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2004-2010 Citroen C4 2.0 i Service & Repair Manual

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🏷️ Basic Information Identification Make: Citroen Model: C4 Model Generation: First Generation (Type P / Type R) Model Years Covered: 2004, 2005, 2006, 2007, 2008, 2009, 2010 Engine Variant: 2.0 i (EW10J4 / EW10A) Codes Chassis Code: Type P (Hatchback), Type R (Coupe) 👋 Introduction Market Position Positioning: Compact family car with a focus on comfort, design, and safety. Competitive Analysis Key Competitors: Volkswagen Golf, Ford Focus, Vauxhall Astra, Peugeot 307, Renault Megane. Key Features Design Language: Distinctive, aerodynamic styling with a focus on passenger comfort and innovative features. Interior Innovations: Fixed-hub steering wheel, digital instrument cluster, advanced climate control, spacious cabin. Manual Advantage Value Proposition: Provides dealership-level diagnostic and repair information, empowering owners and independent workshops. Accuracy: Vehicle-specific, not generic, ensuring correct procedures and specifications. 📋 Manual Details Coverage Areas Primary Coverage: Vehicle Specific Service & Repair Scope: All models and all repairs A-Z Page Count Estimated Pages: Extensive (typically 1500+ pages for comprehensive factory manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF likely, given common industry practice for sales) 📖 Manual Coverage Systems Covered Engine Management: Full diagnostics, component testing, ECU information, fuel injection, ignition system, emissions control. Engine Mechanical: Engine teardown and rebuild, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication, cooling system. Transmission Manual: Clutch, gearbox disassembly and reassembly, shift mechanisms, maintenance. Transmission Automatic: ATF specifications, torque converter, valve body, hydraulic control, electronic controls, seal replacement, overhaul. Suspension: Front and rear suspension systems, components (struts, shocks, control arms, bushings, ball joints), alignment specifications, geometry. Steering: Power steering system (hydraulic or electric), steering rack, column, tie rods, fluid specifications, troubleshooting. Brakes: Front and rear brake systems (disc/disc or disc/drum), ABS, EBD, brake fluid specifications, bleeding procedures, pad and rotor replacement, caliper overhaul. Electrical System: Wiring diagrams, component locations, fuses, relays, lighting, starting and charging system, body electronics, multiplexing. Body And Chassis: Body panels, doors, hinges, latches, glass, seals, chassis components, structural repairs, corrosion protection. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant types, charging procedures, component testing, diagnostics. Safety Systems: Airbag system (SRS) diagnosis and replacement, seatbelt mechanisms. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant service, brake fluid service. Troubleshooting: System-specific diagnostic flowcharts, symptom-based troubleshooting guides, fault code interpretation. Repair: Step-by-step repair instructions for all major vehicle systems, including removal, installation, and adjustment procedures. Diagnostics: Use of diagnostic tools (e.g., Lexia-3/Diagbox), live data interpretation, actuator tests, sensor readings. Specifications: Torque specifications for all fasteners, fluid capacities, electrical specifications, diagnostic parameters. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, in-depth electrical diagnostics, and bodywork. Target Audience: Professional Technicians and Advanced DIYers 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Text-searchable, allowing quick access to specific topics. Print Quality Quality: High resolution, clear diagrams and text suitable for printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: EW10J4 / EW10A Engine Type: Inline 4-cylinder, naturally aspirated Displacement: 1997 cc Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 10.8:1 Valvetrain: DOHC, 16 valves Performance Horsepower Ps: 143 PS (141 hp) @ 6250 rpm (EW10A) Torque Nm: 200 Nm @ 4000 rpm (EW10A) Fuel System Fuel Delivery: Multi-point fuel injection (MPFI) with electronic control. Fuel Type: Unleaded gasoline (RON 95 recommended) Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., PSA Part No. 9736.02 or equivalent) Lubrication System Oil Type: Synthetic SAE 0W-30 or 5W-30, meeting PSA B71 2290 specification. Oil Capacity: Approx. 4.25 liters (with filter) 🔧 Transmission Standard Type: 5-speed Manual Transmission (BE4/2 system) Optional Type: 4-speed Automatic Transmission (AL4 - DP0) Features Automatic Features: Electronic control, 'Sport' and 'Snow' modes. Manual Fluid Fluid Type: SAE 75W-80 GL-4 (e.g., PSA Part No. 9730.AE or equivalent) Automatic Fluid Fluid Type: ATF LT 71141 (e.g., PSA Part No. 9980.40 or equivalent) 📐 Dimensions Exterior Length: 4260 mm (Hatchback) Width: 1773 mm Height: 1460 mm (Hatchback) Wheelbase: 2605 mm Cargo Trunk Volume: Approx. 320 - 360 liters (Hatchback, depending on configuration) Weights Curb Weight: Approx. 1300 - 1370 kg Gross Vehicle Weight: Approx. 1800 kg 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (2004) Child Occupant Protection: 4 Stars Pedestrian Protection: 2 Stars Active Features ABS: Standard, with Electronic Brake-force Distribution (EBD) Esp: Optional or standard on higher trims, includes Traction Control System (TCS) and potentially understeer control. Passive Features Airbags: Driver, passenger, side, and curtain airbags available (depending on trim). Seat Belts: Pre-tensioned with force limiters, ISOFIX child seat anchor points. 💡 Technology Features Infotainment Head Unit: Integrated audio system with CD player, potentially MP3 compatible. Steering wheel mounted controls. Navigation: Optional factory navigation system available. Driver Assistance Cruise Control: Available, typically integrated with speed limiter. Parking Sensors: Optional rear parking...
