ESP CITROEN C6 2005 Owner's Manual

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ENGINE
71
EXHAUST SPECIFICATIONS
Engine: DT17BTED4
Repair.
Respect the precautions to be taken prior to any operation:
- The front flexible pipe must be protected against any external mechanical damage.
- The front flexible pipe must not come into contact with corrosive products.
- Do not deform the front flexible pipe more than 20°angular (X), 20 mm axial, 25 mm shearing
(Y) (front flexible pipe removed).
- 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
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ENGINE
DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT
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.
Draining.
Remove the header tank cap with caution (engine cold).
Open the bleed screw of the radiator.
Slacken the drain screw (1)of the radiator
Open the plug (2)to drain the first bank of cylinders.
NOTE:The plug (2)is provided with a drain tube.
B1GP0BPC
Engine: ES9A
B1BP2BNC
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ENGINE
DRAINING, FILLING AND BLEEDING THE ENGINE COOLING CIRCUIT
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.
Draining.
Remove the header tank cap.
Open the bleed screw of the engine cooling radiator, located under the radiator on the LH side.
Remove the drain screw (1).
Drain the cylinder block.
Engine: DT17BTED4
B1GP0CNC
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INJECTION
BOSCH ME 7.4.7 INJECTION SYSTEM
Engine: ES9AElectrical circuit
Component Location Supplier Reference Observations
Inlet air temperature sensor 27 JAEGER 402 084 012-way greyconnector
Fixing: on the air filter inlet duct
Camshaft position
13 ELECTRICFIL14 43 2514 43 3-way grey connector
sensor25
Fixing: on the inlet camshaft bearing cap cover
3-way green connector
Knock sensor 23 BOSCH 0 261 231 10 Fixing: on the central part of the «V»of the engine block
Essential to respect tightening torque: 2 ± 0,5 m.daN
DAV 402 243 032-way greenconnector
Engine coolant temperature 22Fixing: on the coolant outlet housing
sensor
14 43 32Tightening torque:
ELECTRICFILTighten to: 2 ± 0,2 m.daN
Engine speed sensor 12 14 43 282-way blackconnector
Fixing: on the gearbox clutch housing
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INJECTION
SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM
Safety requirements.
Preamble.
All interventions on the injection system must be carried out to conform
with the following requirements and regulations:
- Competent health authorities.
- Accident prevention.
- Environmental protection.
WARNING: Repairs must be carried out by specialised personnel
informed of the safety requirements and of the precautions to be
taken.
Safety requirements.
IMPERATIVE: Take into account the very high pressures in the high
pressure fuel circuit (1600 bars), and respect the requirements
below:
- No smoking in proximity to the high pressure circuit when work is being
carried out.
- Avoid working close to flame or sparks.
Engine running:
- Do not work on the high pressure fuel circuit.
- Always stay clear of the trajectory of any possible jet of fuel, which could
cause serious injuries.
- Do not place your hand close to any leak in the high pressure fuel circuit.After the engine has stopped, wait 30 secondsbefore any intervention.
NOTE:This waiting time is necessary in order to allow the high pressure
fuel circuit to return to atmospheric pressure.
Cleanliness requirements.
Preliminary operations.
IMPERATIVE: The technician should wear clean overall.
Before working on the injection system, it may be necessary to
clean the apertures of the following sensitive componen (refer to
corresponding procedures):
- Fuel filter.
- Fuel high pressure pump.
- Fuel high pressure common injection rail.
- Fuel high pressure pipes
- Diesel injector carriers.
IMPERATIVE: After dismantling, immediately block the apertures of
sensitive components with plugs, to avoid the entry of impurities.
Work area:
- The work area must be clean and free of clutter.
- Components being worked on must be protected from dust.
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INJECTION
CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT
Engine: DT17BTED4
Tools.
[1] Ø 10 mmlow pressure connector: 4215-T
[2] Ø 8 mmlow pressure connector: 4218-T
[3]Pressure gauge for testing boost pressure: 4073-T Kit 4073-T
[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].
WARNING: Any check of pressure downstream of the fuel filter is prohibited.
NOTE:To check the pressures while the vehicle is being driven, insert the extension [4] between
tool [3]and tools [1]or [2].
B1BP3CRD
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INJECTION
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] LEXIAdiagnostic tool: 4171-T
[4] PROXIAdiagnostic 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
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INJECTION
CHECKING THE AIR SUPPLY CIRCUIT
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.
The value should be 0,85 ± 0,2 bar.
"Swirl" control electrovalve.
Connect the tool [1]on the vacuum supply "b"of the electrovalve (2).
Start the engine.
The value should be 0,85 ± 0,2 bar.
"Swirl" control diaphragm.
Connect the tool [1]on the "Swirl"control diaphragms (3)at "c".
Apply a vacuum of approx. 0,7 ± 0,2 bar, the "Swirl"butterfly should be fully
open.
Engine: DT17BTED4
B1HP26ECB1HP26DC
B1HP26FC
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CLUTCH
GEARBOX
TRANSMISSION
AM6 GEARBOX CONTROLS: «SHIFT LOCK» FUNCTIONIMPERATIVE: 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).
Should it be impossible to unlock the «shift lock»with the «Normal operation»method.
The fault may originate from one of the following components:
- «Shift lock».
- 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
Engines: ES9A - DT17BTED4
C5FP0RBC
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CLUTCH
GEARBOX
TRANSMISSION
DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX
Tool.
[1] Filling cylinder: (-).0340
Respect the safety and cleanliness requirements.
Draining.
IMPERATIVE: Draining of the gearbox must be done with the oil hot (60°C minimum), in order to
ensure that the impurities in suspension in the oil are eliminated.
NOTE:Drainage is only partial, as the torque converter cannot be drained totally.
Raise the vehicle.
Remove:
- The oil level plug (2)by means of the Torx spanner.
- The drain plug (1)using a hexagonalspanner.
NOTE :Around 3 litresof oil should flow out.
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].
B2CP3WZCB1BP317C
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