking brake.
NOTE: Remove the shim (8) from the brake calipers.
IMPERATIVE: Perform the operations that are necessary following a reconnection of the battery
(see corresponding operation).
B3FP7HLD
185
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 186
BRAKES
ELECTRIC PARKING BRAKE CABLES
WARNING: Before disconnecting the battery, partially open the door windows.
Removing.
IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables.
IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in
the central armrest, before operating on the parking brake cables.
IMPERATIVE: Do not introduce any foreign body into the electric parking brake system.
186
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 187
BRAKES
ELECTRIC PARKING BRAKE CABLES
Connector end.
Do up at «b».
B3FP7HZD
187
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 188
BRAKES
ELECTRIC PARKING BRAKE CABLES
Refitting.
Connector end.
B3FP7J2D
188
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 189
BRAKES
ELECTRIC PARKING BRAKE CABLES
Engage the parking brake cable (6) into the electric parking brake system.
IMPERATIVE: Perform the operations that are necessary following a reconnection of the
battery (see corresponding operation).
B3FP7J3D
189
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 immedia-
tely 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.
Tools: Brake fluid tester (*):
Supplier Reference Type
SURETEST TLF
DOW AUTOMOTIVE BETATEST Measures the boiling point of brake fluid
FACOM OUTILLAGE DF.16
EBT 06.1 Measures the rate of hydrometry of brake fluid
(*) The list not exhaustive, refer to the catalogue "Tools and Equipment".
Checks.
Remove the filter of the brake fluid reservoir.
IMPERATIVE: Any pollution of the brake fluid is forbidden. The brake fluid should be limpid and free of suspended matter or sediments.
Check the brake fluid, following the method recommended by the supplier of the testing equipment.
Test values:
Brake fluid Minimum boiling point «Humid»
DOT 3 140°C
DOT 4 155°C
SUPER DOT 4
180°C
DOT 5
NOTE: If the tested value is lower than the minimum "humid" boiling point or within a tolerance of +10 % of this value, replace the brake fluid
(see corresponding operation).
IMPERATIVE: Use exclusively the hydraulic fluids that are approved and recommended.
190
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 191
BRAKES
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
Tools.
[1] Generic bleeding apparatus : «LURO» or similar
[2] LEXIA station : 4171-T
[3] PROXIA station : 4165-T
NOTE: Bleeding of the secondary braking circuit is done with the help of diagnostic tools [2] or [3].
IMPERATIVE: Perform the operations that are necessary following a reconnection of the
battery (see corresponding operation).
B3FP7H3D
191
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.
WARNING: During the bleed operations: take care to maintain the level of the brake fluid in
B3FP7H4D
the reservoir, keep it topped up.
WARNING: The ABS system must not be in action during the bleed operation.
WARNING: Respect the sequence for the opening of the bleed screws.
192
Angl-C6-PAGE170-194-2005 4/02/05 17:35 Page 193
BRAKES
DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM
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.
B3FP7H4D - Check the brake fluid level (should be between «DANGER» level and «MAXI» level).
- Fill if necessary with the approved and recommended synthetic brake fluid.
Without bleeding apparatus.
NOTE: Two operators are necessary.
For each brake circuit:
- Apply the brake pedal to place the circuit under pressure.
- 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.
NOTE: Recommence the process a second time if that is necessary.
- Check the brake fluid level (should be between «DANGER» level and «MAXI» level).
B3FP7H5D - Fill if necessary with the approved and recommended synthetic brake fluid.
193
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).
At the end of the bleeding programme, check the brake fluid level and top up, if necessary.
Check the brake pedal travel (no lengthening), if not satisfactory repeat the bleeding procedure.
B3FP7H3D
194
Angl-C6-page195-202-2005 4/02/05 17:36 Page 195
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.
HYDRAULICS
Safety requirements.
ESSENTIAL: In view of the special features of the hydraulic suspension system, observe the requirements below, before undertaking any
repair.
IMPERATIVE: Depending on the operation to be carried out, respect the requirements for supporting and securing the vehicle.
2-column lift or secure the Depressurisation of the circuit Checking and adjusting of Other operations
vehicle on 4 axle stands (see corresponding operation) heights (switch on ignition) (depressurisation of the
hydraulic circuit)
195
Angl-C6-page195-202-2005 4/02/05 17:36 Page 196
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.
HYDRAULICS
IMPERATIVE: Do not operate on the hydraulic circuit without making the pressure drop (see corresponding operation).
Engine running.
NOTE: In the event of contact of LDS fluid with the eyes, rinse them with copious amounts of water and seek specialist advice.
NOTE: In the event of lengthy contact of LDS fluid with the skin, wash it with soap and water.
WARNING: After the engine has stopped, wait 30 seconds before commencing any operation.
196
Angl-C6-page195-202-2005 4/02/05 17:36 Page 197
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.
WARNING: Non-respect of the cleanliness requirements may cause a contamination of the circuit and a malfunctioning of the suspension.
HYDRAULICS
Preliminary operations.
The work area must be kept clean and uncluttered.
