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CITROEN C6 2005 Service Manual

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Enlarged version
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.

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Summary of Contents for CITROEN C6 2005

  • 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.
  • Page 2 2005 CITROËN C6 «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».
  • Page 3 PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate handbook. The handbook is divided into groups representing the main functions: GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - HYDRAULICS - AIR CONDITIONING.
  • Page 4 If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example: - INSUFFICIENT INFORMATION. - SUPERFLUOUS INFORMATION. - NEED FOR MORE DETAILS. Please send your comments and suggestions to: CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

  • Page 5: Table Of Contents

    CONTENTS GENERAL Auxiliary equipment drive belt IGNITION Checking and setting the valve timing Vehicle identification 1 - 4 Sparking plugs Exhaust line specifications 68 - 72 General specifications: dimensions 5 - 6 CLUTCH - GEARBOX - TRANSMISSION Cooling system specifications 73 - 75 General specifications: weights Speedometer...
  • Page 6 CONTENTS AXLES - SUSPENSION - STEERING AIR CONDITIONING BRAKES Wheels and tyres 121 - 124 Brake specifications Quantities: aircon system R134.a 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...
  • Page 7 IDENTIFICATION OF VEHICLES A - Chassis stamp (cold stamp on suspension leg). B - Chassis stamp (cold stamp on bodywork below rear screen). C - Manufacturer's data plate (on the LH centre pillar). D - AS/RP No. and RP paint code (label on front pillar close to driver's door).
  • Page 8 IDENTIFICATION OF VEHICLES Petrol Diesel BTED4 3.0i 24 S 2.7 24V HDi Emission standard Type code TD XFVJ TD UHZJ Engine type Cubic capacity (cc) 2946 2720 Fiscal rating (hp) Gearbox type Gearbox ident. plate 20 GH 07 20 GG 07...
  • Page 9 IDENTIFICATION OF VEHICLES Manufacturer's plate The manufacturer's plate carries the following information: (a) Type approval number (*) (b) Type serial number (VIN) (c) Gross vehicle weight (*) (d) Gross vehicle weight (*) (e) Maximum weight on front axle (*) (f) Maximum weight on rear axle (*) (g) Manufacturer identification (*) = according to marketing country.
  • Page 10 IDENTIFICATION OF VEHICLES Type approval Structure Version (4) Family (1) Depollution levels Bodywork (2) Alcohol TD XFVJ Euro IV Other Engine (3) 83/87 L3/L4 Euro IV Version (4) Family (1) Bodywork (2) Saloon 4-door 3-box Engine (3) 3.0i 24 S ES9A 2.7 24V HDi DT17BTED4...

  • Page 11: General Specifications: Dimensions

    GENERAL SPECIFICATION: DIMENSIONS Exterior dimensions E1AP13KD...

  • Page 12: General Specifications: Dimensions

    GENERAL SPECIFICATION: DIMENSIONS Exterior dimensions (mm) Vehicles All types Wheelbase 2900 Front overhang 1124 Rear overhang Length overall 4908 Front track at ground level 1586 Width overall 2081 Rear track at ground level 1558 Track width 1860 Height overall ODM 1464 ODM = Vehicle in running order (vehicle empty, levels topped up).

  • Page 13: General Specifications: Weights

    GENERAL SPECIFICATION: WEIGHTS ES9A DT17BTED4 Versions 3.0i 24S 2.7HDi 24V Engine type Gearbox type Payload Weight empty in running order 1816 1871 Gross Vehicle weight 2271 2335 Gross Train weight 3671 Max. trailer weight with brakes Incline 12 % 1400 Incline 10 % 1500 1400...
  • Page 14 OPERATIONS TO BE CARRIED OUT BEFORE AND AFTER A DISCONNECTION OF THE BATTERY Before reconnecting the battery. NOTE: If the window is open at the time the battery is reconnected, action the window switch several times to close it, then re-initialise. Doors and tailgate.
  • Page 15 GENERAL SPECIFICATION: TOWING THE VEHICLE Front towing WARNING: When the engine is not running, steering and braking are no longer power-assisted. Open the boot. Lift the boot floor plate. Towing eye. The towing eye (1) is to be found in the vehicle toolkit (2) stowed in the spare wheel.
  • Page 16 GENERAL SPECIFICATION: TOWING THE VEHICLE Vehicle with automatic gearbox. IMPERATIVE: Never tow the vehicle with the wheels hanging (towing by the wheels). Towing: - It is necessary to raise the front of the vehicle, in order to tow it. - If it is not possible to raise the front of the vehicle. - It is essential to place the selection lever in position "N".

  • Page 17: Lifting And Supporting The Vehicle

    LIFTING AND SUPPORTING THE VEHICLE IMPERATIVE: Respect the safety and cleanliness requirements. Lifting. Front of the vehicle. ATTENTION: Lifting the vehicle by the front can only be done one side at a time. IMPERATIVE: Do not lift the vehicle by taking weight under the front subframe. Do not place blocks under the front subframe.
  • Page 18 LIFTING AND SUPPORTING THE VEHICLE Rear of the vehicle. IMPERATIVE: Do not lift under the spare wheel (risk of deformation of the floor). Do not lift under the rear axle crossmember. Use lateral lifting as for the front of the vehicle, or rear lifting (see diagrams). IMPERATIVE: Do not place a block between the jack and the strengthener «b».
  • Page 19 LIFTING AND SUPPORTING THE VEHICLE Lifting by vehicle jack. NOTE: the vehicle jack, with the extension and handle, is to be found in the toolkit stowed in the spare wheel. Front of the vehicle. Correct position for the vehicle jack (1). Rear of the vehicle.
  • Page 20 LIFTING AND SUPPORTING THE VEHICLE Supporting the vehicle. Incorrect positioning of the axle stand. E2AP018C IMPERATIVE: Do not place the axle stands under the lugs of the jacking points. Correct positioning of the axle stand. E2AP02PD...

  • Page 21: Lifting And Supporting The Vehicle

    LIFTING AND SUPPORTING THE VEHICLE Raising the vehicle on a lift, supported from the jacking points. Equipment involved: - Two-column lift. - Auxiliary lift with blocks. 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).
  • Page 22 CAPACITIES (in litres) Draining methods Oil capacities are defined according to the following methods Draining of the engine lubrication system by GRAVITY Draining of the engine lubrication system by SUCTION Place the vehicle on horizontal ground (in the high position if Place the vehicle on horizontal ground (in the high position if hydropneumatic suspension).
  • Page 23 CAPACITIES (in litres) Petrol Diesel 3.0i 24S 2.7 24V Engine type Engine with filter cartridge 5,25 Max. after draining and change of filter (by suction) 5,75 Max. after draining and change of filter (by gravity) 5,55 Dry sump 5,95 Between min. and max. Dry automatic gearbox Volume of oil remaining after draining Quantity of oil to be put back in after draining...

  • Page 24: Lubricants

    LUBRICANTS - TOTAL recommended oils Engine oil specifications TOTAL ACTIVA or TOTAL ACTIVA QUARTZ Commercial description Synthetic 9000 Semi-synthetic 7000 S.A.E. norms 0W40 5W30 5W40 10W40 15W40 Cold Temperate Climate Climate Temperate ACE: A3 ACE: A5 ACE : A3 Petrol engines API: SJ API: SL ACEA: B5...

  • Page 25: Engine

    LUBRICANTS - TOTAL recommended oils Gearbox oil AM6 automatic gearbox All countries JWS 3309 (ESSO) Power steering oil Power-assisted steering All countries LDS TOTAL H50126 Engine coolant CITROËN references Packs GLYSANTIN G33 REVKOGEL 2000 2 Litres 9979 70 9979 72 CITROËN fluid 5 Litres 9979 71...

  • Page 26: Lubricants

    LUBRICANTS - TOTAL recommended oils Screen wash fluid Packs CITROËN references Concentrate: 250 ml 9980 56 9980 33 ZC 9875 953U Fluid 9980 06 1 Litre ZC 9875 784U All countries ready to 5 Litres 9980 05 ZC 9885 077U ZC 9875 279U Greasing General use...

