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2004-2010 Citroen C4 I Service and Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: C4 Generation: I (First Generation) Year Range: 2004-2010 Codes Platform: PSA PF2 👋 Introduction Market Position Target Audience: Independent repair shops, DIY mechanics, and Citroën enthusiasts seeking professional-level repair information. Competitive Analysis Advantage: Vehicle-specific, dealer-level detail, surpassing generic repair guides in accuracy and scope. Key Features Authenticity: Official or factory-derived documentation equivalent to technician-issued manuals. Completeness: Covers the entire vehicle lifecycle from maintenance to major repairs. Manual Purpose Utility: Essential for accurate diagnosis, efficient repair, and proper maintenance of the Citroën C4 I. 📋 Manual Details Coverage Areas General Coverage: All Models and All Repairs A-Z Page Count Estimated Pages: 1500+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: All Petrol and Diesel variants, including timing belt/chain, cooling, lubrication, fuel injection, ignition, emissions control. Transmission: Manual and Automatic transmissions, clutch operation, gearbox components, drive shafts, differentials. Brakes: Hydraulic systems, ABS, EBD, disc and drum brake service, parking brake, fluid specifications. Suspension Steering: Front and rear suspension components, shock absorbers, springs, ball joints, bushings, power steering system, wheel alignment. Electrical Electronics: Battery, charging system, starter, lighting, ignition system, instrument cluster, body control module (BCM), infotainment, wiring diagrams. Bodywork Interior: Body panel repair, door mechanisms, window regulators, seat adjustments, interior trim, HVAC system operation and repair. HVAC: Air conditioning, heating, ventilation system diagnosis and repair, refrigerant handling. Safety Systems: Airbag systems, seatbelt pre-tensioners, ABS diagnostics, ESP troubleshooting. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, brake inspections, tune-ups. Diagnostics Troubleshooting: Step-by-step diagnostic procedures for common and uncommon faults, fault code interpretation. Repair Replacement: Detailed instructions for component removal, installation, and repair for all major systems. Engine Overhaul: Complete engine disassembly, inspection, and reassembly procedures. Transmission Rebuild: Detailed instructions for rebuilding both manual and automatic transmissions. Electrical Diagnostics: Troubleshooting electrical issues using wiring diagrams, component testing. Emissions Control: Diagnosis and repair of emission control systems, including catalytic converters, oxygen sensors, and EGR valves. Fuel System Service: Fuel pump testing, injector cleaning and replacement, fuel filter replacement procedures. Cooling System: Radiator, water pump, thermostat, fan replacement, coolant flushing and filling. Exhaust System: Catalytic converter replacement, muffler and pipe repair/replacement. Body Panel Repair: Repair procedures for dents, damage, and rust. Includes guidance on panel alignment and fitting. Interior Trim Removal: Detailed instructions for removing and reinstalling dashboard, door panels, and other interior trim for access to components. Airbag System Repair: Safe procedures for airbag component removal, replacement, and system diagnostics. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and body repair. Wiring Diagrams: Includes detailed electrical schematics for all major vehicle systems, aiding in complex electrical fault finding. Torque Specifications: Detailed torque values for critical fasteners across all major assemblies (engine, transmission, suspension, brakes, etc.). Diagnostic Tools: Information on necessary diagnostic tools and equipment, including proprietary Citroën diagnostic interfaces (e.g., Lexia/Diagbox) for electronic systems. 📊 Manual Specifications File Format Compatibility: Viewable on any device with PDF reader (PC, Mac, Tablet, Smartphone). Print Quality Resolution: High-resolution, ensuring clarity of text, diagrams, and illustrations. Binding Type Physical Format: N/A (Digital Format) Paper Type Physical Format: N/A (Digital Format) Manual Type Clarification Type Clarification: This is a comprehensive workshop manual, not an owner's manual. It is designed for repair and maintenance tasks. Searchability Text Searchability: Fully searchable PDF content, allowing quick access to specific topics and repair procedures. ⚙️ Engine Specifications Primary Engine Common Petrol Engines: 1.4L (ET3), 1.6L (TU5/TU5JP4/EP6), 2.0L (EW10/EW10A), 1.6L THP (EP6DT/DTS) Common Diesel Engines: 1.4L HDi (DV4), 1.6L HDi (DV6), 2.0L HDi (DW10) Performance Horsepower Range: 70 HP (1.4 HDi) to 177 HP (1.6 THP) Torque Range: 135 Nm (1.4 HDi) to 260 Nm (1.6 THP) Fuel System Injection Type: Multi-point fuel injection (MPI) for petrol, Common Rail Direct Injection (CRDi) for diesel. Engine Codes Common Petrol Engine Codes: TU5JP4 (NFU), EW10A (RFJ), EP6 (5FW), EP6DT (5FX), EP6DTS (5FT) Common Diesel Engine Codes: DV4TD (8HZ), DV6TED4 (9HX/9HZ), DW10BTED4 (RHR) 🔧 Transmission Standard Standard Transmission: 5-speed Manual (e.g., BE4R) Optional Optional Transmission: 4-speed Automatic (AL4), 5-speed Automated Manual (EGS/VTR Plus) Features Transmission Fluid Spec: Varies by transmission type; e.g., ATF LT 71141 for AL4, specific manual gearbox oil for BE4R. 📐 Dimensions Exterior Body Styles: 5-door Hatchback, 3-door Hatchback (C4 Coupé) Length: Approx. 4273 mm (Hatchback) Width: Approx. 1773 mm Height: Approx. 1471 mm Weights Curb Weight: Approx. 1200-1400 kg depending on engine and configuration 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (2005) Active Features Active Safety: ABS with EBD and Brake Assist, ESP (Electronic Stability Program), Cruise Control, Speed Limiter. Passive Features Passive Safety: Multiple Airbags (front, side, curtain), Height-adjustable seatbelts with pretensioners, Isofix child seat anchor points. 💡 Technology Features Infotainment Infotainment System: Optional: Integrated CD player, radio, MP3 compatibility, Bluetooth hands-free system...
