A--T0DK1 - 406D9 DAM FROM : 8421XX MODIFICATIONS 2000 …cdr.fastmail.fm/pug/manual/Data - D9 Coupe Modifications.pdf · The ES9J4S/L4 engine incorporates the following developments

A--T0DK1 - 406D9 DAM FROM : 8421XX

MODIFICATIONS 2000 1/2 MODEL YEAR

Modifications for 2000 1/2 model year for the 406 range are as follows :

● modification : engines : ● modification : equipment ● modification : electrical equipment

1 - ENGINE ES9J4S/L4

4 DOOR SALOON DAM FROM : 842189 ESTATE DAM FROM : 842189

.

COUPE DAM FROM : 8421U5

ALL MODELS

Replacement of the ES9J4/L3 engine by the ES9J4S/L4 engine .

1 - 1 - IDENTIFICATION

(1) Identification marking comprising :

● (A) the component reference ● (B) the legislation type ● (C) serial number

1 - 2 - DATA

engine type ES9J4S/L4 ES9J4S/L4

engine code XFX

special feature manual gearbox automatic gearbox

unit reference 10FJ2C 10FJ2L

number of cylinders 6

bore x stroke (mm) 87 x 82.6

capacity (cm3) 2946

compression ratio 10.9/1

maximum power (KW - EC) 152

maximum power (HP DIN) 210

engine speed at max. power (r.p.m.) 6000

maximum torque (da.Nm - EC) 28.5

engine speed at max. torque (r.p.m.) 3750

turbocharger N/A

exchanger N/A

injection system one-touch

make BOSCH

type ME7.4

1 - 3 - MAIN CHANGES

The ES9J4S/L4 engine incorporates the following developments compared with the ES9J4/L3 engine :

● fitting of a variable timing system, to improve the torque and consumption, consisting of 2 vtc's (variable timing camshaft) located on the intake camshafts, with this variable timing system it is possible to vary the camshafts setting by 15 o

● new inlet manifold (replacement of the short and long ducts by 6 ducts of equal length) ● addition of a water/oil heat exchanger on the engine (manual gearbox versions) ● new flexible engine flywheel which improves driveability by absorbing engine vibrations

(manual gearbox versions) ● new emission control standard L4 obtained by 2 extra pre-catalysers linked to 4 lambda sensors,

in addition to the 2 catalytic converters, and a new combustion chamber ● new multiple jet injectors ● injection system BOSCH ME7.4.6 for managing eobd and incorporating management of the

cooling (FRIC (cooling function integral with the ECU)) ● addition of a body accelerometer for the eobd function ● ignition provided by 6 BAC1 model pencil coils ● presence of a motorised throttle controlled by the engine management ecu

NOTE : EOBD : European On Bord Diagnosis : diagnosis of the emission control equipment .

2 - MODIFICATION : EQUIPMENT

New audio system amplifierJBL .

The role of the audio system amplifier is to give better reception and sound quality .

This amplifier is located behind the audio system .

3 - MODIFICATION : ELECTRICAL EQUIPMENT

3 - 1 - MODIFICATION OF HARNESSES

The electrical harnesses are undergoing modifications : Refer to the wiring diagram .

Removal of the wheel anti-lock braking system harness :

● the front wheel anti-lock braking system sensors and the ecu are incorporated in the main harness ● the rear wheel anti-lock braking system sensors are incorporated in the passenger compartment

harness

3 - 2 - FUSE BOX

Modifications have appeared to the fusebox and/or the fuses (Refer to the wiring diagram) .

3 - 3 - CONNECTIONS

Reverse connector with SICMA 2 connectors .

A--T0GK1 - 406D9

MODIFICATIONS - METHOD(S) 406

From 01/07/2000, reference to model year discontinued for all vehicles .

Development of 406 range characterised by :

● style ● engine ● the fuel system ● the gearboxes ● the brakes ● equipment ● the electronic structure ● the electrical connections

1 - STYLE

1 - 1 - LEVEL 1 (SR)

The level 1 saloons and estates are fitted with :

● side mouldings with chrome plated inserts ● body colour door handles ● fascia with wood effect inserts

1 - 2 - LEVEL 2 (ST)

The level 2 saloons and estates are fitted with :

● door panels with wood effect inserts ● side sill trims ● front seat armrests

1 - 3 - LEVEL 3 (SV)

Level 406 3 are fitted with leather pack equipment as standard .