  • Page 27: Engine

    ENGINE OIL CONSUMPTION - Oil consumption depends on: - The engine type. - How run-in or worn it is. - The type of oil used. - The driving conditions. II - An engine can be considered RUN-IN after: - 3 000 miles (5 000 km) for a PETROL engine. - 6 000 miles (10 000 km) for a DIESEL engine.

  • Page 28: Engine Specifications

    ENGINE SPECIFICATIONS Engines: ES9A - DT17TED4 Petrol Diesel 3.0i 24S 2,7 24V Engine type Cubic capacity (cc) 2946 2720 Bore/stroke 87/82,6 81x88 Compression ratio 10,9/1 17,3/1 Power ISO or EEC (KW - rpm) 155-6000 150-4000 Torque ISO or EEC (m.daN - rpm) 29-3750 44-1900...
  • Page 29 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: ES9A Torque reaction rod - lower RH engine support 6 ± 0,5 1 ± 0,1 6,5 ± 0,5 LH engine support 3 ± 0,3 6,5 ± 0,6 5 ± 0,5 5,5 ± 0,5 Upper RH engine support 6 ±...
  • Page 30 ENGINE TIGHTENING TORQUES Engine: ES9A Pencil-type ignition coil 0,8 ± 0,3 Sparking plugs Pre-tightening 1 ± 0,1 Angular tightening 90° ± 5° Valve cover Pre-tightening 0,5 ± 0,1 Tightening 1 ± 0,1 Camshaft bearing cap cover Pre-tightening 0,2 ± 0,1 Tightening 1 ±...
  • Page 31 ENGINE TIGHTENING TORQUES Engine: ES9A Exhaust manifold (equipped with a new gasket) Pre-tightening (order from 1 to 10) 1 ± 0,1 Tightening (order from 1 to 10) 3 ± 0,3 Con rod caps Pre-tightening 2 ± 0,2 Angular tightening 74° ± 5° Engine flywheel Pre-tightening 2 ±...
  • Page 32 ENGINE TIGHTENING TORQUES Engine: ES9A 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.
  • Page 33 ENGINE TIGHTENING TORQUES Engine: ES9A Sump Pre-tightening (sequence from 1 to 20) 0,5 ± 0,1 Tightening (sequence from 1 to 20) 0,8 ± 0,1 Crankshaft pinion Pre-tightening 4 ± 0,4 Angular tightening 80° Crankshaft pulley 2,5 ± 0,2 Inlet distributor (with new seals) Pre-tightening 0,4 ±...
  • Page 34 ENGINE TIGHTENING TORQUES Engine: ES9A Camshaft hubs Pre-tightening 2 ± 0,2 Angular tightening 57° 1,5 ± 0,1 Guide roller 8 ± 0,8 Camshaft pulley Pre-tightening 2 ± 0,2 Angular tightening 115° Camshaft pulleys 1 ± 0,1 B1BP2D3D Timing belt tensioner roller 2,5 ±...
  • Page 35 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: DT17BTED4 RH engine support Screws 8,2 ± 1,25 Screws 6 ± 0,6 Screws 2,8 ± 0,4 6,5 ± 0,6 Screws 6 ± 0,6 Front piloted torque reaction rods Screws 6 ± 0,6 B1BP3EPD Screws Screws 4,3 ±...
  • Page 36 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: DT17BTED4 Rear piloted torque reaction rods Screws Screws 6 ± 0,6 Screws Screws LH gearbox support Screws 6 ± 0,6 Screws 5,5 ± 0,8 B1BP3ERD Screws 6 ± 0,6 Screws 5,5 ± 0,8 B2CP45CD...
  • Page 37 TIGHTENING TORQUES: POWER UNIT SUSPENSION Engine: DT17BTED4 Gearbox impact absorber Screws 4 ± 0,6 B2CP45DC Driveshaft bearing Screws 6 ± 0,6 B2CP45EC...
  • Page 38 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).
  • Page 39 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Cylinder head Butterfly housing Inlet valve cover screws (*) 0,9 ± 0,2 Inlet valve cover studs (*) Coolant outlet housing Cylinder heads Pre-tightening 2 ± 0,2 Tightening 4 ± 0,5 Tightening 8 ± 0,5 Angular tightening 180 ±...
  • Page 40 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Order of tightening of screws (2) (2) Camshaft bearing cover screws (from 1 to 13) (2) Camshaft bearing cover studs (from 1 to 13) B1DP1M1C Order of tightening of bolts (4) (from 1 to 8) (4) Cylinder head bolts B1DP1M2C...
  • Page 41 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Cylinder block Coolant pump 0,9 ± 0,2 Con rod screws Pre-tightening 2 ± 0,1 Angular pre-tightening 45 ± 5° Angular tightening 45 ± 5° Starter gearwheel carrier Pre-tightening 5 ± 0,5 Angular pre-tightening 45 ± 5° Angular tightening 45 ±...
  • Page 42 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Order of tightening for screws (14) and (15) (14) Lower engine block screw (screw M6) (15) Lower engine block screw (screw M8) Method of tightening: - Tighten the 10 screws (15) (from 1 to 10) to : 2,3 ±...
  • Page 43 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Lubrication Oil filter cover 2,3 ± 0,3 Oil filter support 0,9 ± 0,2 Oil/coolant heat exchanger Oil pressure switch 1,3 ± 0,2 Oil pump assembly 0,9 ± 0,2 Oil gauge 2,3 ± 0,3 Oil level sensor 2,7 ±...
  • Page 44 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Valve timing Camshaft pulley hub screw Tightening 8 ± 0,8 Angular tightening 90° ± 5° Camshaft pulley screw 2,3 ± 0,3 Camshaft bearing caps (*) Tightening 0,5 ± 0,1 Pre-tightening 0,9 ± 0,1 Tensioner roller for the fuel high pressure pump drive belt 2,5 ±...
  • Page 45 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 ;...
  • Page 46 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Injection circuit Diesel fuel/cooolant exchanger 2,2 ± 0,3 Diesel injection pump on support 2,3 ± 0,3 Diesel injection pump pinion 5 ± 0,2 Diesel injector fixing flange screw 0,9 ± 0,1 Union on diesel injector Pre-tightening 1,5 ±...
  • Page 47 ENGINE TIGHTENING TORQUES Engine: DT17BTED4 Accessories 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 Guide roller 4,7 ± 0,7 Accessories support 2,3 ± 0,3 Multifunction support 2,3 ±...

  • Page 48: Cylinder Head Tightening

    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.

  • Page 49: Cylinder Head Tightening

    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.
  • Page 50 BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE Tools 4122-T (C.TRONIC.105.5) 4099-T (C.TRONIC.105)

  • Page 51: Auxiliary Equipment Drive Belt

    AUXILIARY EQUIPMENT DRIVE BELT Petrol Diesel 3.0i 24S 2,7 24V Engine type See pages: 47 to 48...
  • Page 52 AUXILIARY EQUIPMENT DRIVE BELT Engines : all types Petrol and Diesel Tools. Belt tension measuring instrument : 4122-T.(C.TRONIC 105.5). WARNING: If using tool 4099-T (C.TRONIC 105). Essential. Before refitting the auxiliary equipment drive belt, check that: - 1 / The roller(s) rotate freely (no play or stiffness). - 2 / The belt is correctly engaged in the grooves of the various pulleys.
  • Page 53 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».
  • Page 54 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].
  • Page 55 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.

