2006 Citroen C4 I Service and Repair Manual

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Basic Information Identification Make: Citroën Model: C4 Generation: First Generation (C4 I) Model Years Covered: 2006 Codes Platform: PSA PF2 Introduction Market Position Market Segment: Compact car (C-segment) Design Philosophy:...

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Description

Basic Information
Identification
Make:	Citroën
Model:	C4
Generation:	First Generation (C4 I)
Model Years Covered:	2006
Codes
Platform:	PSA PF2

Introduction
Market Position
Market Segment:	Compact car (C-segment)
Design Philosophy:	Emphasized distinctive, aerodynamic styling, innovative features, and occupant comfort.
Competitive Analysis
Key Competitors:	Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Renault Mégane, Peugeot 307.
Key Features
Unique Features:	Fixed-hub steering wheel (original C4 design), highly sculpted interior, advanced safety features for its class.
Target Audience
Target Audience:	Consumers seeking stylish, comfortable, and well-equipped compact vehicles with European flair.

Manual Details
Coverage Areas
Coverage Scope:	All models and all repairs A-Z
Page Count
Page Count:	Extensive (actual count varies by edition, typically 1000+ pages)
Manual Type
Manual Type:	Service and Repair Manual
Language
Language:	English (assumed, common for international service manuals)
Format
Format:	Digital (likely PDF, consistent with dealership technician use)

Manual Coverage
Systems Covered
Engine Systems:	Engine mechanicals (cylinder head, block, pistons, crankshaft), fuel system (injection, pumps, injectors), ignition system, cooling system, lubrication system, exhaust system, emissions control.
Transmission Drivetrain:	Manual transmission, Automatic transmission (including electronic control), clutch, driveshafts, CV joints, differentials.
Braking System:	Front and rear brakes (discs/drums), hydraulic system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake assist.
Suspension Steering:	Front suspension (MacPherson struts, wishbones), rear suspension (torsion beam, multi-link), shock absorbers, springs, steering system (hydraulic power steering), steering column.
Electrical Electronic Systems:	Battery, alternator, starter motor, lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, body control module (BCM), engine control unit (ECU), CAN bus communication.
Body Chassis:	Body structure, panels, doors, windows, locks, hinges, bumpers, underbody, corrosion protection.
Hvac Comfort Systems
HVAC Comfort Systems:	Air conditioning system, heating, ventilation, climate control unit.
Safety Systems
Safety Systems:	Airbag system (SRS), seatbelts, passive safety features.
Procedures Included
Maintenance Procedures:	Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, brake pad/disc replacement, tire rotation.
Troubleshooting Diagnostics:	Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics, mechanical fault finding.
Repair Procedures:	Engine component rebuilds, transmission overhaul, suspension component replacement, brake system repair, electrical component diagnosis and replacement, body panel repair and replacement.
Component Replacement:	Detailed steps for replacing virtually all components, from minor sensors to major powertrain units.
Body Repair:	Procedures for body panel alignment, repair of dents, rust prevention, and replacement of body components (doors, bumpers, hood, etc.).
HVAC System Repair:	Diagnosis and repair of air conditioning system leaks, compressor replacement, heater core replacement, blower motor issues, and climate control module troubleshooting.
Fuel System Diagnostics:	Testing fuel pressure, diagnosing injector issues, fuel pump testing and replacement, and emissions system diagnostics.
Technical Depth
Diagnostic Depth:	Advanced diagnostics including OBD-II scanning, specific diagnostic routines, and live data interpretation.
Repair Depth:	Comprehensive repair procedures ranging from routine maintenance to complete vehicle overhauls and component rebuilds.
Special Tools:	Identification and usage instructions for specialized tools required for specific repairs and diagnostics.
Torque Specifications:	Precise torque values for all fasteners to ensure correct assembly and prevent damage.
Wiring Diagrams:	Detailed, color-coded electrical wiring diagrams for all systems, essential for troubleshooting electrical faults.
Diagnostic Tools Required:	Diagnostic scan tools compatible with PSA vehicles (e.g., Diagbox/Lexia, though this manual predates some of the later software).

Manual Specifications
File Format
File Format:	PDF (Searchable, Printable)
Print Quality
Print Quality:	High-resolution scans of original documentation, ensuring clarity of text and diagrams.
Binding Type
Binding Type:	N/A (Digital Format)
Paper Type
Paper Type:	N/A (Digital Format)

Engine Specifications
Primary Engine
Engine Family:	PSA EC/EW/EP engines
Available Engines:	1.4L (EP3/EP3C), 1.6L (EP6, ET3), 1.6L HDi Diesel (DV6), 2.0L HDi Diesel (DW10).
Performance
1.6L Vti (Ep6) Performance:	Approx. 120 PS (88 kW; 118 hp) @ 6000 rpm, 160 Nm (118 lb-ft) @ 4250 rpm
1.6L Hdi Diesel (Dv6) Performance:	Approx. 92 PS (68 kW; 91 hp) or 109 PS (80 kW; 108 hp) depending on tune, torque around 230-245 Nm.
Fuel System
Fuel System Type:	Multi-point fuel injection (MPI) for petrol, Common Rail Direct Injection (CRDi) for diesel.
Engine Codes Examples
Petrol Engine Codes:	EP3C, EP6 (BMW-PSA collaboration)
Diesel Engine Codes:	DV6TED4, DW10TD

