body Citroen C4 2005 2.G Workshop Manual

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1
IDENTIFICATION OF THE VEHICLE
E1AP0EWD
A- Manufacturer's name plate
A1 -Front RH chassis member = All versions except
CITROËN C4Coupé EW10J4S
(right hand drive).A2 -LH centre pillar = CITROËN C4 coupé EW10J4S(right hand drive).
B - Cold stamp
(cold stamp engraved on the bodywork).
C - AS/RP No. and RP paint code
(on the front pillar on driver's side).
D - Tyre pressures and tyre type
(on the front pillar on driver's side).
E - Serial number on bodywork.
F - Gearbox ident. reference - Factory serial no.
G - Engine legislation type - Factory serial no.
GENERAL
C4
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GENERAL
Structure Version (4)
L Family (1)Depollution levels
A Bodywork (2)L3 L4 L5 US Others K Alcohol
LA KFUC KFU Engine (3)W3 83/87 K' L3/L4 L5
C Version (4)Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5)Manual 4-speed gearbox E F R W 6 9 2
Family (1)Manual 6-speed gearbox G H S X 3
L C4 Automatic 6-speed gearbox D J N U
Body shape (2)Axle and/or gearbox gears K L T Y 7 0 4
A 3-door saloon Other possible combinations M
C 5-door saloon No gearbox Z
G3-door saloon not
convertible from van
R5-door saloon not
convertible from van
Engine (3) Variants (5)
KFU 1.4i 16V ET3J4 Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
RFJ EW10A Without FAP SF
RFN 2.0i 16V EW10J4 Fiscal incentives IF
RFK EW10J4S Piloted manual gearbox P
9HY
DV6TED4Downgraded depollution D
9HZ 1.6 16V HDi LPG dual fuel GL
9HX DV6ATED4 CNG dual fuel GN
RHR 2.0 16V HDi DW10BTED4 STT2 (Stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
C4
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GENERAL
Structure Version (4)
N Family (1)Depollution levels
2 Bodywork (2)15.04Spécif US93/59 96/69 98/69A 98/69B Alcohol
N2 RFN1/IFRFN Engine (3)K ≠ CEE L/W2 L3/W3 L4 L5 L3/L4
1 Version (4)Manual 4-speed gearbox V
/IF Variant (5)Manual 5-speed gearbox G H E F B 1 K
Family (1)Manual 6-speed gearbox
N XSARA Automatic 3-speed gearbox T D L 2
Body shape (2)Automatic 4-speed gearbox U R M N 3 4
2 Estate Axle and/or gearbox gears W S J C P 9
Manual 5-speed gearbox
Mercosur/IranXYA5
No gearbox Z
Engine (3) Variants (5)
KFW 1.4i TU3JP Entreprise convertible T
NFU 1.6i 16V TU5JP4 Integral alternator-starter (ADIN) AD
RFN 2.0i 16V EW10J4 Without FAP SF
8HZ 1.4 HDi DV4TD Fiscal incentives IF
8HY 1.4 16V HDi DV4TED4 Piloted manual gearbox P
WJY 1.9D DW8B Downgraded depollutionD (car or van not
TD (van convertible)
convertible)
RHY
2.0 HDiDW10TD LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
RHZ DW10ATED STT2 (stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
XSARA
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5
IDENTIFICATION OF THE VEHICLEXSARA PICASSO
E1AP088D
A- Chassis stamp
(cold stamp on bodywork).
B -Chassis no. reminder
(label located at bottom of windscreen right hand side).
C -Manufacturer's data plate
(located at bottom of RH central pillar).
D -Label:
(located on front LH door inner panel)
- Tyre pressures.
- Tyre identification.
- Spare wheel identification.
E -Label:
(located on fuse box cover)
- Factory code.
- A-S / RP N°.
- Paint code.
F -Gearbox identification ref.
G -Engine legislation type - Factory serial number.