  • Page 56: Checking And Setting The Valve Timing

    CHECKING AND SETTING THE VALVE TIMING Petrol Diesel 3.0i 24BS 2,7 24V Engine type See pages: 51 to 57 58 to 67...
  • Page 57 CHECKING THE VALVE TIMING Engine: ES9A Tools. [1] Camshaft setting pegs : (-).0187.B [2] Crankshaft setting peg : (-).0187.A [3] Fuel pressure take-off union : 4192-T [4] Belt retaining pin : (-).0187.J [5] Exhaust camshaft hubs immobilising tool : (-).0187.F [6] Inlet camshaft hubs immobilising tool : FACOM D12 [7] SEEM belt tension measuring equipment...
  • Page 58 CHECKING THE VALVE TIMING Engine: ES9A Checking the valve timing (continued). Peg the crankshaft, using tool [1]. Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys. Remove the tools [1] and [2]. Refit: - The lower timing cover (13).
  • Page 59 CHECKING AND SETTING THE VALVE TIMING Engine: ES9A Setting the valve timing. Remove the components as necessary for the operation. Remove the screws (19) and the plate (20). Peg the crankshaft, using tool [2]. NOTE: Damp the rotation of the camshafts (15) and (17), using tool [6]. Untighten the camshaft pulley screws (15) and (17).
  • Page 60 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.
  • Page 61 CHECKING AND SETTING THE VALVE TIMING Engine: ES9A Setting the valve timing (continued). Adjusting the timing belt tension. Preliminary operations. Pivot the plate (25) of the tensioner roller (24), using a spanner (type FACOM S.161). Engage the screw (21) on the plate (25). Tighten the screws (21) and (22), tighten to 2,5 ±...
  • Page 62 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.
  • Page 63 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).
  • Page 64 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.
  • Page 65 CHECKING THE VALVE TIMING Engine: DT17BTED4 Remove: - The auxiliary drive belt (5) (see corresponding operation). - The upper timing covers (6). B1EP1J9D Position the camshaft pegging holes "a" and "b" at "c" and "d", 30° ± 5° forward of their pegging holes "e"...
  • Page 66 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.
  • Page 67 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...
  • Page 68 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.
  • Page 69 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.
  • Page 70 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).
  • Page 71 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Reposition the timimg belt, strip «j» well tensioned, in the following order: - Guide roller (19). - Camshaft pulley (18). - Guide roller (16). - Camshaft pulley (23). - Tensioner roller (20). NOTE: If necessary, turn the pulleys (23) and (18) slightly anti-clockwise (the offset must not be B1EP1JHD more than one tooth).
  • Page 72 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Tighten the screws (15) and (17) : 2,2 ± 0,2. Remove tools [2] and [3]. Rotate the crankshaft 8 times in the normal direction of rotation. Fit the tool [2]. Peg the camshafts using tools [3], at "h" and "g". NOTE: If it is not possible to refit the tools [3], slacken the screws (15) and/or (17) of the camshafts and drive the camshafts by means of their central screws (25) and/or (26).
  • Page 73 CHECKING AND SETTING THE VALVE TIMING Engine: DT17BTED4 Remove tools [2] and [3]. Refit: The lower timing cover (10), the upper timing covers (11), the crankshaft pulley (9), the engine support (12), the coolant pump pulley (13), the accessories drive belt (8) (see corresponding operation), the engine support (4) on the chassis member, the upper RH engine support (5) and the upper RH engine support tie bar.
  • Page 74 EXHAUST SPECIFICATIONS Engine: ES9A Upstream oxygen sensor (rear) Downstream oxygen sensor (rear) 4,7 ± 0,5 Downstream oxygen (front) Upstream oxygen sensor (front) Precatalyser (rear) 3,5 ± 0,5 Precatalyser (front) Resonator Catalytic converter Rear silencer Clips 2,6 ± 0,3 B1JP08AD...
  • Page 75 EXHAUST SPECIFICATIONS Engine: ES9A Repair. Respect the precautions to be taken prior to any operation: - The front flexible pipe must be protected against any external mechanical damage. - The front flexible pipe must not come into contact with corrosive products. - Do not deform the front flexible pipe more than 20°...
  • Page 76 EXHAUST SPECIFICATIONS Engine: DT17BTED4 B1JP07QD Engine versions Clip Particle filter Intermediate pipe Exhaust Rear Front silencer precatalyser precatalyser TR PSA F016 TR PSA K330 PSA 4234 TR PSA K311 TR PSA K310...
  • Page 77 EXHAUST SPECIFICATIONS Engine: DT17BTED4 Repair. Respect the precautions to be taken prior to any operation: - The front flexible pipe must be protected against any external mechanical damage. - The front flexible pipe must not come into contact with corrosive products. - Do not deform the front flexible pipe more than 20°...
  • Page 78 TIGHTENING TORQUES - EXHAUST LINE Engine: DT17BTED4 Clip 2,6 ± 0,4 Particle filter hangers Intermediate pipe hangers 0,8 ± 0,1 Silencer hangers Rear precatalyser screw 2 ± 0,3 Front precatalyser screw 2 ± 0,3 B1JP07ZD...
  • Page 79 COOLING SYSTEM SPECIFICATIONS Engines: ES9A - DTE17BTED4 3.0i 24S 2,7 24V Engine type Capacity 11,3 13,2 Radiator surface 27 dm 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...
  • Page 80 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...
  • Page 81 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...

  • Page 82: Checking The Oil Pressure

    CHECKING THE OIL PRESSURE Engine ES9A DT17BTED4 Temperature (°C) 80°C Pressure (bars) Pressure (bars) 1 to 4 3000 2500 Pressure (bars) 2279-T.Bis 4103-T (-).1503.K 4202-T NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.

  • Page 83: Valve Clearances

    VALVE CLEARANCES Inlet Exhaust All types Hydraulic adjustment...
  • Page 84 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 IMPERATIVE: Respect the safety and cleanliness requirements. The draining and refilling operations can be carried out using coolant fluid replacement equipment. It is essential to follow the instructions as stated for that equipment.
  • Page 85 DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT Engine: ES9A Open the plug (3) to drain the second bank of cylinders. Remove the drain plugs (2) and (3). Filling and bleeding the circuit. Prior to any filling, rinse the cooling with fresh water. WARNING: Check the sealing of the cooling circuit.
  • Page 86 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).
  • Page 87 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 IMPERATIVE: Respect the safety and cleanliness requirements. The draining and refilling operations can be carried out using coolant fluid replacement equipment. It is essential to follow the instructions as stated for that equipment.
  • Page 88 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 ±...

  • Page 89: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Synopsis. (1) Fuel consumption information (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...

  • Page 90: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Synopsis. (15) Canister purge electrovalve (16) Cooling fan (17) Pencil type ignition coil (x6) (18) Petrol injector (x6) (19) Variable timing electrovalve (x2) (20) Downstream oxygen sensor (x2) (21) Upstream oxygen sensor (x2) (22) Engine coolant temperature sensor (23) Knock sensor (x2) (24) Power steering pressure sensor...

  • Page 91: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Synopsis. (30) Pulse damper (31) Sparking plugs (x6) (32) Fuel tank (33) Canister reservoir (34) Discharge valve (35) Exhaust line Specifications. Cylindrical capacity (cc) : 2946. Idling speed (rpm) non-adjustable : 700 ± 50. Cut-off at maximum engine speed (rpm) : 6520.

  • Page 92: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Fuel circuit Component Location Supplier Reference Observations Recommended fuel Super unleaded 95 RON or 98 RON Capacity 65 litres Fuel tank Composition polyethylene Electric pump submerged in the tank Voltage, 12 V Fuel pump, filter and MARWALL Pressure, 3 bars pressure regulator...

  • Page 93: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Air circuit Component Location Supplier Reference Observations DS-S2 0 3-way grey connector Integrated pressure sensor 261 260 140 Integrated in the inlet manifold DVE5 6-way black connector Motorised butterfly housing BOSCH 0 280 750 041 Fixing, on the inlet manifold 14 43 33 6-way black connector...

  • Page 94: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Electrical circuit Component Location Supplier Reference Observations 2-way grey connector Inlet air temperature sensor JAEGER 402 084 01 Fixing: on the air filter inlet duct 3-way grey connector Camshaft position 14 43 2514 43 ELECTRICFIL sensor Fixing: on the inlet camshaft bearing cap cover...

