CITROEN C4 2.0i 16V 2004 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Citroen Model: C4 Year: 2004 Engine Variant: 2.0i 16V 👋 Introduction Market Position Positioning: Compact Family Car, known for distinctive styling and comfort-oriented ride. Competitive Analysis Competitors: Ford Focus, Volkswagen Golf, Opel Astra, Renault Mégane. Key Features Design: Unique, aerodynamic exterior design; spacious interior with a focus on passenger comfort and practicality. Technology: Early adoption of safety features and innovative driver aids for its class. 📋 Manual Details Coverage Areas Coverage Type: Full Service and Repair Page Count Estimated Page Count: Over 1500 Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Engine Mechanical, Engine Control System (ECU), Fuel System, Ignition System, Cooling System, Lubrication System Transmission: Manual Transmission, Automatic Transmission (if applicable), Clutch System Brakes: Hydraulic Brake System, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake Discs, Brake Pads, Calipers, Master Cylinder, Brake Lines Electrical: Wiring Diagrams, Battery, Alternator, Starter Motor, Lighting System, Fuses, Relays, Power Windows, Power Locks, Central Locking, Wiper System, Horn Suspension: Front Suspension (MacPherson Struts), Rear Suspension (Torsion Beam/Multi-link), Shock Absorbers, Springs, Bushings, Anti-roll Bars Steering: Power Steering System, Steering Rack, Tie Rods, Steering Column Body: Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Seals, Interior Trim, Seats, Dashboard Climate Control: Air Conditioning System, Heater Core, Ventilation System Safety Systems: Airbag System, Seatbelt Pre-tensioners Procedures Included Maintenance: Oil Changes, Filter Replacements, Spark Plug Service, Coolant Flushes, Brake Fluid Replacement, Belt Inspection/Replacement, Tire Rotation Troubleshooting: Diagnostic Procedures, Symptom-based Troubleshooting Charts, Error Code Interpretation Repair: Component Removal and Installation, Reassembly Procedures, Specific Repair Techniques Diagnostics: OBD-II Scan Procedures, Sensor Testing, Actuator Testing Rebuilds: Engine Rebuild Specifications, Transmission Rebuild Procedures Electrical Diagnostics: Detailed wiring diagrams for all electrical circuits, component testing procedures, and fault tracing. Body And Interior: Procedures for panel removal/installation, door mechanism repairs, seat adjustment and removal, dashboard disassembly. Technical Depth Depth: Comprehensive (from basic maintenance to complete overhaul and advanced diagnostics) Torque Specifications: All critical torque specifications for engine, transmission, suspension, and chassis components. Diagrams: High-quality exploded diagrams, schematics, and illustrations for clear understanding of assembly and disassembly. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Fully Printable Zoom Functionality Zoom: Zoom In/Out for detailed viewing Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: EW10J4 (likely) Engine Type: Inline 4-cylinder, DOHC (Double Overhead Camshaft), 16 valves Displacement: 1997 cc (2.0 Liters) Bore X Stroke: 85 mm x 88 mm Performance Horsepower: 138 PS (136 bhp / 101 kW) @ 6000 rpm Torque: 192 Nm (142 lb-ft) @ 4000 rpm Fuel System Injection Type: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (Octane Rating 95 Recommended) Engine Management ECU System: Bosch Motronic (likely) or Siemens VDO 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (BE4/5) Optional Transmission Type: 4-speed Automatic Transmission (AL4) Features Manual Gear Ratios: Specific gear ratios available within the manual, detailed for each gear. Fluid Specifications Manual Fluid: API GL-4 SAE 75W-80 (e.g., PSA S71 2306 specification) Automatic Fluid: LF-Type (Low Friction) ATF (e.g., Mobil ATF LT 71141 or equivalent) 📐 Dimensions Exterior Length: 4260 mm (167.7 in) Width: 1773 mm (69.8 in) Height: 1458 mm (57.4 in) Wheelbase: 2605 mm (102.6 in) Weights Curb Weight: Approximately 1300-1400 kg (2866-3086 lbs), varies by transmission and equipment Cargo Trunk Capacity: 320 liters (11.3 cu ft) 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (for 2004 model) Active Features ABS: Standard (Anti-lock Braking System) Esp: Optional (Electronic Stability Program) / Included on higher trims Ebs: Standard (Emergency Brake Assist) Passive Features Airbags: Frontal Airbags, Side Airbags, Curtain Airbags (depending on trim) Seatbelts: 3-point Seatbelts with Pre-tensioners and Load Limiters 💡 Technology Features Infotainment Head Unit: Factory CD Player with RDS, optional MP3 compatibility. Steering wheel audio controls. Driver Assistance Cruise Control: Optional cruise control and speed limiter. Parking Sensors: Optional rear parking sensors. Connectivity Bluetooth: Optional Bluetooth hands-free system on higher trims. Comfort Features Climate Control: Manual or automatic dual-zone climate control. Lighting Headlights: Halogen projector headlights, optional Xenon headlights with cornering function. 🔧 Maintenance Service Intervals Oil Change: Every 12,500 miles or 1 year, whichever comes first. Check manual for specific conditions. Spark Plugs: Approximately every 37,500 miles for standard plugs or 62,500 miles for iridium plugs (check specific plug type). Timing Belt: Recommended replacement every 75,000 miles or 5 years for the 2.0i 16V engine. CRITICAL to follow this interval to prevent engine damage. Fluid Specifications Engine Oil: SAE 5W-40, meeting ACEA A3/B4 or PSA B71 2296 specifications. Coolant: Long-life coolant, typically orange or pink (PSA S71 5111 specification) - mixture of 50% antifreeze and 50% distilled water. Brake Fluid: DOT 4 (e.g., PSA S71 2113 specification). Known Issues Timing Belt Tensioner: Failure of the timing belt tensioner...