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Type: Car
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Sku: 457635
Collecties: ALL Citroen

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2004-2010 Citroen C4 I Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Citroën
Model:
C4
Generation:
I (First Generation)
Year Range:
2004-2010
Codes
Platform:
PSA PF2
👋 Introduction
Market Position
Target Audience:
Independent repair shops, DIY mechanics, and Citroën enthusiasts seeking professional-level repair information.
Competitive Analysis
Advantage:
Vehicle-specific, dealer-level detail, surpassing generic repair guides in accuracy and scope.
Key Features
Authenticity:
Official or factory-derived documentation equivalent to technician-issued manuals.
Completeness:
Covers the entire vehicle lifecycle from maintenance to major repairs.
Manual Purpose
Utility:
Essential for accurate diagnosis, efficient repair, and proper maintenance of the Citroën C4 I.
📋 Manual Details
Coverage Areas
General Coverage:
All Models and All Repairs A-Z
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
All Petrol and Diesel variants, including timing belt/chain, cooling, lubrication, fuel injection, ignition, emissions control.
Transmission:
Manual and Automatic transmissions, clutch operation, gearbox components, drive shafts, differentials.
Brakes:
Hydraulic systems, ABS, EBD, disc and drum brake service, parking brake, fluid specifications.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, ball joints, bushings, power steering system, wheel alignment.
Electrical Electronics:
Battery, charging system, starter, lighting, ignition system, instrument cluster, body control module (BCM), infotainment, wiring diagrams.
Bodywork Interior:
Body panel repair, door mechanisms, window regulators, seat adjustments, interior trim, HVAC system operation and repair.
HVAC:
Air conditioning, heating, ventilation system diagnosis and repair, refrigerant handling.
Safety Systems:
Airbag systems, seatbelt pre-tensioners, ABS diagnostics, ESP troubleshooting.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, brake inspections, tune-ups.
Diagnostics Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon faults, fault code interpretation.
Repair Replacement:
Detailed instructions for component removal, installation, and repair for all major systems.
Engine Overhaul:
Complete engine disassembly, inspection, and reassembly procedures.
Transmission Rebuild:
Detailed instructions for rebuilding both manual and automatic transmissions.
Electrical Diagnostics:
Troubleshooting electrical issues using wiring diagrams, component testing.
Emissions Control:
Diagnosis and repair of emission control systems, including catalytic converters, oxygen sensors, and EGR valves.
Fuel System Service:
Fuel pump testing, injector cleaning and replacement, fuel filter replacement procedures.
Cooling System:
Radiator, water pump, thermostat, fan replacement, coolant flushing and filling.
Exhaust System:
Catalytic converter replacement, muffler and pipe repair/replacement.
Body Panel Repair:
Repair procedures for dents, damage, and rust. Includes guidance on panel alignment and fitting.
Interior Trim Removal:
Detailed instructions for removing and reinstalling dashboard, door panels, and other interior trim for access to components.
Airbag System Repair:
Safe procedures for airbag component removal, replacement, and system diagnostics.
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including electrical diagnostics and body repair.
Wiring Diagrams:
Includes detailed electrical schematics for all major vehicle systems, aiding in complex electrical fault finding.
Torque Specifications:
Detailed torque values for critical fasteners across all major assemblies (engine, transmission, suspension, brakes, etc.).
Diagnostic Tools:
Information on necessary diagnostic tools and equipment, including proprietary Citroën diagnostic interfaces (e.g., Lexia/Diagbox) for electronic systems.
📊 Manual Specifications
File Format
Compatibility:
Viewable on any device with PDF reader (PC, Mac, Tablet, Smartphone).
Print Quality
Resolution:
High-resolution, ensuring clarity of text, diagrams, and illustrations.