1 - 4 - ST PACK SPORT VERSIONS

The ST PACK SPORT versions are fitted with special equipment in relation to level 406 2 .

Exterior styling :

● 16" alloy wheels ● chrome plated exhaust nozzle ● body colours : Piana Blue ; Delft Blue ; Bianca White ; Platinum Silver ; Cossack Grey ;

Obsidian Black

Interior styling :

● instrument panel from the coupé ● leather steering wheel with blue cross-stitching ● leather gear lever knob with blue cross-stitching ● half-leather half-cloth trim with double blue stitching ● leather door panels with blue stitching ● bluish brushed aluminium effect front and rear door mouldings and fascia ● front and rear mats with blue stitching

Standard equipment :

● audio equipment RD2 with cd player

Optional equipment :

● satellite navigation system and cd rom ● sun roof ● audio equipment RM2 with cassette player, cd changer and amplifier JBL ● audio equipment RM2 with cassette player and cd changer ● electric front seats ● cruise control (all engines, except for ES9J4S - standard)

2 - ENGINE EW12J4/L4

Introduction of the EW12J4/L4 engine with ML5T gearbox .


Engine type reference plate including :

● (a) : legislation type ● (b) : unit reference ● (c) : build order number

2 - 2 - DATA

engine type EW12J4/L4

legislation type 3FZ


bore x stroke (mm) 86 x 96

capacity (cm3) 2230


maximum power : EU standards (KW) 116

maximum power : standard DIN (HP) 160


maximum torque : EU standards (da.Nm) 21.7



make MAGNETI MARELLI

type 4MP

catalytic converter yes

3 - ENGINE EW7J4/IFL5 (TAX INCENTIVE)

Introduction of the EW7J4/IFL5 engine with BE4 gearbox .

The engine structure is identical to that of the EW10J4 engine .




3 - 2 - DATA

engine type EW7J4/IFL5 (tax incentive)

legislation type 6FZ


bore x stroke (mm) 82.7 x 81.4

capacity (cm3) 1749







injection system multipoint

make SAGEM

type S2000


4 - ENGINE EW10J4/IFL5 (TAX INCENTIVE)

Introduction of the EW10J4/IFL5 engine with BE4 gearbox .

The engine structure is identical to that of the EW10J4/L4 engine .




4 - 2 - DATA

engine typeEW10J4/IFL5 (tax

incentive)

legislation type RFN



capacity (cm3) 1997





maximum torque : EU standards (da.Nm) 19



make MAGNETI MARELLI

type 4.8 P


5 - ENGINE EW10D/L4

The range is extended by the introduction of the EW10D/L4 engine ( Petrol direct injection) .

The EW10D engine is fitted with the BE4 manual gearbox .

Petrol direct injection permits operation with a lean mixture and thus reduction of petrol consumption .

In addition, the EW10D engine is fitted with 15° vtc (variable timing camshaft) identical to EW10J4 permitting improvement of the torque at low engine speeds .

This engine is characterised by 3 types of modification in relation the EW10J4 engine :

● inlet ducts ; combustion chamber ● high pressure direct injection

● emission control




5 - 2 - DATA

engine type EW10D/L4

legislation type RLZ



capacity (cm3) 1998







injection system high pressure multipoint

make SIEMENS

type SIRIUS 81


Quantity of oil with replacement of the filter cartridge: 4.25 litre(s) .

5 - 3 - MOTOR OPERATION

The petrol direct injection engine is controlled by the engine management ecu in line with two operating modes :

● uniform mixture operation ● stratified lean mixture operation

Uniform mixture operation :

● the petrol is injected during the inlet phase ● the gas recirculation rate (egr) is low ● the engine load is controlled by the throttle housing

This operating mode is similar to petrol indirect injection .