  • Page 95: Injection

    BOSCH ME 7.4.7 INJECTION SYSTEM Engine: ES9A Ignition circuit Component Location Supplier Reference Observations Electrode gap: 1 mm BOSCH FGR8MQPE Tightening torque Sparking plugs Tighten to: 1 ± 0,1 m.daN PFR6E 10 Angular tightening: 90° Pencil type ignition SAGEM BAC 1 4-way black connector coils 2526140...

  • Page 96: Direct Injection

    PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engine: DT17BTED4 Cleaning. The use of high pressure cleaners is prohibited. Do not use compressed air. Fuel supply circuit. Required fuel: Diesel. WARNING: Do not use other fuels. Electrical circuit. Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. It is forbidden to supply a diesel injector with 12 volts.

  • Page 97: Direct Injection

    PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM Engine: DT17BTED4 Diesel injectors. WARNING: Diesel and ultrasonic cleaners are prohibited. Do not separate the diesel injector carrier (2) from the following components: - Diesel injector (g) (no replacement parts). - The fuel flow actuator (e) (destruction). B1HP23HC Do not move the nut (f) (will cause a malfunction).
  • Page 98 SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM Safety requirements. After the engine has stopped, wait 30 seconds before any intervention. Preamble. NOTE: This waiting time is necessary in order to allow the high pressure All interventions on the injection system must be carried out to conform fuel circuit to return to atmospheric pressure.

  • Page 99: Supply Circuit

    CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: DT17BTED4 Tools. [1] Ø 10 mm low pressure connector : 4215-T [2] Ø 8 mm low pressure connector : 4218-T [3] Pressure gauge for testing boost pressure : 4073-T Kit 4073-T [4] Extension : 4251-T Checks.

  • Page 100: Supply Circuit

    CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT Engine: DT17BTED4 Checks on pressure: static. Switch on the ignition. For 3 seconds (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 1.1 ± 0.4 bar. - Fuel return pressure shown by the pressure gauge [3] = 2 ± 0.5 bar. Abnormal functioning: Fuel supply Fuel return...
  • Page 101 CHECKS: TURBO PRESSURE Engine: DT17BTED4 Tools. [1] Pressure gauge for checking the pressure : 7073-T.A [2] Tool for checking the inlet air pressure/vacuum : (-).0171.G3 [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.
  • Page 102 CHECKS: TURBO PRESSURE Engine: DT17BTED4 Connect: - The tool [2a] in place of the turbo pressure sensor (1). - The turbo pressure sensor (1) on the tool [2b]. - Tool [1] on tool [2], at "b". Connect the diagnostic tool [3] or [4] to the vehicle's diagnostic socket: - Put the diagnostic tool [3] or [4] in parameter measures.
  • Page 103 CHECKS: TURBO PRESSURE Engine: DT17BTED4 Significant difference in pressure between the two turbochargers: - Stop the engine. - Remove the air filter with the two flowmeters. - Mark the flowmeters "d" and "c". - Remove both flowmeters. Refit: - Flowmeter "d" in place of flowmeter "c". - Flowmeter "c"...
  • Page 104 CHECKING THE AIR SUPPLY CIRCUIT SPECIFICATIONS Engine: DT17BTED4 (1) Air filter: MECAPLAST (2) Air/air heat exchanger: BEHR (3) Front turbocharger: GARETT (4) Air butterfly housing: MAN HUMEL (5) Rear turbocharger: GARETT (6) Flowmeters: SIEMENS VDO B1HP26UD...

  • Page 105: Checking The Air Supply Circuit

    CHECKING THE AIR SUPPLY CIRCUIT Engine: DT17BTED4 Tool. [1] Manual pressure-vacuum pump : FACOM DA 16 Checks. IMPERATIVE: Respect the safety and cleanliness specific to high pressure diesel injection engines. Checking the vacuum source (vacuum pump). Connect the tool [1] on the take-off "a" of the vacuum pump (1). Start the engine.

  • Page 106: Sparking Plugs

    SPARKING PLUGS Electrode Electrode Vehicles Engine BOSCH Tightening torque (m.daN) Tightening : 1 ± 01 3.0i 24S ES9A FGR8MQPE 1 mm PFR6E10 1 mm Angular tightening : 90° ± 5°...

  • Page 107: Speedometer

    SPEEDOMETER An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates: - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed «SD»...

  • Page 108: Am6 Automatic Gearbox Specifications

    AM6 AUTOMATIC GEARBOX SPECIFICATIONS Vehicle Engine Gearbox type Sequence Torque ratio Drive ratio ES9A 20 GH 07 49 X 52 15 x 53 DT17BTED4 20 GG 07 54 X 47...
  • Page 109 PROCEDURE PRIOR TO OPERATIONS: AM6 AUTOMATIC GEARBOX Engines: ES9A - DT17BTED4 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).
  • Page 110 PRECAUTIONS TO BE TAKEN : AM6 AUTOMATIC GEARBOX Engines: ES9A - DT17BTED4 Precautions to be taken Towing. When performing electrical checks: The front of the vehicle must be raised in order to be towed. - The battery should be correctly charged. If the front of the vehicle cannot be raised.
  • Page 111 AM6 AUTOMATIC GEARBOX: GENERAL SPECIFICATIONS Engines: ES9A - DT17BTED4 Identification. (1) identification plate (riveted on the casing) "a" Type of automatic gearbox (AISIN) "b" Type of automatic gearbox (PSA) "c" Component marking "d" Serial no. (2) identification label (affixed on the ECU) B2CP3YRC "e"...
  • Page 112 AM6 GEARBOX: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Automatic gearbox heat exchanger 4,2 ± 0,4 Hydraulic valve block casing 1,5 ± 0,2 Filler plug 4 ± 0,4 Torque converter screw [(ES9 3 screw) (DT17 6 screw)] Pre-tightening 2 ± 0,2 Slackening 100°...
  • Page 113 AM6 GEARBOX: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Oil induction cover 1 ± 0,1 Hydraulic valve block (in the order indicated) 1 ± 0,1 Oil temperature sensor tightening plate 1 ± 0,1 ECU screws 2,5 ± 0,2 Oil drain and overflow plug 1 ±...
  • Page 114 AM6 GEARBOX CONTROLS Engines: ES9A - DT17BTED4 The gear selector is guided by the shape of the stepped gate and by a retaining spring which pulls it to the left hand side. The gear control has 5 positions: - Position "P": parking (locking and immobilisation of the vehicle). - Position "R": reverse gear.
  • Page 115 AM6 GEARBOX CONTROLS Engines: ES9A - DT17BTED4 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 ;...
  • Page 116 AM6 GEARBOX CONTROLS Engines: ES9A - DT17BTED4 Gearbox end. The automatic gearbox is controlled by a cable. “b” Push-button in pushed-in position (1) Sleeve stop (2) Control lever with ball-joint (3) Automatic adjustment Automatic adjustment: - Pull out button “b” to adjust the control. - Push in button “b”...