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GENERAL
Structure Version (4)
C Family (1)Depollution levels
H Bodywork (2)L3 L4 L5 US Others K Alcohol
CH 6FZC/IF 6 F ZEngine (3)W3 83/87 K' L3/L4 L5
C Version (4)Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5)Manual 4-speed gearbox E F R W 6 9 2
Family (1)Manual 6-speed gearbox G H S X 3
C XSARA PICASSO Automatic 6-speed gearbox D J N U
Body shape (2)Axle and/or gearbox gears K L T Y 7 0 4
H Monoshell Other possible combinations M
No gearbox Z
Engine (3)Variants (5)
NFV 1.6i TU5JP Entreprise convertible T
6FZ 1.8i 16V EW7J4 Integral alternator-starter (ADIN) AD
RFN 2.0i 16V EW10J4 Without FAP SF
9HZ
1.6 16V HDi DV6TED4Fiscal incentives IF
9HY Piloted manual gearbox P
RHY 2.0 HDi DW10TD Downgraded depollutionD (car or van not
convertible)TD (van convertible)
LPG dual fuel GPL (cylindrical tank) GL (ring-shaped tank)
STT2 (stop and start) S
IDENTIFICATION OF THE VEHICLE
Type approval
XSARA PICASSO
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GENERAL
Structure Version (4)
G Family (1)Depollution levels
J Bodywork (2)L3 L4
Euro IVUS Others K Alcohol
GJ NFUC/IF N F UEngine (3)W3 83/87 K' L3/L4 Euro IV
C Version (4)Manual 5-speed gearbox A B C P V 5 8 1
/IF Variant (5)Manual 4-speed gearbox E F R W 6 9 2
Family (1)Manual 6-speed gearbox G H S X 3
Automatic 6-speed gearbox D J N U
Body shape (2)Axle and/or gearbox gears K L T Y 7 0 4
Other possible combinations M
No gearbox Z
Engine (3)Variants (5)
KFW 1.4i TU3JP 2 sliding side doors standard for 800 Kg WJY PLC Van Turkey TR
NFU 1.6i 16V TU5JP4 Multi-function roof standard for Car WJY PMF Van Spain ES
WJY 1.9D DW8B Without FAP SF Car/Van 5-seater PL
RHY 2.0 HDi DW10TD Fiscal incentives IF
4x4 DANGEL DGL
Downgraded depollution D
Bi-carburation GPL GL
Bi-carburation GNV GN
STT2 (stop and stard) S
IDENTIFICATION OF THE VEHICLE
Type approval
BERLINGO
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SPECIAL FEATURES - TIGHTENING TORQUES (m.daN)
Cylinder block
14 Crankshaft bearing cap sealing screw (*) 0,8 ± 0,1
15 Knock sensor 2 ± 0,4
16 Coolant pump stud screw 1,6 ± 0,2
17 Coolant pump cover screw 0,6 ± 0,1
18 Screw of coolant pump body on cylinder block 6,5 ± 0,6
19 Cooling circuit plug 3 ± 0,5
20 Oil circuit plugs 3 ± 0,5
21 Flywheel screw (*) 6,7 ± 0,6
22 Con rod cap fixing nut 3,7 ± 0,4
23 Accessories drive belt pulley screw 0,8 ± 0,2
Crankshaft pinion screw
24Tightening4 ± 0,4
Angular tightening45°±4°
Crankshaft bearing cap cover screw (*)
25Tightening2
Angular tightening44°±4°
Engine: KFU
B1DP1KVP
(*) = IMPERATIVE: Respect the tightening sequence (see following page).
C4
ENGINE
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CLUTCH
GEARBOX
TRANSMISSION
TIGHTENING TORQUES: MA/5 GEARBOX
Engines: KFU - NFU
Tightening torques (m.daN).
(8)Gearbox support shaft nut: 6,5 ± 0,6
(9) Screws fixing gearbox support on body: 1,9 ± 0,1
(10)Gearbox support plate nut: 2,5 ± 0,2
(11)Nut fixing gearbox support on body: 1,9 ± 0,1
(12)Nut securing rubber bush: 3 ± 0,3
B2CP3ZKC
C4
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AXLES
SUSPENSION
STEERING
C4TIGHTENING TORQUES: FRONT AXLE
Tightening torques (m.daN).
(1)Nut fixing suspension leg on body: 6,9 ± 0,6
(2) Nut fixing upper damper cup: 6,9 ± 0,6
(3)Upper fixing of anti-roll bar rod: 3,6 ± 0,3
(4)Lower fixing of anti-roll bar rod: 3,6 ± 0,3
(5)Nut fixing pivot lower ball-joint: 4,2 ± 0,4
(6)Fixing of pivot lower ball-joint on pivot: 23 ± 2,3
(7)Hub nut: 32,5 ± 2,6
(8)Steering ball-joint on pivot: 3,5 ± 0,3
(9)Fixing of suspension leg on pivot: 9 ± 0,9
Anti-roll bars
Engines Diameter (mm) Colour
ET3J4 TU5JP - EW10A/J4
DV621.5 Pink
EW10J4S DW10BTED4 22 White
B3BP18ZP
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AXLES
SUSPENSION
STEERING
C4TIGHTENING TORQUES: FRONT AXLE
Tightening torques (m.daN).
(10)Fixing of subframe extension on body: 5,1 ± 1,2
(11)Fixing of tie-rod on body: 1,8 ± 0,4
(12)Tie-rod screw on front subframe: 9,8 ± 0,9
(13) Fixing of anti-roll bar bearing on subframe: 10,4 ± 1
(14)Fixing of lower suspension arm on subframe: 11,1 ± 1
(15)Fixing of subframe extension on body: 8,5 ± 0,8
(16)Fixing of steering mechanism on subframe: 8 ± 0,8
B3CP08TD
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