Stratified lean mixture operation :

● the petrol is injected just before ignition, during the compression phase, near the spark plug ● the gas recirculation rate (egr) is high, around 30 % ● the engine load is controlled by variation of the flow injected ● the motorised throttle housing is in the open position

The high pressure injection pump driven at the end of the camshaft, clutch side, delivers between 70 and 120 bars .

The injection rail is fitted with a pressure sensor and a pressure regulator permitting the return of fuel to the high pressure pump inlet to regulate the petrol pressure in the rail .

5 - 4 - ENGINE STRUCTURE

The pistons are specific with an adapted bowl at the injector jet .

The cylinder head with 4 valves per cylinder and 2 camshafts is specific ; The air inlet pipes (1) are incorporated in the cylinder head, their position is almost vertical .

The shape of the piston combined with the position of the air inlet pipes (1) and of the injector (2) create a swirl (inverse tumble) permitting the following actions :

● ensure that the mixture is uniform during conventional operation (I) ● direct the small quantity of petrol towards the spark plug during lean mixture operation (II)

5 - 5 - ENGINE CHECK

The engine management assembly is controlled by an ecu SIEMENS of the SIRIUS 81 type .

This ecu is fitted with a flash eprom memory .

In relation to the EW10J4 engine, this ecu controls the following additional functions :

● calculation of the engine load ● engine synchronisation ● driving pleasure ● driver's engine torque requirement (input of accelerator pedal position) ● cruise control ● exhaust gas emission control

● braking vacuum management ● air conditioning cooling requirement ● air conditioning compressor management ● electrical energy management ● can network multiplexing

5 - 6 - EXHAUST GAS EMISSION CONTROL

The exhaust line consists of :

● (3) exhaust manifold ● (6) tri-function pre-catalyst fitted with upstream (4) and downstream (9) temperature sensors ● (5) proportional oxygen sensor upstream of the pre-catalyst ● (8) denox catalytic converter ● (7) on/off oxygen sensor at the catalytic converter outlet

The temperature sensors permit checking of the effectiveness of the pre-catalyst .

The proportional oxygen sensor enables the ecu to adjust the richness of the mixture .

Operation in lean mixture mode produces a large quantity of nitrogen oxide (nox) which the pre-catalyst cannot eliminate sufficiently. the role of the catalytic converter is to reduce the amount of nitrogen oxide in the exhaust gas .

The denox catalytic converter stores the nitrogen oxide during the phases of operation in lean mixture mode .

The engine management ecu estimates how full the catalytic converter is using the information supplied by the pre-catalyst downstream temperature sensor and triggers the switch to rich mixture mode ; The switch to rich mixture mode causes the release of the nitrogen oxide (nox) by providing hydrocarbons .

The downstream oxygen sensor permits detection of the end of purging (presence of hydrocarbons) .

6 - ENGINE ES9J4S/IFL5 (TAX INCENTIVE)

Replacement of the ES9J4S/L4 engine by the ES9J4S/IFL5 engine .

6 - 1 - DATA

engine type ES9J4S/IFL5 (tax incentive)

legislation type XFX


bore x stroke (mm) 87 x 82.6

capacity (cm3) 2946








make BOSCH

type ME7.4.6


7 - ENGINE DW12TED4

Introduction of the DW12TED4 engine with particulate emission filter .




7 - 2 - DATA

engine type DW12TED4

legislation type 4HX



capacity (cm3) 2179

compression ratio 18/1




maximum torque : EU standards (da.Nm) 4000

engine speed at max. torque (r.p.m.) 31.5

injection system HDI

make BOSCH

type EDC15C2


7 - 3 - ACCESSORIES

Only one ancillary drive system version is available with the following options :

● air conditioning ● power steering

(10) Automatic roller tensioner .

(11) Fixed idler roller .

(12) Alternator pulley with free wheel .

7 - 4 - PARTICLE FILTER

The particulate emission filter positioned after the catalytic converter traps the particles of carbon which are then burned during the regeneration phases .

The additive added to the fuel automatically every time the tank is filled permits lowering of the soot combustion temperature ; The additive reservoir is taken from the 607 (capacity 5 litres) .

The particulate emission filter is controlled by the engine management ecu and by the diesel additive ecu; its operation is identical to 607 .