Specific gear ratios available within the manual, detailed for each gear.
Fluid Specifications
Manual Fluid:
API GL-4 SAE 75W-80 (e.g., PSA S71 2306 specification)
Automatic Fluid:
LF-Type (Low Friction) ATF (e.g., Mobil ATF LT 71141 or equivalent)
📐 Dimensions
Exterior
Length:
4260 mm (167.7 in)
Width:
1773 mm (69.8 in)
Height:
1458 mm (57.4 in)
Wheelbase:
2605 mm (102.6 in)
Weights
Curb Weight:
Approximately 1300-1400 kg (2866-3086 lbs), varies by transmission and equipment
Cargo
Trunk Capacity:
320 liters (11.3 cu ft)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (for 2004 model)
Active Features
ABS:
Standard (Anti-lock Braking System)
Esp:
Optional (Electronic Stability Program) / Included on higher trims
Ebs:
Standard (Emergency Brake Assist)
Passive Features
Airbags:
Frontal Airbags, Side Airbags, Curtain Airbags (depending on trim)
Seatbelts:
3-point Seatbelts with Pre-tensioners and Load Limiters
💡 Technology Features
Infotainment
Head Unit:
Factory CD Player with RDS, optional MP3 compatibility. Steering wheel audio controls.
Driver Assistance
Cruise Control:
Optional cruise control and speed limiter.
Parking Sensors:
Optional rear parking sensors.
Connectivity
Bluetooth:
Optional Bluetooth hands-free system on higher trims.
Comfort Features
Climate Control:
Manual or automatic dual-zone climate control.
Lighting
Headlights:
Halogen projector headlights, optional Xenon headlights with cornering function.
🔧 Maintenance
Service Intervals
Oil Change:
Every 12,500 miles or 1 year, whichever comes first. Check manual for specific conditions.
Spark Plugs:
Approximately every 37,500 miles for standard plugs or 62,500 miles for iridium plugs (check specific plug type).
Timing Belt:
Recommended replacement every 75,000 miles or 5 years for the 2.0i 16V engine. CRITICAL to follow this interval to prevent engine damage.
Fluid Specifications
Engine Oil:
SAE 5W-40, meeting ACEA A3/B4 or PSA B71 2296 specifications.
Coolant:
Long-life coolant, typically orange or pink (PSA S71 5111 specification) - mixture of 50% antifreeze and 50% distilled water.
Brake Fluid:
DOT 4 (e.g., PSA S71 2113 specification).
Known Issues
Timing Belt Tensioner:
Failure of the timing belt tensioner can lead to belt slippage and severe engine damage. Regular inspection and replacement are crucial.
Coil Packs:
Ignition coil pack failures can cause misfires and rough running.
Automatic Transmission Solenoids:
The AL4 automatic transmission is known for potential solenoid failures, leading to shifting issues.
Water Pump:
Leaks from the water pump seal, especially during timing belt replacement, are common.
Suspension Bushings:
Wear in suspension bushings can lead to knocking noises and poor handling.
📚 Vehicle History
Brand Heritage
Heritage:
Citroën, a French manufacturer with a long history of innovation in automotive design and engineering, particularly known for its hydraulic suspension systems and avant-garde styling.
Model Evolution
Generation:
First Generation (2004-2010). The C4 marked a significant shift for Citroën, replacing the Xsara and establishing a new design language.
Production
Manufacturing Locations:
Primarily manufactured in France (Aulnay-sous-Bois) and Spain (Vigo).
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