Transmission
Standard
Standard Transmission:	5-speed Manual
Optional
Optional Transmission:	4-speed Automatic (AL4), 6-speed Automated Manual (EGS/BMP)
Features
Automated Manual Features:	Single-clutch automated manual transmission offering fuel economy benefits but often criticized for shift smoothness.
Fluid Specifications
Manual Transmission Fluid:	Refer to manual for specific SAE grade and API specifications (e.g., SAE 75W-80 API GL-4 or GL-5).
Automatic Transmission Fluid:	Specific ATF for AL4 transmission, e.g., LT 71141 or equivalent.

Dimensions
Exterior
Body Styles:	Hatchback (3-door and 5-door), Sedan (4-door)
Wheelbase:	Approx. 2605 mm (102.6 in)
Length:	Approx. 4276 mm (168.3 in) for 5-door hatchback
Width:	Approx. 1773 mm (69.8 in)
Height:	Approx. 1494 mm (58.8 in) for 5-door hatchback
Weights
Curb Weight:	Varies by engine/spec, typically 1200-1400 kg (2645-3086 lbs)
Gross Vehicle Weight Rating:	Refer to VIN plate/manual for specific ratings.

Safety Features
Ratings
Euro Ncap Rating:	5 Stars (for 2006 model year, achieved with optional equipment on some tests)
Active Features
Active Safety Features:	ABS, EBD, Brake Assist, ESP (Electronic Stability Program) often optional or standard on higher trims.
Passive Features
Passive Safety Features:	Multi-stage front airbags, front side airbags, curtain airbags, seatbelt pre-tensioners, ISOFIX child seat anchors.

Technology Features
Infotainment
Infotainment System:	Original system likely featured a basic radio/CD player, possibly with MP3 compatibility. Higher trims may have offered integrated navigation and a larger display.
Driver Assistance
Driver Assistance Features:	Cruise control, speed limiter, parking sensors (often optional or on higher trims).
Connectivity
Connectivity Options:	Auxiliary input for audio (standard on most models from 2006), Bluetooth hands-free calling (optional/later models).
Lighting Technology
Lighting Features:	Halogen headlights, optional Xenon headlights with cornering function.

Maintenance
Service Intervals
Oil Change Interval:	Typically every 20,000 km (12,500 miles) or 2 years, whichever comes first, depending on engine and driving conditions (refer to manual for exact schedule).
Timing Belt Replacement:	For petrol engines with timing belts, typically around 120,000 km (75,000 miles) or 5 years. Diesel HDi engines with timing chains may have different service life expectations (check manual).
Brake Fluid Change:	Typically every 2-3 years or 60,000 km (37,000 miles), depending on moisture absorption.
Fluid Specifications
Engine Oil Specification:	Specific ACEA A3/B4 or A5/B5 specifications, with viscosity grades like 0W-30, 5W-30, or 5W-40 depending on engine (e.g., Total Quartz).
Coolant Specification:	Ethylene glycol-based coolant with organic acid technology (OAT), typically blue or pink. Refer to Total Glacelf Auto Supra or equivalent.
Power Steering Fluid:	Specific hydraulic fluid, often PSA S71 2710 or equivalent.
Known Issues
Common Faults Petrol:	Coil pack failures (especially on 1.6 THP EP6DT), thermostat issues, timing chain stretch (EP6 engine), exhaust lambda sensor faults.
Common Faults Diesel:	DPF (Diesel Particulate Filter) regeneration issues, EGR valve problems, turbocharger issues on HDi engines, injector problems, glow plug failures.
Electrical Issues:	CAN bus communication faults, issues with BSI (Body Systems Interface) module, sensor failures (ABS, crankshaft position, etc.), window regulator failures.
Suspension Steering Issues:	Wear on suspension bushings and ball joints, power steering pump leaks or failure.

Vehicle History
Brand Heritage
Citroen Legacy:	Citroën has a long history of innovation in automotive engineering, known for comfort, distinctive design, and pioneering technologies (e.g., hydropneumatic suspension).
Model Evolution
C4 Launch:	Launched in 2004 as a replacement for the Citroën Xsara, available in hatchback and sedan forms. The C4 I design carried through to 2010 before the second generation.
Production
Manufacturing Locations:	Primarily manufactured in France (e.g., PSA's Mulhouse plant) and other PSA global facilities.

Awards & Recognition
Recognitions
Euro Ncap Award:	Achieved a 5-star Euro NCAP safety rating, signifying strong occupant protection for its era.
Other Accolades:	The C4 received various accolades in different markets for its design and comfort, though specific major awards for the 2006 model year are less prominent than its safety rating.