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2004-2010 Citroen C4 2.0 i Service & Repair Manual
🏷️ Basic Information
Identification
Make:
Citroen
Model:
C4
Model Generation:
First Generation (Type P / Type R)
Model Years Covered:
2004, 2005, 2006, 2007, 2008, 2009, 2010
Engine Variant:
2.0 i (EW10J4 / EW10A)
Codes
Chassis Code:
Type P (Hatchback), Type R (Coupe)
👋 Introduction
Market Position
Positioning:
Compact family car with a focus on comfort, design, and safety.
Competitive Analysis
Key Competitors:
Volkswagen Golf, Ford Focus, Vauxhall Astra, Peugeot 307, Renault Megane.
Key Features
Design Language:
Distinctive, aerodynamic styling with a focus on passenger comfort and innovative features.
Interior Innovations:
Fixed-hub steering wheel, digital instrument cluster, advanced climate control, spacious cabin.
Manual Advantage
Value Proposition:
Provides dealership-level diagnostic and repair information, empowering owners and independent workshops.
Accuracy:
Vehicle-specific, not generic, ensuring correct procedures and specifications.
📋 Manual Details
Coverage Areas
Primary Coverage:
Vehicle Specific Service & Repair
Scope:
All models and all repairs A-Z
Page Count
Estimated Pages:
Extensive (typically 1500+ pages for comprehensive factory manuals)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF likely, given common industry practice for sales)
📖 Manual Coverage
Systems Covered
Engine Management:
Full diagnostics, component testing, ECU information, fuel injection, ignition system, emissions control.
Engine Mechanical:
Engine teardown and rebuild, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication, cooling system.
Transmission Manual:
Clutch, gearbox disassembly and reassembly, shift mechanisms, maintenance.
Transmission Automatic:
ATF specifications, torque converter, valve body, hydraulic control, electronic controls, seal replacement, overhaul.
Suspension:
Front and rear suspension systems, components (struts, shocks, control arms, bushings, ball joints), alignment specifications, geometry.
Steering:
Power steering system (hydraulic or electric), steering rack, column, tie rods, fluid specifications, troubleshooting.
Brakes:
Front and rear brake systems (disc/disc or disc/drum), ABS, EBD, brake fluid specifications, bleeding procedures, pad and rotor replacement, caliper overhaul.
Electrical System:
Wiring diagrams, component locations, fuses, relays, lighting, starting and charging system, body electronics, multiplexing.
Body And Chassis:
Body panels, doors, hinges, latches, glass, seals, chassis components, structural repairs, corrosion protection.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant types, charging procedures, component testing, diagnostics.
Safety Systems:
Airbag system (SRS) diagnosis and replacement, seatbelt mechanisms.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug replacement, coolant service, brake fluid service.
Troubleshooting:
System-specific diagnostic flowcharts, symptom-based troubleshooting guides, fault code interpretation.
Repair:
Step-by-step repair instructions for all major vehicle systems, including removal, installation, and adjustment procedures.
Diagnostics:
Use of diagnostic tools (e.g., Lexia-3/Diagbox), live data interpretation, actuator tests, sensor readings.
Specifications:
Torque specifications for all fasteners, fluid capacities, electrical specifications, diagnostic parameters.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, in-depth electrical diagnostics, and bodywork.
Target Audience:
Professional Technicians and Advanced DIYers
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Text-searchable, allowing quick access to specific topics.