The 4 point clamp between the catalytic converter and the particulate emission filter is specific; the particulate emission filter 406 is shorter than the particulate emission filter 607 (length 9 inches) .

(13) Upstream pressure sensor .

(14) Downstream pressure sensor .

(15) Downstream temperature sensor .

(16) Upstream temperature sensor .

Measuring the upstream/downstream pressure difference permits calculation of the particulate emission filter's soot load .

Measuring the temperatures permits checking of the operation during the regeneration phase .

Regular maintenance must be carried out every 80000 miles kilometres) or at the request of the engine management ecu :

● maintenance of the particulate emission filter ● filling of the additive reservoir

It is possible to force regeneration using the diagnostic equipment DIAG 2000 .

WARNING : during regeneration, the temperatures at the exhaust line are very high ; the working area must be clear ; do not connect the exhaust gas extraction take-off .

8 - ENGINE DW10

8 - 1 - PLASTIC WATER OUTLET HOUSING

The aluminium water outlet housing has been replaced with a plastic water outlet housing on DW10TD - DW10ATED engines .

Modified parts :

● water outlet housing ● cylinder head degas water pipe ● exchanger outlet water pipe ● radiator outlet water pipe ● heater matrix inlet water pipe ● fuel unions ● left front lifting eye ● style cover fixings

The water pipes are only modified at the engine end .

Old assembly/new assembly mixtures are not permitted .

Parts division will continue to supply the old parts .

8 - 2 - ELECTRIC DIESEL HEATER

The diesel heating system previously incorporated in the aluminium water outlet housing has been replaced with an electric diesel heater positioned on top of the engine .

9 - FUEL TANK

New fuel circuit: the tank and the filler spout have been modified to meet the requirements of evaporation standard EURO 3 and to permit the installation of the additive reservoir (versions with particulate emission filter) .

Addition of a switch positioned in the tank pipe transmitting tank cap presence information to an instrument panel warning light .

Petrol tank (EW10 , ES9J4S) .

Petrol tank (XU7JP , Overseas export) .

Diesel tank (DW10) without particulate emission filter .

Diesel tank (DW12) with particulate emission filter .

(17) Filler spout .

(18) Reservoir .

(19) New pump gauge module with incorporated filter .

(20) Pump gauge module .

(21) Petrol filter .

(22) Diesel additive reservoir incorporating the pump and additive low gauge functions .

(23) Additive reservoir breather .

(24) Additive injector .

10 - GEARBOX

10 - 1 - AUTOMATIC GEARBOX

The AL4 - 4HP20 automatic gearboxes have been modified :

● elimination of the key-lock function (locking of the key and audible warning if the gear lever is not in position P or N)

● standardisation of the shift-lock function (locking of the gear lever in position P if the driver does not press the brake pedal)

10 - 2 - BE4 GEARBOX

engine type EW10D/L4 EW7J4/IFL5 (tax incentive)

unit reference 20DL46 20DL43

type of gearbox BE4/5J BE4/5V

1st gear 11 x 38 11 x 38

2nd gear 23 x 43 23 x 43

3rd gear 25 x 32 25 x 34

gear no. 4 41 x 39 39 x 41

gear no. 5 44 x 35 44 x 35

reverse 12 x 31 x 40 12 x 31 x 40

final drive gears 19 x 77 19 x 79

speedometer drive gear 22 x 18 22 x 18

oil capacity (litre(s)) 1.9 1.9

At EW10J4/IFL5 (Tax incentive) :

● the saloons and estates are still fitted with the BE4/5N - BE4/5V gearbox ● the coupés are still fitted with the BE4/5S gearbox

10 - 3 - ML5T GEARBOX

engine type EW12J4/L4 DW12TED4/L4

unit reference 20LE92 20LE75

type of gearbox ML5T/G ML5T/I

1st gear 12 x 39 12 x 41

2nd gear 23 x 41 23 x 41

3rd gear 31 x 37 33 x 37

gear no. 4 41 x 37 44 x 35

gear no. 5 45 x 33 51 x 31

reverse 13 x 26 x 41 13 x 26 x 41

final drive gears 16 x 69 17 x 67

speedometer drive gear 25 x 20 25 x 20

oil capacity (litre(s)) 1.85 1.85

11 - WHEELS

Aluminium wheels are receiving mixed mounting bolts .