The technician must wear clean overalls.
Components being stored during the repair must be protected from dust.
The tooling required for an operation on the suspension system should always be cleaned prior to the operation.
During the operation:
- Before operating on the suspension circuit, proceed to clean the hydraulic components and unions.
Any component that has been removed must be plugged and placed in a clean plastic bag.
IMPERATIVE: After a dismantling, any cleaning using compressed air or products is strictly prohibited. Any LDS fluid that is collected must
not be re-used. Any topping-up must be done with new fluid.
197
Angl-C6-page195-202-2005 4/02/05 17:36 Page 198
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.
B3BP1BJD
198
Angl-C6-page195-202-2005 4/02/05 17:36 Page 199
Specifications.
The «slimline» accumulators are grey in colour.
NOTE: Recharging the «slimline» accumulators with nitrogen is impossible.
Volume of nitrogen : 385 ± 15 cc.
Suspension cylinder accumulators (front).
HYDRAULICS
ES9A
GO 50
DT17BTED4
NOTE: The dampers are integral to the suspension cylinders (AMVAR cartridge). (*)
199
Angl-C6-page195-202-2005 4/02/05 17:36 Page 200
The suspension cylinders on the same axle have to be equipped with the same type of suspension accumulators.
IMPORTANT: Tightening torque for the suspension accumulators : 2,7 ± 0,5 m.daN.
200
Angl-C6-page195-202-2005 4/02/05 17:36 Page 201
Tools.
Go into the menu:
[1] PROXIA station : 4165-T - Suspension.
[2] LEXIA station : 4171-T - De-pressurisation.
Follow the instructions displayed on the screen.
De-pressurisation. Wait for the vehicle's suspension to sink completely.
NOTE: This operation takes around 3 minutes.
NOTE: It is possible to de-pressurise the suspension by individual axle. Switch off the ignition.
HYDRAULICS
Disconnect the battery.
201
Angl-C6-page195-202-2005 4/02/05 17:36 Page 202
Front suspension: Undo the pressure release screw (1) by one turn.
Rear suspension: Undo the pressure release screw (2) by one turn.
B3BP1BED Wait for the pressure in the hydraulic circuit to drop fully.
B3FP7HDD
202
Angl-C6-page203-217-2005 4/02/05 17:40 Page 203
ES9A 625
C6 12/05 ➔ SD 7 C16 135 SP 10
DT17BTED4 525
CONDITIONING
AIR
203
Angl-C6-page203-217-2005 4/02/05 17:40 Page 204
The variable capacity air conditioning compressor has external control. The condenser has a cylinder incorporating the function of aircon fluid
The internal pneumatic valve is replaced by an external electrovalve. reservoir and with integral filtering cartridge.
204
Angl-C6-page203-217-2005 4/02/05 17:40 Page 205
- Aircon compressor.
- Aircon condenser.
CONDITIONING
AIR
C5HP1CWC
205
Angl-C6-page203-217-2005 4/02/05 17:40 Page 206
The pollen filter is located on the driver's side under the dashboard to the
right of the steering column.
Removing.
NOTE: If the tab "b" is damaged, position a screw for soft materials at "a".
CONDITIONING
Refitting.
C5HP1BDD
206
Angl-C6-page203-217-2005 4/02/05 17:40 Page 207
ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil.
CONDITIONING
c) - Replacing a compressor.
- Remove the old compressor, drain it and measure the oil quantity.
AIR
- Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor.
- No more oil should be added when filling the system with R 134.a fluid.
207
Angl-C6-page203-217-2005 4/02/05 17:40 Page 208
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.
208
Angl-C6-page203-217-2005 4/02/05 17:40 Page 209
CONDITIONING
AIR
E5AP2N4D E5AP2N5D
209
Angl-C6-page203-217-2005 4/02/05 17:40 Page 210
Testing procedure.
Checking.
Position the equipment - Exxoclim or Clim test 2 - (see instructions).
Preliminary operations.
210
Angl-C6-page203-217-2005 4/02/05 17:40 Page 211
CONDITIONING
SC > 15°C Lack of aircon fluid in the cooling circuit Add some aircon fluid
SC < 2°C Excess aircon fluid in the cooling circuit Remove some aircon fluid
AIR
Blown air temperature.
The blown air temperature should be between 2°C and 10°C.
211
Angl-C6-page203-217-2005 4/02/05 17:40 Page 212
212
Angl-C6-page203-217-2005 4/02/05 17:40 Page 213
CONDITIONING
AIR
213
Angl-C6-page203-217-2005 4/02/05 17:40 Page 214
214
Angl-C6-page203-217-2005 4/02/05 17:40 Page 215
CONDITIONING
NOTE: In all cases, measure the excessive heating (SC) and the blow air temperature.
AIR
215
Angl-C6-page203-217-2005 4/02/05 17:40 Page 216
C5HP1E0P
216
Angl-C6-page203-217-2005 4/02/05 17:40 Page 217
CONDITIONING
«a» Compressor front support : 3,9
«b» Compressor rear support : 2,5
AIR
C5HP1DRP
217
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.