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CITROEN C4 2004-2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: C4 Codes Platform Code: PSA PF2 Generation Generation Designation: First Generation (Type B58) Year Range Covered Years: 2004-2009 👋 Introduction Market Position Target...
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CITROEN C4 2004-2009 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Citroën
Model:
C4
Codes
Platform Code:
PSA PF2
Generation
Generation Designation:
First Generation (Type B58)
Year Range
Covered Years:
2004-2009
👋 Introduction
Market Position
Target Audience:
Owners with basic mechanical skills and independent auto service professionals.
Segment:
Compact family car (C-segment).
Competitive Analysis
Value Proposition:
Provides dealer-level specifications and procedures at a fraction of the cost, empowering owners to understand and manage their vehicle's maintenance and repairs.
Key Features
Access Method:
Instant download upon payment, eliminating shipping costs and wait times.
Device Compatibility:
Viewable on PC, Mac, and various devices including smartphones and e-readers (e.g., Kindle).
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair procedures for Citroën C4 (2004-2009)
Specific Engines Covered:
1.6L Petrol (likely the TU5/EC5 variants) and 1.6L HDi Diesel engines
Page Count
Estimated Page Count:
Varies by edition, but typically 1000+ pages for a comprehensive service manual.
Manual Type
Type:
Service and Repair Manual
Language
Language:
Spanish
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine service and overhauling, fuel system, induction, emission control, mechanical components, transmission, differentials.
Chassis And Body:
Chassis, bodywork, steering, suspension, brakes (including ABS).
Electrical And Diagnostics:
Wiring diagrams, control systems, troubleshooting, and diagnostics.
Emission Control Systems:
Covers diagnosis and repair of emission control systems, including catalytic converters, oxygen sensors, and EGR (Exhaust Gas Recirculation) valves.
Control Systems:
Detailed information on engine management systems, ABS control modules, and other electronic control units (ECUs).
Fuel System:
Covers fuel tank, pump, lines, injectors (petrol), and high-pressure fuel pump and injectors (diesel).
Induction And Exhaust:
Includes intake manifolds, air filters, exhaust systems, and turbocharger systems for diesel variants.
Steering And Suspension:
Details on steering rack, power steering pump, control arms, shock absorbers, and wheel bearing replacement.
Procedures Included
Maintenance:
Routine maintenance procedures, fluid checks and changes, filter replacements, scheduled servicing.
Diagnostics And Repair:
Fault diagnosis, symptom analysis, component testing, repair procedures for all covered systems, including engine rebuilding and transmission overhauling.
Technical Guidance:
Specific terminal pin connections, expected readings, engine management system analysis, common fault fixes, pre-emptive maintenance tips.
Wiring Diagram Interpretation:
Provides detailed wiring diagrams with specific terminal pin connections and expected voltage/resistance readings for accurate electrical troubleshooting.
Diagnostic Techniques:
Outlines diagnostic strategies, including fault code retrieval, symptom-based troubleshooting, and 'secret techniques' used by professional mechanics.
Practical Solutions:
Offers practical, quick solutions to common drivability issues like no-starts, hesitations, and stalling, often with illustrative drawings.
Mechanic Interaction:
Empowers owners to communicate effectively with mechanics, understand proposed repairs, and verify completed work.
Engine Overhauling Steps:
Detailed procedures for engine disassembly, inspection, measurement, and reassembly, including piston ring replacement, bearing checks, and cylinder head work.
Brake System Repairs:
Covers brake pad and disc replacement, caliper servicing, brake line inspection and replacement, and bleeding procedures.
Technical Depth
Depth Level:
Comprehensive, covering basic owner checks to advanced diagnostic techniques and complete mechanical overhauls. Suitable for both DIY owners and independent professionals.
Torque Settings:
Includes detailed torque specifications for all major fasteners and components, crucial for correct assembly and preventing damage.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Printable pages for practical use, avoiding damage to original documents.
Binding Type
Binding Format:
N/A (Digital PDF)
Paper Type
Paper Quality:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine 1 6 Petrol:
Likely the 1.6L 16v TU5JP4 (EW10J4 precursor) or EC5 engine, producing around 110 PS (108 hp; 81 kW).