  • Page 117: Shift Lock Function

    AM6 GEARBOX CONTROLS: «SHIFT LOCK» FUNCTION Engines: ES9A - DT17BTED4 IMPERATIVE: Respect the safety and cleanliness requirements, with reference to the brochure: «Recommendations-Precautions». The «shift lock» is a system that locks the gear selection lever in position «P». Unlocking the «SHIFT LOCK» (normal operation). Switch on the ignition.
  • Page 118 PROCEDURE FOR INITIALISATION OF THE AUTOMATIC GEARBOX ECU NOTE: For all these operations, follow the procedure in the diagnostic tool. Replacement of the automatic gearbox without replacement of the ECU. Carry out the following operations: - Initialisation of the neutral position of the gear selection lever position sensor. - Initialisation of the adaptation of the oil pressure regulators and electrovalves.
  • Page 119 PROCEDURE FOR INITIALISATION OF THE AUTOMATIC GEARBOX ECU Replacement of the automatic gearbox and of the automatic gearbox ECU. Carry out the following operations: - Initialisation of the autoadaptatives. - Resetting the oil usage counter to zero. - Initialisation of the adaptation of the oil pressure regulators and electrovalves. Draining of the automatic gearbox oil.
  • Page 120 DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX Tool. [1] Filling cylinder : (-).0340 Respect the safety and cleanliness requirements. Draining. IMPERATIVE: Draining of the gearbox must be done with the oil hot (60°C minimum), in order to ensure that the impurities in suspension in the oil are eliminated. NOTE: Drainage is only partial, as the torque converter cannot be drained totally.
  • Page 121 DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX WARNING: Do not take account of the information mentioned on tool [1]. Oil capacity for a dry gearbox: 7 litres (approx.). Type of oil: JWS 3309 ESSO (red in colour). Volume of oil remaining after draining: 4 litres (approx.). Quantity of oil to be added: 3 litres (approx.).
  • Page 122 DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX Thread of oil, then "drip-drip". Refit the level plug (2). Tighten the plug (2) to : 0.8 ± 0,1 mdaN. "drip-drip" or nothing. Refit the level plug (2). Stop the engine. Add 0.5 litre of extra oil into the gearbox.
  • Page 123 CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX Tools. [1] Flexible pipe and pressure gauge : 4601- TF1 Toolkit 4601-T [2] Flexible union : (-).0336.X Toolkit 8010-T IMPERATIVE: Respect the safety and cleanliness requirements. B2CP45FC Preliminary operations. Remove the air filter housing. Move aside the pipe (1).
  • Page 124 CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX WARNING: Clean the flexible pipe of the tool [1] each time before use; the different automatic gearbox oils cannot be intermixed. Fit the tool [1] on the tool [2]. Perform the following operations: - Raise the vehicle, wheels hanging.
  • Page 125 CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX Checking the torque converter. WARNING: This check has to be of short duration (2 seconds), as it causes a rapid rise in the temperature of the oil in the automatic gearbox. Respect the following checking conditions: - Engine at operating temperature.
  • Page 126 TRANSMISSION Tightening torques (m.daN) Gearbox oil seal mandrels Driveshaft Driveshaft Engines Right Left Tool kit Vehicle Gearbox bearing (-).0336.U (-).0336.V ES9A - DT17BTED4 2 ± 0,2 34,5 ± 2 8010-T (-).0336.W (1) (1) Guide for fitting driveshaft seal. Tightening torques (m.daN) of the wheel bolts ES9Al Steel CITROËN...

  • Page 127: Wheels And Tyres

    WHEEL AND TYRES 3.0i 24S 2,7 24V Engine plate Tyre/circumference 225/55 R17 97W/2,071 m 245/45 R18 100W/2,065m 245/45 R18 100W/2,065m Type Michelin PRIMACY Wheel 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: 2,4/2,4 2,4/2,4...
  • Page 128 WHEEL AND TYRES Identification of inflation pressures NOTE: The label indicating the recommended tyre pressures is affixed to the front LH door pillar. «a» Recommended tyre inflation pressures (empty and under load) «b» Tyre specifications «c» Type of tyres «d» Recommended inflation pressure for the spare wheel B2GP01FD...
  • Page 129 WHEEL AND TYRES Identification of the wheel bolts (1) Wheel bolt (all rim types) (2) Light alloy wheel (3) Steel aluminium wheel NOTE: If mixed fixing bolts are fitted on steel wheels, the shoulders of the bolts remain free. Tightening torques for the wheel bolts. 9 ±...

  • Page 130: Wheels And Tyres

    WHEEL AND TYRES Deflation detection system (4) Valve (8) Seal (5) Antenna (9) Cap (6) HF transmitter unit (10) Nut (7) Washer Composition. A SIEMENS HF transmitter module (6) integral to each wheel in the place of the valve, each including a lithium battery. An HF receiver in the communication module under the dashboard.

  • Page 131: Checking And Adjusting The Vehicle Height

    CHECKING AND ADJUSTING VEHICLE HEIGHT Reference heights: REFERENCE = Ignition switched on IMPERATIVE: Respect the safety and cleanliness requirements. 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...
  • Page 132 CHECKING AND ADJUSTING VEHICLE HEIGHT Warning: During measurement of reference heights: Do not switch off the ignition Reference heights: REFERENCE = Ignition switched on Measuring the front wheel radiuses Measuring the front heights B3CP0AQD B3CP0ASD B3CP0ARD Place the tool [1] on the wheel Measure, using tool [2].
  • Page 133 CHECKING AND ADJUSTING VEHICLE HEIGHT Reference heights: REFERENCE = Ignition switched on Measuring the rear wheel radiuses Measuring the rear heights B3CP06AC B3CP0AUD B3CP0ATD 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.
  • Page 134 CHECKING AND ADJUSTING VEHICLE HEIGHT Reference heights: REFERENCE = Ignition switched on Adjusting the heights. Calculate the following values: - Front LH : K1M = R1 - H1M. - Front RH : K2M = R2 - H2M. - Rear LH : K3M = R3 - H3M.

  • Page 135: Values For Checking And Adjusting The Axle Geometries

    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. Check and adjust if necessary the vehicle heights (see corresponding [1] Gauge for measuring radius of wheels (5 bolts) : 9801-T operation).
  • Page 136 VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES Rod for adjusting the rear tracking. (1) Locking screw (2) Adjusting screw B3BP1BND...
  • Page 137 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»...
  • Page 138 VALUES FOR CHECKING AND ADJUSTING AXLE GEOMETRIES Warning: During measuring of PARKING heights: Switch off the ignition PARKING heights: (values given AS A GUIDE only) Front and rear PARKING heights (ignition switched off) Front axle Rear axle B3CP0ATD B3CP0ARD Front LH: K1 = 175 ± 6 mm Front RH: K2 = 175 ±...
  • Page 139 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.

  • Page 140: Front Axle

    FRONT AXLE ES9A Front subframe. Front subframe in cast aluminium alloy. NOTE: Subframe positioned by indexing on body. Front subframe frame with screwed-in subframe extensions (UHZ engine). (1) Front subframe frame crossmember B3CP09BD (2) Subframe extensions DT17BTED4 (3) Front subframe Front subframe frame with welded subframe extensions (XFV engine).

  • Page 141: Front Axle

    FRONT AXLE Front pivot. Front pivot fixed on the pivot support by means of an upper balljoint and a lower balljoint. Front hub bearing: - Diameter 83 mm. - Bearing with double row of balls, with an integral magnetic wheel (48 pairs of poles). Suspension leg: - Front axle with wheels independent, of multi-arm type.

  • Page 142: Front Axle Tightening Torques

    FRONT AXLE: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Suspension leg Body suspension upper support 2,6 ± 0,3 Front suspension cylinder on Suspension upper support 2,4 ± 0,3 Suspension upper arm on Suspension upper support 4,5 ± 0,6 Suspension upper arm on Pivot support 8,5 ±...
  • Page 143 FRONT AXLE: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Suspension leg Pivot lower balljoint on Pivot support 6,5 ± 0,9 Pivot lower balljoint on Pivot support 17 ± 1,7 Steering rack balljoint on Front pivot 3,5 ± 0,3 B3CP09FC...
  • Page 144 FRONT AXLE: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Front subframe Front subframe frame tie-bar on Body 5 ± 0,7 Front subframe frame tie-bar on Front subframe frame 6,5 ± 0,9 Front absorber support tie-bar 6,5 ± 0,9 Front subframe frame on Subframe extension 10 ±...
  • Page 145 FRONT AXLE: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Front subframe Suspension lower arm support on Front subframe 6,5 ± 0,9 Suspension lower arm on Front subframe 12,3 ± 1,2 B3CP09TC...