Binding Type
Physical Format:
N/A (Digital Format)
Paper Type
Physical Format:
N/A (Digital Format)
Manual Type Clarification
Type Clarification:
This is a comprehensive workshop manual, not an owner's manual. It is designed for repair and maintenance tasks.
Searchability
Text Searchability:
Fully searchable PDF content, allowing quick access to specific topics and repair procedures.
⚙️ Engine Specifications
Primary Engine
Common Petrol Engines:
1.4L (ET3), 1.6L (TU5/TU5JP4/EP6), 2.0L (EW10/EW10A), 1.6L THP (EP6DT/DTS)
Common Diesel Engines:
1.4L HDi (DV4), 1.6L HDi (DV6), 2.0L HDi (DW10)
Performance
Horsepower Range:
70 HP (1.4 HDi) to 177 HP (1.6 THP)
Torque Range:
135 Nm (1.4 HDi) to 260 Nm (1.6 THP)
Fuel System
Injection Type:
Multi-point fuel injection (MPI) for petrol, Common Rail Direct Injection (CRDi) for diesel.
Engine Codes
Common Petrol Engine Codes:
TU5JP4 (NFU), EW10A (RFJ), EP6 (5FW), EP6DT (5FX), EP6DTS (5FT)
Common Diesel Engine Codes:
DV4TD (8HZ), DV6TED4 (9HX/9HZ), DW10BTED4 (RHR)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual (e.g., BE4R)
Optional
Optional Transmission:
4-speed Automatic (AL4), 5-speed Automated Manual (EGS/VTR Plus)
Features
Transmission Fluid Spec:
Varies by transmission type; e.g., ATF LT 71141 for AL4, specific manual gearbox oil for BE4R.
📐 Dimensions
Exterior
Body Styles:
5-door Hatchback, 3-door Hatchback (C4 Coupé)
Length:
Approx. 4273 mm (Hatchback)
Width:
Approx. 1773 mm
Height:
Approx. 1471 mm
Weights
Curb Weight:
Approx. 1200-1400 kg depending on engine and configuration
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (2005)
Active Features
Active Safety:
ABS with EBD and Brake Assist, ESP (Electronic Stability Program), Cruise Control, Speed Limiter.
Passive Features
Passive Safety:
Multiple Airbags (front, side, curtain), Height-adjustable seatbelts with pretensioners, Isofix child seat anchor points.
💡 Technology Features
Infotainment
Infotainment System:
Optional: Integrated CD player, radio, MP3 compatibility, Bluetooth hands-free system (later models/options), directional indicator fixed hub steering wheel with integrated controls.
Driver Assistance
Driver Assistance:
Front and rear parking sensors (optional), Rain-sensing wipers, Automatic headlights.
Connectivity
Connectivity Features:
Auxiliary input for audio devices (optional).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 20,000 km or 12 months (whichever comes first) for petrol, 30,000 km or 24 months for diesel, subject to driving conditions and specific engine variant.
Timing Belt Replacement:
Varies by engine; e.g., 1.6 HDi typically around 240,000 km or 10 years, 1.6 VTi/THP around 120,000 km or 6 years. Check manual for exact specifications.
Fluid Specifications
Engine Oil:
e.g., Total Quartz INEO ECS 5W-30 (low SAPS) for HDi engines, Total Quartz 7000 10W-40 or Quartz 9000 5W-40 for petrol engines. Refer to manual for exact API/ACEA specifications.
Coolant:
Citroën specific coolant (e.g., Paraflu) or equivalent antifreeze with extended life protection, typically OAT based.
Brake Fluid:
DOT 4
Power Steering Fluid:
Citroën LHM or equivalent hydraulic fluid (if equipped with hydropneumatic systems - typically not C4) or ATF for electro-hydraulic power steering.
Transmission Fluid Manual:
API GL-4 or GL-5 specified SAE 75W-80 or 75W-90 gear oil, depending on transmission type.
Known Issues
Common Faults:
DPF regeneration issues (diesel), early AL4 automatic gearbox problems, electronic component failures (e.g., BSI, instrument cluster), suspension bush wear, air conditioning compressor issues.
📚 Vehicle History
Brand Heritage
Citroen Philosophy:
Known for innovative design, comfortable ride quality (e.g., hydropneumatic suspension in other models, advanced suspension tuning in C4), and distinctive styling.
Model Evolution
C4 Positioning:
Replaced the Citroën Xsara, positioned as a more modern and stylish compact family car.
Production
Manufacturing Locations:
Primarily manufactured in France (e.g., Mulhouse) and Spain (e.g., Vigo).
🏆 Awards & Recognition
Recognitions
Design Awards:
Often praised for its avant-garde interior design, particularly the central digital instrument cluster and aerodynamic exterior styling.
Ratings
Reliability Perception:
Mixed; while comfortable and innovative, some earlier models and specific components have faced reliability criticisms compared to certain competitors, making a good service manual essential.
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