12 - BRAKES

12 - 1 - BRAKE VACUUM CIRCUIT

The engine brake vacuum circuit EW10D is specific .

(25) Inlet manifold .

(26) Pipes .

(27) Brake servo .

(28) Vacuum valve .

(29) Vacuum sensor .

(30) Interface accommodating the vacuum sensor and the vacuum valve .

(31) Retaining of the vacuum sensor on the interface by bolting .

(D) Black section towards the source of the vacuum .

(E) White section towards the servo .

EW10D engine operation in lean mixture mode (throttle open) does not permit creation of the vacuum necessary for servo-assisted braking .

The vacuum level in the servo is monitored by the engine management ecu via a vacuum sensor (23) .

When the vacuum level in the servo is too low, the engine management ecu closes the throttle (operation in uniform mixture mode) until the vacuum level in the brake servo is sufficient .

If the vacuum circuit fails, the engine management ecu positions the throttle to guarantee a sufficient vacuum level .

This fault is stored by the engine management ecu but the driver is not informed .

12 - 2 - ADAM EMERGENCY BRAKING ASSISTANCE SYSTEM

Introduction of the adam CONTINENTAL TEVES emergency braking assistance system as standard on all engines .

Adam: advanced dynamic aid mechanism .

The brake servo (32) is fitted with a device permitting reduction of the braking distance in the event of emergency braking .

It is a mechanical system permitting 2 operating modes :

● during slow braking, the servo-assistance ratio is 6 ● during emergency braking, the servo-assistance ratio is 23

The system is triggered when the power of the pedal (force x speed) exceeds a threshold; this threshold is set at the factory .

The master cylinder remains a conventional system (Tandem master cylinder) .

This system does not require any modification to the brake circuit bleed procedure .

Data :

● F : pedal force ● P : master cylinder pressure ● (33) slow braking graph ● (34) emergency braking graph

12 - 3 - DISC BRAKES

The 406 vehicle is fitted with 4 disc brakes as standard on all models .

Reminder :

● handbrake adjustment must be accompanied by bedding in of the brake linings ● adjustment of the handbrake and bedding in of the linings must be carried out at each service

13 - EQUIPMENT

13 - 1 - DYNAMIC STABILITY CONTROL

Vehicles fitted with the ES9J4S engine are fitted with esp dynamic stability control as standard .

The purpose of the esp dynamic stability control system is to improve active safety in extreme driving conditions (slippery road surface, avoidance manoeuvre...) .

The esp dynamic stability control ecu controls the following functions :

● dynamic stability control (ESP) ● anti-lock brakes (ABS) ● electronic braking distribution (REF) ● traction control (ASR)

To determine the trajectories, the ecu checks the following information and compares it with models :

● steering wheel angle sensor (desired trajectory) ● accelerometer/gyrometer dual-purpose sensor (actual trajectory) ● front and rear wheel sensors

The trajectory is modified by action on :

● braking (via a pre-charge pump and a hydraulic unit) ● the torque transmitted to the wheels

The asr traction control and esp dynamic stability control functions can be switched off partially by means of a switch to increase the traction of the front wheels .

Once they have been switched off by the driver, these functions remain off irrespective of the vehicle speed .

3 warning lights indicate the appearance of a fault in the system .

Description of the ESP pre-charge pump hydraulic circuit :

● (34) reservoir ● (35) pre-charge pump ● (36) low pressure pipe (intake) ● (37) high pressure pipe (discharge) ● (38) master cylinder

It is essential to bleed the esp hydraulic circuit in the following cases :

● opening of the ESP pre-charge pump hydraulic circuit ● opening of the circuit between the master cylinder and the hydraulic unit ● presence of air in the master cylinder ● periodic replacement of the brake fluid ● replacement of the brake fluid reservoir

Bleeding requires the use of the diagnostic equipment DIAG 2000; the procedure is described in the DIAG 2000 .

13 - 2 - AMVAR AUTOMATICALLY ADJUSTED SUSPENSION

The amvar suspension option (ES9J4S engine) has been discontinued .