  • Page 146: Rear Axle

    REAR AXLE Rear axle (1) Rear axle crossmember (2) Rear axle crossmember rear rubber bush (3) Rear axle crossmember front rubber bush (4) Suspension longitudinal arm NOTE: Rear axle in cast aluminium alloy, of multi-arm type. (5) Suspension upper arm (6) Rear pivot (7) Hub-bearing (8) Tracking adjustment rod...
  • Page 147 REAR AXLE (10) Rear anti-roll bar bearing (11) Rear anti-roll bar bearing half-support (12) Rear anti-roll bar (13) Rear anti-roll bar rod NOTE: The rear anti-roll bar bearings are not separable. Anti-roll bar Engines Diameter (mm) Colour ref. ES9A - DT17BTED4 20,6 Orange Vehicle geometry.

  • Page 148: Rear Axle Tightening Torques

    REAR AXLE: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Rear axle crossmember on Body 7,5 ± 0,7 Rear anti-roll bar bearing on Body Tracking adjustment rod on Rear pivot Rear suspension cylinder on Rear pivot Suspension longitudinal arm on Rear pivot 7 ±...

  • Page 149: Rear Axle Tightening Torques

    REAR AXLE: TIGHTENING TORQUES Engines: ES9A - DT17BTED4 Suspension upper arm on Rear pivot Suspension upper arm on Rear axle crossmember 7 ± 0,7 Rear suspension cylinder on Rear axle crossmember Rear anti-roll bar rod on Rear pivot 4 ± 0,6 Rear anti-roll bar rod on Rear anti-roll bar Rear anti-roll bar bearing half support 1,8 ±...

  • Page 150: Active Suspension With Variable Damping

    ACTIVE SUSPENSION WITH VARIABLE DAMPING Location of components A: Front suspension B: Rear suspension NOTE: The rear stiffness regulator is equipped with two accumulators. (1) Variable damping suspension actuator (2) Front suspension accumulator (3) LDS fluid reservoir B3BP1ASD (4) Front suspension cylinder Front axle (5) Built-in Hydro-electronic Interface (BHI) (6) Front stiffness regulator...
  • Page 151 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.
  • Page 152 ACTIVE SUSPENSION WITH VARIABLE DAMPING Built-in Hydro-electronic Interface (BHI) Composition of the Built-in Hydro-electronic Interface: - An electric motor. - A pump with 5 pistons. - 4 electrovalves. - 2 non-return valves. - A pressure limiter. - An anti-pulse accumulator. - A filter.
  • Page 153 ACTIVE SUSPENSION WITH VARIABLE DAMPING Wheel travel sensor (9) Front RH wheel travel sensor The wheel travel sensor defines the angular position of the suspension lower arm. Identification of the sensors: - Front RH wheel travel sensor : Yellow. - Front LH wheel travel sensor : Red.
  • Page 154 ACTIVE SUSPENSION WITH VARIABLE DAMPING Variable damping suspension actuator Each suspension cylinder has a variable damping suspension actuator. (1) Variable damping suspension actuators (front) (12) Variable damping suspension actuators (rear) Anti-roll bars: Front anti-roll bar. ES9A : Diameter 23.5 mm Yellow. DT17BTED4 : Diameter 24 mm Pink.
  • Page 155 ACTIVE SUSPENSION WITH VARIABLE DAMPING One-touch control for body height «g» One-touch control to raise body height «h» Sport mode activation/deactivation switch «j» One-touch control to lower body height C5FP0R8C...

  • Page 156: Suspension Tightening Torques

    SUSPENSION: TIGHTENING TORQUES Front suspension Body suspension upper support 2,6 ± 0,3 Front suspension cylinder on Suspension upper support 2,4 ± 0,3 Suspension upper arm on Suspension upper support 4,5 ± 0,6 Suspension upper arm on Pivot support 8,5 ± 0,8 Suspension upper arm on Pivot support 20,5 ±...
  • Page 157 SUSPENSION: TIGHTENING TORQUES Front pivot lower balljoint on Pivot support 6,5 ± 0,9 Front pivot lower balljoint on Pivot support 17 ± 1,7 Steering rack balljoint on Front pivot 3,5 ± 0,3 Rear fixing of suspension lower arm on Front subframe 11 ±...
  • Page 158 SUSPENSION: TIGHTENING TORQUES Fixing of suspension lower arm support on Front subframe 8 ± 0,8 Front fixing of suspension lower arm on Front subframe 12,3 ± 1,2 B3CP09XD...
  • Page 159 SUSPENSION: TIGHTENING TORQUES Rear suspension Tracking adjustment rod on Rear pivot Lower fixing of rear suspension cylinder on Rear pivot 7 ± 0,7 Suspension longitudinal arm on Rear pivot Suspension lower arm on Rear pivot Rear anti-roll bar bearing on Body 7,5 ±...

  • Page 160: Suspension Tightening Torques

    SUSPENSION: TIGHTENING TORQUES Rear suspension Upper fixing of rear anti-roll bar rod on Rear pivot Lower fixing of rear anti-roll bar rod on Rear anti-roll bar 4 ± 0,6 Fixing of rear anti-roll bar half-bearing 1,8 ± 0,4 B3DP0CRD...

  • Page 161: Draining-Filling-Bleeding The Hydraulic Steering/Suspension Circuit

    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. Start the engine. Place the vehicle in the low position. Stop the engine. Raise and support the vehicle, wheels hanging.
  • Page 162 DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Filling. Couple the hose (2) on the LDS fluid reservoir. Refit: - The clip (1). - The front RH splash-shield. - The front RH wheel. Lower the vehicle. "a" maximum level for the LDS fluid Fill the LDS fluid reservoir up to the maximum level for the LDS fluid "a".
  • Page 163 DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Bleeding. Connect tool [2] or [3] to the vehicle's diagnostic socket. Switch on the ignition. Perform a global test. Go into the menu: - Variable damping. - Bleeding the suspension circuit. Follow the instructions on the screen. Apply a pressure of 0.5 bar in the LDS fluid reservoir (using a tool FACOM 920).
  • Page 164 DRAINING, FILLING AND BLEEDING THE HYDRAULIC SUSPENSION/STEERING CIRCUIT Checking and topping up the LDS fluid level. NOTE: Checking the LDS fluid level is done with the vehicle in the forced low position (hydraulic suspension circuit depressurised). "a" Maximum level for the LDS fluid "b"...

  • Page 165: Power Steering Specifications

    POWER STEERING SPECIFICATIONS Top of column (1) Driver's airbag (2) Steering wheel (3) Controls under the steering wheel (4) Steering lock (5) Fixing of steering wheel on the shaft of the steering column C5FP0U2D Steering column (6) Steering column support (7) Fixing of steering cardan on the distributor valve stem B3EP17SD...
  • Page 166 POWER STEERING SPECIFICATIONS Steering mechanism The steering mechanism with integral ram is fixed on the front subframe by two studs. The steering assistance valve has groove technology. The hydraulic supply and return pipes are fixed on the steering assistance valve by means of a flange.
  • Page 167 POWER STEERING SPECIFICATIONS Steering assistance circuit (8) Steering assistance valve (9) Steering mechanism with integral ram (10) Low pressure piping (11) High pressure piping (12) Power steering pump (13) LDS fluid reservoir LDS fluid reservoir. The LDS fluid reservoir supplies the suspension circuit as well as the steering assistance circuit (fluid: LDS TOTAL H50126).
  • Page 168 POWER STEERING SPECIFICATIONS Setting the steering rack mid-point. IMPERATIVE: Respect the precautions to be taken prior to any operation (refer to the brochure "Recommendations-precautions"). Preliminary operation. Raise and support the vehicle on 2-column lift. Remove (on the RH side): - The clip (1). - The clip (2).

  • Page 169: Power Steering Tightening Torques

    POWER STEERING: TIGHTENING TORQUES Steering column Engines: ES9A - DT17BTED4 Steering wheel bolt 3,3 ± 0,5 Upper nuts 2 ± 0,3 Lower nuts 2 ± 0,3 Fixing of steering cardan on valve stem 2 ± 0,3 Union of hydraulic pipe on ram 1,4 ±...
  • Page 170 POWER STEERING: TIGHTENING TORQUES Steering assistance pump: Engines: ES9A - DT17BTED4 ES9A engine Fixation of steering assistance pump on support 2,5 ± 0,6 Fixation of pulley on steering assistance pump 0,8 ± 0,2 Fixation of pulley on steering assistance pump 2,2 ±...

