Get Clutch, Gearbox, Transmission Guide for Citroen C6 4 Door First Generation (2005-2012)

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» and the speed travelled «ST», there must always be the following relationship:

ST < SD < 1.10 ST + 4 Kph

Example: For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph.

The speed indicated by the speedometer may be influenced by:

- 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

AM6 AUTOMATIC GEARBOX SPECIFICATIONS

Vehicle

C6

Engine

Gearbox type

Sequence

Torque ratio

Drive ratio

ES9A

20 GH 07

20 GG 07

49 X 52

54 X 47

AM6

15 x 53

DT17BTED4

102

PROCEDURE PRIOR TO OPERATIONS: AM6 AUTOMATIC GEARBOX

Engines: ES9A - DT17BTED4

If a gearbox malfunction occurs, there are two possible configurations

depending on the seriousness of the fault:

Oil level.

- Gearbox in back-up mode with a replacement programme of (the fault

values are taken in substitution).

- Gearbox in back-up mode with an emergency programme (3rd hydraulic).

Preliminary conditions:

- Vehicle horizontal, parking brake off.

- Check that the gearbox is not in back-up mode (using a diagnostic tool).

- The oil temperature should be 60°C (+8, -2) (using a diagnostic tool).

- Press on the brake pedal, change through all the gears.

- Place the gear lever in position P.

WARNING: In the emergency programme, an impact is felt when

changing P/R or N/R.

Reception of the customer.

Discuss with the customer, to find out all the malfunction symptoms.

With the engine running at idle, without power consumers (aircon,

heating, etc.):

- Remove the oil level plug.

The oil should flow out, then drip-drip.

Refit the oil level plug (the oil level is correct).

The oil does not flow out through the oil level plug (see operation: drain

fill - bleed the gearbox).

Oil quality.

If the gearbox has suffered a serious fault resulting in a malfunction or

the destruction of a clutch, the oil will overheat and become

contaminated with impurities: the oil is said to be «burnt».

This is characterised by a black colour and the presence of an

unpleasant smell.

ESSENTIAL: The gearbox must be replaced.

103

PRECAUTIONS TO BE TAKEN : AM6 AUTOMATIC GEARBOX

Engines: ES9A - DT17BTED4

Precautions to be taken

Towing.

The front of the vehicle must be raised in order to be towed.

If the front of the vehicle cannot be raised.

When performing electrical checks:

- The battery should be correctly charged.

- Never use a voltage source higher than 16V.

- Never use a test lamp.

IMPERATIVE:

- Put gear lever in position «N».

- Do not add any oil.

- Do not exceed 70 km/h (45 mph) over a distance of 100 km (60 miles)

maximum.

Repairs on mechanical components.

Never place the gearbox on the ground without protection.

Do not use the unions on the gearbox as handles for moving the

gearbox.

It is imperative that the converter retaining peg should be in place

when removing the gearbox.

It is imperative to use the centring pegs to couple the gearbox on the

engine.

Remove the converter retaining peg before coupling the gearbox on

the engine.

Driving.

Never drive with the ignition switched off.

NOTE: The automatic gearbox is only lubricated when the engine is

running.

Repairs on electrical components.

Do not disconnect:

- The battery when the engine is running.

- The ECU when the ignition is switched on.

Before reconnecting a switch, check:

- The condition of the various contacts (for deformation, corrosion etc.)

- The presence and condition of the mechanical locking.

104

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" Date of manufacture

"f" Homologation code (PSA)

"g" ECU no. (PSA)

"h" Bar code (PSA)

"j" Gearbox no. (PSA)

"k" Bar code (AISIN)

"l" Serial no.

Specifications

Weight

Torque capacity

: 93 kg (approx.).

: 33 m.daN.

B2CP3YSC

105

AM6 GEARBOX: TIGHTENING TORQUES

Engines: ES9A - DT17BTED4

1

2

3

Automatic gearbox heat exchanger

4,2 0,4

1,5 0,2

Hydraulic valve block casing

Filler plug

4

0,4

Torque converter screw [(ES9 3 screw) (DT17 6 screw)]

Pre-tightening

Slackening

Tightening

2

100°

6

0,2

0,6

4

B2CP42WD

5

6

7

8

9

Sleeve stop

3,5 0,3

5,5 0,5

0,8 0,1

Gearbox support

Engine speed sensor (ES9J4)

Fixing of gearbox on cylinder block

Closing panel fixing

6

2

0,6

0,2

B2CP42XD

106

AM6 GEARBOX: TIGHTENING TORQUES

Engines: ES9A - DT17BTED4

12

11

12

13

14

15

Oil induction cover

1

0,1

Hydraulic valve block (in the order indicated)

Oil temperature sensor tightening plate

ECU screws

2,5 0,2

0,1

4,8 0,5

Oil drain and overflow plug

Oil level plug

1

B2CP42YD

B2CP42ZD

107

AM6 GEARBOX CONTROLS

Engines: ES9A - DT17BTED4

The gear selector is guided by the shape of the stepped gate and by a retaining spring which

pulls it to the left hand side.