Engine 1 6 Hdi Diesel:
The 1.6L HDi turbodiesel engine, available in various power outputs (e.g., 90 PS / 89 hp / 66 kW and 110 PS / 108 hp / 80 kW variants) with common rail direct injection.
Fuel System
Petrol Fuel System:
Multi-point fuel injection (MPI).
Diesel Fuel System:
Common Rail Direct Injection (CDi) with turbocharging and intercooling for HDi variants.
Performance
1 6 Hdi Power Output:
The 1.6 HDi engine was typically offered in 90 PS (66 kW) and 110 PS (80 kW) variants, with peak torque figures around 205 Nm and 240 Nm respectively.
1 6 Petrol Power Output:
The 1.6 16v petrol engine usually produced around 110 PS (81 kW) with a torque output in the region of 150 Nm.
🔧 Transmission
Standard
Gearbox Options:
Typically offered with a 5-speed manual transmission (e.g., BE series) and a 4-speed automatic transmission (e.g., AL4).
Features
Automatic Transmission Features:
The AL4 automatic often featured Tiptronic (manual override) functionality.
📐 Dimensions
Exterior
Body Styles:
Available as a 5-door hatchback and a 3-door hatchback. A 4-door sedan and a station wagon (C4 Picasso) were also part of the C4 family but might not be covered in detail for this specific manual focus.
Weights
Curb Weight:
Approx. 1200-1350 kg (2645-2976 lbs) depending on engine and specification.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Achieved a 5-star Euro NCAP safety rating for adult occupant protection.
Passive Features
Airbags:
Multiple airbags including front, side, and curtain airbags.
Active Features
ABS Esp:
Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD) and Emergency Brake Assist (EBA). Electronic Stability Program (ESP) was often optional or standard on higher trims.
💡 Technology Features
Infotainment
Audio System:
Standard radio/CD player with steering wheel controls. Higher trims may include MP3 compatibility and a more advanced audio system.
Driver Assistance
Cruise Control:
Cruise control with speed limiter was available on many models.
Connectivity
Auxiliary Input:
Auxiliary input for external audio devices may be present on later models or as an option.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 15,000 km (9,300 miles) or 1 year, whichever comes first, depending on engine type and driving conditions. Consult manual for exact intervals.
Fluid Specifications
Engine Oil Specification:
For petrol engines, typically a 5W-30 or 5W-40 synthetic oil meeting ACEA A3/B3 or A3/B4 specifications. For HDi diesel, usually a low-SAPS 5W-30 oil meeting ACEA C2 specifications (e.g., PSA B71 2290).
Coolant Specification:
An antifreeze coolant concentrate, typically blue or green, meeting PSA standards (e.g., PSA B71 5100) mixed with distilled water.
Brake Fluid Specification:
DOT 4 brake fluid is standard.
Transmission Fluid Specification Manual:
Gear oil meeting specifications like SAE 75W-80 GL-4.
Transmission Fluid Specification Auto:
For the AL4 automatic transmission, specialized ATF (Automatic Transmission Fluid) meeting PSA specifications is required, often a LT 71141 type fluid.
Known Issues
Common Problems:
Potential issues can include automatic transmission (AL4) valve body problems, electronic throttle body failures, DPF (Diesel Particulate Filter) issues on HDi models, and occasional suspension component wear.
📚 Vehicle History
Brand Heritage
Citroen Heritage:
Citroën has a long history of innovation, particularly in suspension and chassis design, dating back to André Citroën's early automotive ventures.
Model Evolution
C4 Lineage:
The C4 replaced the Citroën Xsara and was positioned as a more modern and stylish alternative in the compact family car segment. It shared its platform with the Peugeot 307.
Design Philosophy:
Characterized by innovative design, including a fixed-hub steering wheel and a distinctive body shape, aiming for comfort and advanced styling.
Production
Manufacturing Locations:
Primarily manufactured in France (e.g., Mulhouse) and also in other international locations depending on market.
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