Print Quality
Quality:
High resolution, clear diagrams and text suitable for printing.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
EW10J4 / EW10A
Engine Type:
Inline 4-cylinder, naturally aspirated
Displacement:
1997 cc
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
10.8:1
Valvetrain:
DOHC, 16 valves
Performance
Horsepower Ps:
143 PS (141 hp) @ 6250 rpm (EW10A)
Torque Nm:
200 Nm @ 4000 rpm (EW10A)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPFI) with electronic control.
Fuel Type:
Unleaded gasoline (RON 95 recommended)
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., PSA Part No. 9736.02 or equivalent)
Lubrication System
Oil Type:
Synthetic SAE 0W-30 or 5W-30, meeting PSA B71 2290 specification.
Oil Capacity:
Approx. 4.25 liters (with filter)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (BE4/2 system)
Optional
Type:
4-speed Automatic Transmission (AL4 - DP0)
Features
Automatic Features:
Electronic control, 'Sport' and 'Snow' modes.
Manual Fluid
Fluid Type:
SAE 75W-80 GL-4 (e.g., PSA Part No. 9730.AE or equivalent)
Automatic Fluid
Fluid Type:
ATF LT 71141 (e.g., PSA Part No. 9980.40 or equivalent)
📐 Dimensions
Exterior
Length:
4260 mm (Hatchback)
Width:
1773 mm
Height:
1460 mm (Hatchback)
Wheelbase:
2605 mm
Cargo
Trunk Volume:
Approx. 320 - 360 liters (Hatchback, depending on configuration)
Weights
Curb Weight:
Approx. 1300 - 1370 kg
Gross Vehicle Weight:
Approx. 1800 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (2004)
Child Occupant Protection:
4 Stars
Pedestrian Protection:
2 Stars
Active Features
ABS:
Standard, with Electronic Brake-force Distribution (EBD)
Esp:
Optional or standard on higher trims, includes Traction Control System (TCS) and potentially understeer control.
Passive Features
Airbags:
Driver, passenger, side, and curtain airbags available (depending on trim).
Seat Belts:
Pre-tensioned with force limiters, ISOFIX child seat anchor points.
💡 Technology Features
Infotainment
Head Unit:
Integrated audio system with CD player, potentially MP3 compatible. Steering wheel mounted controls.
Navigation:
Optional factory navigation system available.
Driver Assistance
Cruise Control:
Available, typically integrated with speed limiter.
Parking Sensors:
Optional rear parking sensors.
Lighting:
Halogen headlights, optional Xenon headlights, automatic headlights available.
Connectivity
Bluetooth:
Optional Bluetooth hands-free connectivity.
Usb Aux:
Auxiliary input socket for external audio devices often standard or optional.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 miles or 12 months, whichever comes first (check manual for specific conditions).
Timing Belt:
Recommended replacement at 75,000 miles or 5 years, whichever comes first (if equipped with belt).
Spark Plugs:
Recommended replacement at 60,000 miles (for platinum/iridium plugs).
Fluid Specifications
Brake Fluid:
DOT 4 (e.g., PSA Part No. 9980.42 or equivalent)
Power Steering Fluid:
Typically PSA S71 2710 specification (mineral oil based, usually green or yellow).
Air Conditioning Refrigerant:
R134a
Known Issues
Common Wear Items:
Front wishbone bushings, rear axle mountings, exhaust system, brake discs/pads.
Electrical Gremlins:
Occasional issues with door wiring harnesses, CAN bus communication errors, immobilizer problems.
Engine Specific:
Potential for ignition coil failure, oil leaks from the rocker cover gasket, thermostat issues.
Transmission Specific:
AL4 automatic transmission can exhibit jerky shifts or failure to engage if not maintained properly (e.g., fluid changes).
📚 Vehicle History
Brand Heritage
Citroen Legacy:
Citroën's history of innovative automotive design and comfort-focused engineering.
Model Evolution
C4 Predecessor:
Successor to the Citroën Xsara.
Platform Sharing:
Shares platform and many components with Peugeot 307.
Production
Manufacturing Locations:
Primary production in Mulhouse, France, and significant production in Spain and Argentina.
Production Years
First Generation Start:
2004
First Generation End:
2010 (facelifted in 2008)
🏆 Awards & Recognition
Recognitions
Top Gear Award:
Named 'Sexiest Car of the Year' by Top Gear Magazine in 2004.
Ratings
Autocar Reviews:
Generally praised for its innovative design, comfort, and handling, though some found the engine refinement average.
Certifications
Euro Ncap:
Achieved a 5-star Euro NCAP safety rating, demonstrating strong structural integrity and occupant protection.
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