The gear control has 5 positions:

- Position "P": parking (locking and immobilisation of the vehicle).

- Position "R": reverse gear.

- Position "N": neutral.

- Position "D" : drive (for use of the 6 gears in autoadaptive automatic operation).

- Position "M": manual (this position allows the driver to select his gears in one-touch mode by

pulling "M -" or pushing "M +" on the gear selector).

NOTE: Only positions "P" or "N" authorise starting of the engine.

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

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 ; 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

has limited adhesion.

To revert to the normal programme, you have to press a second time on the sport or snow

switch.

B2CP430D

109

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” to lock the adjustment of the control.

B2CP431C

110

AM6 GEARBOX CONTROLS: «SHIFT LOCK» FUNCTION

Engines: ES9A - DT17BTED4

IMPERATIVE: Respect the safety and cleanliness requirements, with reference to the brochure:

«Recommendations-Precautions».

The «shift lock» is a system that locks the gear selection lever in position «P».

Unlocking the «SHIFT LOCK» (normal operation).

Switch on the ignition.

Press the brake pedal and keep it pressed.

Move the gear selection lever out of position «P».

Unlocking the «SHIFT LOCK» (with an operating fault).

Should it be impossible to unlock the «shift lock» with the «Normal operation» method.

C5FP0RBC

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

111

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.

112

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).

113

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.

B1BP317C

Remove:

- The oil level plug (2) by means of the Torx spanner.

- The drain plug (1) using a hexagonal spanner.

NOTE : Around 3 litres of 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].

B2CP3WZC

114

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.).

Refit the filler plug (3) (with a new seal).

Tighten the plug (3) to

Initialise the oil usage counter (follow the procedure in the diagnostic tool).

: 4 1 mdaN.

B1BP317C

Checking the oil level.

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

DRAINING, FILLING AND TOPPING UP THE AM6 AUTOMATIC GEARBOX

Thread of oil, then "drip-drip".

Refit the level plug (2).

Tighten the plug (2) to

: 0.8 0,1 mdaN.

"drip-drip" or nothing.

Refit the level plug (2).

Stop the engine.

Add 0.5 litre of extra oil into the gearbox.

Repeat the topping-up procedure.

NOTE: The level is correct when the thread of oil becomes "drip-drip".

Refit the level plug (2) (with a new seal).

B1BP317C

Tighten the plug (2) to

: 0.8 0,1 mdaN.

Refit the filler plug (3) (with a new seal).

Tighten the plug (3) to

: 4 1 mdaN.

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

CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX

Tools.

[1] Flexible pipe and pressure gauge

[2] Flexible union

: 4601- TF1 Toolkit 4601-T

: (-).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).

Remove the screw (2).

Screw in the tool [2] in place of the screw (2).

B2CP45GC

117

CHECKING THE OIL PRESSURE IN THE AM6 AUTOMATIC GEARBOX

WARNING: Clean the flexible pipe of the tool [1] each time before use; the different

automatic gearbox oils cannot be intermixed.

Fit the tool [1] on the tool [2].

Perform the following operations:

- Raise the vehicle, wheels hanging.

- Apply the parking brake.

- Start the engine.

- Check the oil pressure.

WARNING: Wait for the gearbox oil to reach a temperature between 58°C and 68°C.

Check the level of oil in the gearbox (see corresponding operation).

NOTE: Check the temperature of the oil using the diagnostic tool in parameter measures.

Gear lever position

Engine speed

Principal oil pressure

: D.

: Idling.

: 3.7 to 4.2 bars.

B1BP3END

118

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.

- Gear lever in position D.

- Press on the brake pedal.

- Accelerate the engine to the maximum engine speed (see below).

Gear lever position.

Maximum engine speed for ES9A

Maximum engine speed for DT17

: D.

: 2400 50 rpm.

: 2600 50 rpm.

Diagnosis:

- 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

TRANSMISSION

Gearbox oil seal mandrels

Tightening torques (m.daN)

Driveshaft

bearing

Driveshaft

nut

Engines

Right

(-).0336.U

Left

Tool kit

Vehicle

C6

Gearbox

AM6

(-).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

Alloy

CITROËN

9

1

DT17BTED4

120

Clutch, Gearbox, Transmission for Your Citroen C6 4 Door First Generation (2005-2012)

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