  • Page 171: Checking The Steering Assistance Pressure (Es9A Engine)

    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...
  • Page 172 CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) Attach the tool [3a]. Do up: - The union [5] on the pipe (2). - The union [4] on the steering assistance pump. Connect the assembly [3] to the unions [4] and [5]. Tighten all the unions.
  • Page 173 CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) Checking the valve sealing. Remove the exhaust line (3). Move aside the heat shield from the steering mechanism. Slacken the union (6) on the power steering ram. Remove: - The screw (4). - The bracket (7). Uncouple the two supply pipes (5) from the distributor valve, and move them aside.
  • Page 174 CHECKING THE STEERING ASSISTANCE PRESSURE (ES9A ENGINE) Remove: - The exhaust line (3). - The tool [6]. Couple the two supply pipes (5) on the distributor valve. Refit: - The bracket (7). - The screw (4), tighten to 0,8 ± 0,1 m.daN. Retighten the union (6) on the power steering ram;...

  • Page 175: Bleeding The Hydraulic Steering Assistance Circuit

    BLEEDING THE HYDRAULIC STEERING ASSISTANCE CIRCUIT Precautions to be taken. Proceed with care so as to prevent any entry of polluting particles. IMPERATIVE: Respect the safety and cleanliness requirements. IMPERATIVE: Fill the LDS fluid reservoir with new fluid: TOTAL LDS. Bleeding.

  • Page 176: Brake Specifications

    BRAKE SPECIFICATIONS 3.0i 24S 2,7 24S Engine plate ES9A DT17BTED4 Master cylinder/diameter/travel 23,8 / 19,8/20,2/AFU (1) Amplifier/supplier/type 254 / TEVES / AMCT / AFT (2) Supplier/type/piston diameter TRW / C II 40 + 45 WE - 30-12 PE / 40 et 45 Disc diameter Ventilated Disc thickness/min.

  • Page 177: Braking System: General Specifications

    BRAKING SYSTEM: GENERAL SPECIFICATIONS Braking system Braking circuit Braking circuit in the form of an X. Disc brakes at the front and at the rear (vehicles all types): - The front brake discs are ventilated. - The rear brake discs are ventilated. Electric parking brake (FSE) acting via cables on the rear wheels.
  • Page 178 BRAKING SYSTEM: GENERAL SPECIFICATIONS ABS/ESP hydraulic valve block Components Supplier Reference Observations Located on the front LH chassis member: Hydraulic valve block 4 regulation channels VSC 440 25-way connector Integral to the hydraulic valve block 2-way black connector Front wheel sensor The sensors, of inductive type, are fitted on the pivot SIEMENS Air gap non-adjustable: 0.25 to 1.65 mm...
  • Page 179 BRAKING SYSTEM: GENERAL SPECIFICATIONS Parking brake (1) Electrically-controlled parking brake system (FSE) (2) Parking brake cables (3) Cable for manual unlocking of the electric parking brake (FSE). WARNING: It is forbidden to open the electric parking brake system in After Sales. If a malfunctioning of the electric parking brake is diagnosed, it is necessary to replace it.

  • Page 180: Braking System: Tightening Torques

    TIGHTENING TORQUES: BRAKING SYSTEM Front brakes Front brake disc 1 ± 0,1 Yoke on brake caliper 3 ± 0,2 Unions on brake piping 4 ± 0,5 Front brake caliper 11,5 ± 1 Hydraulic valve block on intermediate support 0,8 ± 0,2 Intermediate support on support Front wheel sensor 0,8 ±...
  • Page 181 TIGHTENING TORQUES: BRAKING SYSTEM Braking amplifier Braking amplifier on support Support on bulkhead 2,1 ± 0,3 Master-cylinder B3FP7HQD B3FP7HRD...
  • Page 182 TIGHTENING TORQUES: BRAKING SYSTEM Rear brakes Rear brake caliper 3,5 ± 0,3 Unions on brake piping 1,5 ± 0,1 Rear brake caliper support 10,8 ± 1 Rear wheel sensor 0,8 ± 0,1 B3FP7HSD B3FP7HTD...
  • Page 183 TIGHTENING TORQUES: BRAKING SYSTEM Parking brake Electric parking brake system (FSE) 0,4 ± 0,06 Nut for parking brake cables 6 ± 0,6 Gyrometer/accelerometer sensor on support 0,9 ± 0,1 Sensor support on body 0,4 ± 0,06 B3FP7HUD Gyrometer/accelerometer sensor B3FP7HVD...

  • Page 184: Values For Checking And Adjusting The Braking System

    VALUES FOR CHECKING AND ADJUSTING THE BRAKING SYSTEM Front brakes Rear brakes Engines ES9A - DT17BTED4 Engines ES9A - DT17BTED4 Type Ventilated brake discs Type Ventilated brake discs Diameter (mm) Diameter (mm) Nominal thickness (mm) Nominal thickness (mm) Minimum thickness (mm) Minimum thickness (mm) Difference in maximum thickness Difference in maximum thickness...

  • Page 185: General Feataures Of The Electric Parking Brake

    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).
  • Page 186 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 "a"...
  • Page 187 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"...
  • Page 188 GENERAL FEATURES OF ELECTRIC PARKING BRAKE Releasing of the electric parking brake (with a fault). NOTE: Impossible to release the parking brake with the method "Normal functioning". The fault may be caused by the following components: - Battery voltage. - Malfunctioning of the electric parking brake system. Open the central armrest.
  • Page 189 ELECTRIC PARKING BRAKE SYSTEM Removing-refitting the electric parking brake system. IMPERATIVE: Respect the safety and cleanliness requirements. WARNING: Before disconnecting the battery, partially open the door windows. Removing. IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables. IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in the central armrest, before operating on the parking brake cables.
  • Page 190 ELECTRIC PARKING BRAKE SYSTEM Uncouple the parking brake cable (6) from the brake caliper (on each side). Unclip the parking brake cable at "a" (on each side). Detach the brake cables from their attachments on the bodywork. B3FP7HHD Extract the manual unlocking cable of the electric parking brake from its location at "b". B3FP7HJD...
  • Page 191 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"...
  • Page 192 ELECTRIC PARKING BRAKE CABLES Removing-refitting the parking brake cables. IMPERATIVE: Respect the safety and cleanliness requirements. WARNING: Before disconnecting the battery, partially open the door windows. Removing. IMPERATIVE: Disconnect the battery prior to operating on the parking brake cables. IMPERATIVE: Perform a manual unlocking of the parking brake, using the handle located in the central armrest, before operating on the parking brake cables.
  • Page 193 ELECTRIC PARKING BRAKE CABLES Connector end. Unclip and push back the ring (4). Uncouple the parking brake cable (5). Manual unlocking cable end. B3FP7JOD B3FP7HYD Do up at «b». Uncouple the parking brake cable. B3FP7HZD...
  • Page 194 ELECTRIC PARKING BRAKE CABLES Refitting. Connector end. Clip the parking brake cable (5) at «c». Clip the ring (4). NOTE: Align the pin «d» with the notch «e». B3FP7J1D Do up the nut (3). Tighten the nut (3) to : 0,6 ± 0,1 m.daN. B3FP7J2D...

  • Page 195: The Electric Parking Brake

    ELECTRIC PARKING BRAKE CABLES Manual unlocking cable end. NOTE: Grease the cable worm (6). Engage the parking brake cable (6) into the electric parking brake system. Do up 3 turns anti-clockwise at "b". NOTE: Align the pin "g" with the notch "f". Do up the nut (3).

  • Page 196: Brake Fluid Checks

    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.