13 - 3 - AUDIO SYSTEMS

New RM2 model radio, made by CLARION with cassette player in the front panel .

New RD2 model radio, made by CLARION with CD player in the front panel .

This audio equipment is fitted with the automatic speed-related volume adjustment function .

These audios are able to run a cd player .

In service, the audio equipment and the multifunction display (B or C) must be configured using the DIAG 2000 (This function will become available during the course of the year) .

The amplifier JBL is available as an option on estate versions .

The role of the audio system amplifier is to give better reception and sound quality .

The amplifier JBL is secured to the satellite navigation system ecu support .

13 - 4 - TRIP COMPUTER

The trip computer is standard on level 1 saloons and estates .

13 - 5 - POWER STEERING

Vehicles fitted with the DW10TD engine are fitted with falling output power steering as standard .

13 - 6 - INSTRUMENT PANEL

Modification to the instrument panel graphics .

Addition of the following warning lights :

● (39) fuel tank cap open ● (40) particulate emission filter fault ● (41) dynamic stability control

13 - 7 - ANTI-LOCK BRAKES

The anti-lock brake system is standard on all models .

14 - ELECTRONIC STRUCTURE

New electronic structure and new bsi incorporating the can gateway .

The bsi 406 controls the comfort van network (42) :

● (43) instrument panel ● (44) radio ● (45) CD player ● (46) on-board navigation system ● (47) multi-function display (B or C) ● (48) air conditioning

Introduction of the can network (G) including :

● (49) ecm engine management ecu ● (50) automatic gearbox ECU (according to specification - 4HP20 or AL4) ● (51) Electronic Stability Programme ECU (according to specification) ● (52) steering wheel angle sensor (according to specification)

Introduction of the body van network (H) (for DW12TED4 versions with particulate emission filter) including :

● (53) diesel fuel additive control unit

For vehicles equipped with esp, the vehicle speed information is transmitted to the bsi by the esp ecu .

For vehicles fitted with abs, the abs ecu (54) transmits the vehicle speed information to the engine management ecu (49) which distributes it on the can network .

15 - ELECTRICAL EQUIPMENT

15 - 1 - HARNESS MODIFICATIONS

Modification to the electrical harnesses .

Front panel harness integrated in main panel .

15 - 2 - CONNECTIONS

Front door locks with connector SICMA 2 .

16 - COOLANT

From spare parts organisation number 08576 : The cooling circuits are filled with long-life coolant REVKOGEL 2000 or Glysantin G33 .

A--T04K1 - 406D9

MODIFICATION LOCATION OF BUILD CODE (DAM)

The tyre inflation pressure label has changed to include the paint code and build code sequence .

1 - TYRE PRESSURE LABEL

1 - 1 - EARLIER SPECIFICATION

(1) : Tyre pressures .

(2) : Tyre size .

(3) : Approved tyres .

1 - 2 - NEW SPECIFICATION

(1) : Tyre pressures .

(2) : Tyre size .

(3) : Approved tyres .

(4) : Build code .

(5) : Serial number .

(6) : Paint reference .

(7) : VIN number .

(8) : Checking tolerance .

WARNING : on certain vehicles, the build code no longer contains 6 characters but 7 .

2 - INSTALLATION

2 - 1 - TYRE PRESSURE LABEL

Earlier installation .

(A) Tyre inflation pressure label on edge of driver's door .

DAM FROM : 814489

Later installation .

(B) Tyre pressure label on the front door pillar on the driver's side .

3 - BUILD CODE - PAINT CODE - SEQUENCE CODE

3 - 1 - EARLIER INSTALLATION

The build code number is located at : (C) - (D) or (E) .

3 - 2 - LATER INSTALLATION

COUPE

The build code number is located at (E), on the front left shock absorber tower .

The new tyre pressure label including the build code, the paint code and the serial number, is at (B), on the driver's side .

Documents

A--T0DK1 - 406D9 DAM FROM : 8421XX MODIFICATIONS 2000 …cdr.fastmail.fm/pug/manual/Data - D9 Coupe Modifications.pdf · The ES9J4S/L4 engine incorporates the following developments