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Downloaded from www.Manualslib.com manuals search engine GENERAL
Vehicle identification1 - 4
General specifications: dimensions 5 - 6
General specifications: weights7
Operations to be performed before and
after a disconnection of the battery8
Towing specifications9 - 10
Lifting and supporting the vehicle11 - 15
Capacities18
Lubricants18 - 20
ENGINE
Engine specifications22
Engine suspension tightening torques: ES9A23
Tightening torques: ES9A engine24 - 28
Suspension tightening torques: DT1729 - 31
Adjustment of torque reaction rod32
Tightening torques: DT17 engines33 - 41
Cylinder head tightening42 - 43IGNITION
Sparking plugs100
CLUTCH - GEARBOX - TRANSMISSION
Speedometer101
AM6 automatic gearbox specifications
102
Procedure before operations103
Precautions: AM6 gearbox104
AM6 gearbox specifications105
Tightening torques: AM6 gearbox106 - 107
AM6 gearbox control specifications 108 - 110
Shift lock function111
Initialisation of the AM6 gearbox112 - 113
Draining-filling-topping up
the AM6 gearbox114 - 116
Oil pressure checks: AM6 gearbox117 - 119
Transmission120
CONTENTS
Auxiliary equipment drive belt45
Checking and setting the valve timing50
Exhaust line specifications68 - 72
Cooling system specifications73 - 75
Checking the oil pressure76
Valve clearances77
Drain-fill-bleed the engine cooling circuit78 - 82
INJECTION
BOSCH 7.4.7 injection system83 - 89
Prohibited operations: SIEMENS HDi
direct injection90 - 91
Safety requirements: HDi direct injection92
Checking the low pressure fuel
supply circuit 93 - 94
Turbo pressure checks95 - 97
Air supply circuit specifications98
Checking the air supply circuit99
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Downloaded from www.Manualslib.com manuals search engine AXLES - SUSPENSION - STEERING
Wheels and tyres121 - 124
Checking and adjusting the vehicle height125 - 128
Values for checking and adjusting
the axle geometries129 - 133
Front axle134 - 135
Front axle tightening torques136 - 139
Rear axle140 - 141
Rear axle tightening torques142 - 143
Active suspension with variable damping144 - 149
Suspension tightening torques150 - 154
Draining-filling-bleeding
the hydraulic steering/suspension circuit155 - 158
Power steering specifications159 - 162
Power steering tightening torques163 - 164
Checking the steering assistance
pressure (ES9A engine)165 - 168
Bleeding the hydraulic steering
assistance circuit169AIR CONDITIONING
Quantities: aircon system R134.a 203
Special features: air conditioning circuit 204 - 205
Pollen filter206
Checking the compressor oil level207 - 208
Checking the efficiency of
the air conditioning circuit209 - 215
Air conditioning circuit: ES9A216
Air conditioning circuit: DT17217
CONTENTS
BRAKES
Brake specifications170
Braking system: general specifications171 - 173
Braking system: tightening torques174 - 177
Values for checking and adjusting
the braking system178
General feataures of
the electric parking brake179 - 189
Brake fluid checks190
Drain-fill-bleed the braking system191 - 194
HYDRAULICS
Safety requirements:
active suspension with variable damping195 - 197
Suspension spheres: general specifications 198
Suspension spheres:
specification - identification199 - 200
Depressurising the hydraulic
suspension circuit201 - 202
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ENGINE
ENGINE TIGHTENING TORQUES
Lubrication
19 Oil filter cover 2,3 ± 0,3
20 Oil filter support
0,9 ± 0,221 Oil/coolant heat exchanger22 Oil pressure switch 1,3 ± 0,223 Oil pump assembly 0,9 ± 0,224 Oil gauge 2,3 ± 0,325 Oil level sensor 2,7 ± 0,526 Oil sump 0,9 ± 0,227 Drain plug 2,3 ± 0,328 Oil suction strainer 0,9 ± 0,129 Piston skirt spray jets 1 ± 0,130 Turbocharger lubrication pipe 0,9 ± 0,231 Turbocharger lubrication pipe 1,3 ± 0,3Engine: DT17BTED4
B1DP1M6P
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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.BisX
4103-TX
(-).1503.KX
4202-T X
NOTE: Oil pressure should be checked with the engine cold, after checking the oil level.
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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
(25)Integrated pressure sensor
(26)Accelerator pedal position sensor
(27)Inlet air temperature sensor
(28)Diagnostic connector
(29)Ignition injection ECU
B1HP1Z9P
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CLUTCH
GEARBOX
TRANSMISSION
PROCEDURE FOR INITIALISATION OF THE AUTOMATIC GEARBOX ECU
NOTE:For all these operations, follow the procedure in the diagnostic tool.
Replacement of the automatic gearbox without replacement of the ECU.
Carry out the following operations:
- Initialisation of the neutral position of the gear selection lever position sensor.
- Initialisation of the adaptation of the oil pressure regulators and electrovalves.
- Initialisation of the autoadaptatives.
- Resetting the oil usage counter to zero.
Replacement of the automatic gearbox ECU.
Carry out the following operations:
- Read the value of the gearbox oil usage counter from the old ECU.
- Write the value of the oil usage counter into the new ECU.
- Initialisation of the neutral position of the gear selection lever position sensor.
- Initialisation of the adaptation of the oil pressure regulators and electrovalves.
- Initialisation of the autoadaptatives.
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CLUTCH
GEARBOX
TRANSMISSION
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.
Carry out the following operations:
- Initialisation of the adaptation of the oil pressure regulators and electrovalves.
- Resetting the oil usage counter to zero.
NOTE:If downloading the automatic gearbox ECU, there is no specific operation, follow the procedure in the diagnostic tool.
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).
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CLUTCH
GEARBOX
TRANSMISSION
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.
Preliminary operations.
Remove the air filter housing.
Move aside the pipe (1).
Remove the screw (2).
Screw in the tool [2]in place of the screw (2).
B2CP45GCB2CP45FC
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