  • Page 197: Drain-Fill-Bleed The Braking System

    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]. Draining the brake fluid reservoir.
  • Page 198 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Filling the braking circuit. WARNING: Use only the approved and recommended hydraulic fluids. IMPERATIVE: Only use new brake fluid that has not emulsified; avoid any introduction of impurities into the hydraulic circuit. Fill the brake fluid reservoir (4). Bleeding the primary braking circuit.
  • Page 199 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.
  • Page 200 DRAINING, FILLING AND BLEEDING THE BRAKING SYSTEM Bleeding the secondary braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up. NOTE: Connect the bleeding apparatus [1] on the brake fluid reservoir (4). Use the diagnostic tools [2] or [3].

  • Page 201: Safety Requirements

    SAFETY REQUIREMENTS: ACTIVE SUSPENSION WITH VARIABLE DAMPING All operations on the hydraulic suspension circuit must be performed in conformity with the following requirements and regulations: Authorities competent in matters of health: - Accident prevention. - Environmental protection. WARNING: Operations should be carried out by specialised personnel who have had training in the safety requirements and precautions to be taken.
  • Page 202 SAFETY REQUIREMENTS: ACTIVE SUSPENSION WITH VARIABLE DAMPING During the operation. 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.

  • Page 203: Safety Requirements

    SAFETY REQUIREMENTS: ACTIVE SUSPENSION WITH VARIABLE DAMPING IMPERATIVE: Do not remain underneath the vehicle during an operation to adjust vehicle heights or during actuator (electrovalve) tests. IMPERATIVE: Any deforming of the wheel travel sensor supports is forbidden. If there is any deformation found, replace the component. Cleanliness requirements.

  • Page 204: Suspension Spheres: General Specifications

    SUSPENSION SPHERES: GENERAL SPECIFICATION Each suspension sphere is identified at "a", by one number and two letters, marked in bold characters: - The number consists of 2 digits, corresponding to the nitrogen pressure inside the suspension sphere. - The two letters identify the location of the suspension sphere. Other information marked on the suspension sphere: - Day of the year of manufacture.

  • Page 205: Suspension Spheres: Specification - Identification

    SUSPENSION SPHERES: SPECIFICATION - IDENTIFICATION Specifications. The «slimline» accumulators are grey in colour. NOTE: Recharging the «slimline» accumulators with nitrogen is impossible. Volume of nitrogen : 385 ± 15 cc. Suspension cylinder accumulators (front). Engine version Suspension sphere marking Pressure rating (bars) ES9A DT17BTED4 Suspension cylinder accumulators (rear).
  • Page 206 SUSPENSION SPHERES: SPECIFICATION - IDENTIFICATION Stiffness regulator accumulators (front). NOTE: The dampers are integral to the hydractive regulator. Engine version Suspension sphere marking Pressure rating (bars) ES9A DT17BTED4 Stiffness regulator accumulators (rear). NOTE: The dampers are integral to the hydractive regulator. Engine version Suspension sphere marking Pressure rating (bars)

  • Page 207: Depressurising The Hydraulic Suspension Circuit

    DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT 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.
  • Page 208 DE-PRESSURISING THE HYDRAULIC SUSPENSION CIRCUIT Front suspension: Undo the pressure release screw (1) by one turn. Wait for the pressure in the hydraulic circuit to drop fully. Rear suspension: Undo the pressure release screw (2) by one turn. Wait for the pressure in the hydraulic circuit to drop fully. B3BP1BED B3FP7HDD...

  • Page 209: Air Conditioning

    AIR CONDITIONING R 134.a (HFC) Compressor Refrigerant Variable Vehicle Engine version Date Refill Oil quantity (± 25 gr) capacity reference ES9A 12/05 SD 7 C16 SP 10 DT17BTED4...

  • Page 210: Special Features: Air Conditioning Circuit

    SPECIAL FEATURES: AIR CONDITIONING SYSTEM Compressor Condenser 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. NOTE: The filtering cartridge is not interchangeable.
  • Page 211 SPECIAL FEATURES: AIR CONDITIONING SYSTEM Tightening Requirements for fitting the inlet and outlet brackets: - Aircon compressor. - Aircon condenser. - Aircon pressure reducer valve. IMPERATIVE: Assembly requirement: the bracket(s) «f» must be against their interface(s) before the nut(s) are tightened. IMPERATIVE: Respect the tightening torques.

  • Page 212: Pollen Filter

    SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Pollen filter The pollen filter is located on the driver's side under the dashboard to the right of the steering column. IMPERATIVE: Respect the safety and cleanliness requirements. Removing. Remove the trim (1) under the dashboard (driver's side). Release the tab at "b".

  • Page 213: Checking The Compressor Oil Level

    SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Compressor lubricant ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level There are three specific cases: - 1) Repairs to a system without leaks. - 2) Slow leak. - 3) Fast leak.

  • Page 214: Checking The Compressor Oil Level

    SPECIAL FEATURES: AIR CONDITIONING SYSTEM (R 134.a) Checking the compressor oil level (continued) 2) Slow leak. Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3) Fast leak. This type of leak causes both oil loss as well as allowing air to enter the system.

  • Page 215: Checking The Efficiency Of

    CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Equipment: EXXOTest Equipment:VALEO Tooling (tools and Equipment flash). Tooling. Exxoclim : 2.4.2-1. Clim test 2 : 4372-T. Method of use : See instructions. Method of use : See instructions. E5AP2N5D E5AP2N4D...
  • Page 216 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Testing procedure. Checking. Position the equipment - Exxoclim or Clim test 2 - (see instructions). Preliminary operations. Close all the front air vents. Start the engine. Open the front air vent. Activate the «air conditioning» control. Position the air distribution control to «frontal flow».
  • Page 217 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Reminder (for information) Under-cooling. The under-cooling represents the difference between the condensation temperature and the aircon fluid temperature at the aircon condenser outlet. The under-cooling gives the quantity of aircon fluid (in the liquid state) in the air conditioning circuit. Values for under-cooling (SR).
  • Page 218 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Possible causes Aircon compressor clutch Lack of aircon fluid in the aircon circuit The clutch of the aircon compressor does not Aircon pressostat engage, or disengages suddenly Aircon evaporator sensor The aircon compressor does not turn...
  • Page 219 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Possible causes Incorrect adjustment of the aircon compressor clutch The clutch of the aircon compressor Aircon fluid quantity remains engaged Aircon compressor defective The aircon compressor makes an abnormal Lack of aircon fluid in the aircon circuit noise...
  • Page 220 CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Possible causes Aircon pressure reducer defective Low pressure and high pressure too high Duct clogged Low pressure too high and high pressure too low Aircon compressor seal defective Aircon evaporator sensor defective Low pressure too low and high pressure too high...

  • Page 221: Checking The Efficiency Of

    CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM Aircon circuit diagnosis table (for information) Principal problem Symptom Possible causes Low pressure normal and high pressure too high Presence of air in the aircon circuit Aircon pressostat defective Low pressure normal and high pressure too low Evaporator sensor defective Abnormal levels of pressure Low pressure too high and high pressure normal...

  • Page 222: Air Conditioning Circuit: Es9A

    AIR CONDITIONING SYSTEM R.134.a Engine: ES9A Tightening torques (m.daN). (1) High pressure valve (2) Low pressure valve (3) Pressure reducer (4) Pressure reducer outlet, tighten to : 0,6 (5) Pressure reducer inlet, tighten to : 0,6 (6) Clickfit union, tool : 8005-T.A Black (7) Compressor inlet, tighten to : 0,7...
  • Page 223 AIR CONDITIONING SYSTEM R.134.a Engine: DT17BTED4 Tightening torques (m.daN). (1) High pressure valve (2) Low pressure valve (3) Pressure reducer (4) Pressure reducer outlet, tighten to : 0,6 (5) Pressure reducer inlet, tighten to : 0,6 (6) Clickfit union, tool : 8005-T.A Black (7) Compressor inlet, tighten to : 0,7...

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