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2004 Citroen C4 I Service and Repair Manual

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🏷️ Basic Information Identification Make: Citroen Model: C4 I Year: 2004 Generation: First Generation (2004-2010) Codes Chassis Code: LC 👋 Introduction Market Position Market Position: The Citroën C4 I, launched in 2004, was positioned as a significant contender in the highly competitive compact family car segment, aiming to blend distinctive French styling with practicality and innovative features. It succeeded the Xsara and aimed to appeal to buyers seeking comfort, technology, and a unique design proposition. Competitive Analysis Competitive Analysis: Key competitors for the C4 I included the Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Renault Mégane, and Peugeot 307. The C4 differentiated itself with its avant-garde interior design (e.g., the fixed-hub steering wheel), comfort-oriented suspension, and emphasis on safety. Key Features Key Features: Distinctive 'V-shaped' styling, innovative fixed-center steering wheel, spacious and comfortable interior, advanced safety features, a range of efficient petrol and diesel engines, and a focus on ride quality. 📋 Manual Details Coverage Coverage Areas: All models and all repairs A-Z Page Count Page Count: Comprehensive (Specific count not provided, but described as extensive for A-Z repairs) Manual Type Manual Type: Service and Repair Manual Language Language: English (Assumed for global distribution, actual language may vary by specific product listing) Format Format: Digital (Likely PDF, enabling searchability and easy access) 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, Engine management and diagnostics, Fuel system, Cooling system, Lubrication system, Exhaust system, Ignition system, Clutch, Manual transmission, Automatic transmission, Driveshafts, Axles, Suspension (front and rear), Steering system, Brakes (hydraulic and pneumatic), ABS, ESP, Bodywork and exterior, Interior trim, Electrical system (wiring diagrams, components), Air conditioning, Heating system, SRS airbag system, Immobilizer, Radio and navigation systems, Emission control systems Electrical System Detail: Extensive coverage of the electrical system, including detailed wiring diagrams for all circuits, location of electrical components, diagnostic procedures for faults, and explanations of control modules (e.g., BSI - Body Style Interface). Chassis Systems Detail: Detailed procedures for suspension component replacement (shock absorbers, springs, control arms, bushes), steering rack overhaul, and brake system servicing (pad/disc replacement, caliper overhaul, bleeding procedures for ABS systems). Procedures Included Procedures Included: Routine maintenance, Scheduled servicing, Troubleshooting, Diagnostic procedures, Component removal and installation, Overhaul and repair of major sub-assemblies, Electrical troubleshooting, Wiring harness repair, Body panel repair, Interior component repair, Software updates and coding (where applicable) Troubleshooting Methodology: Structured troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) provided by OBD-II scanners, and step-by-step diagnostic flowcharts. Bodywork Repair: Detailed instructions for body panel alignment, dent repair, rust prevention and treatment, and replacement of external trim components. Includes specific instructions for bumpers, doors, hoods, and tailgates. Interior Trim Removal: Step-by-step guides for removing and refitting interior panels, seats, dashboard components, and roof lining, crucial for accessing other systems or performing repairs. Technical Depth Technical Depth: Complete rebuilds, Advanced diagnostics, Detailed component specifications, Torque values, Clearances, Timing procedures, Diagnostic trouble codes (DTCs) and their interpretations, Schematics and wiring diagrams Engine Diagnostics: In-depth diagnostics for engine management systems, including fuel injection timing, ignition timing, sensor data interpretation, and actuator testing for both petrol and diesel engines. Diagnostic Tools: Information on required diagnostic tools, including specific Peugeot/Citroën diagnostic software (e.g., DIAGBOX/PP2000) for advanced parameter reading, actuator tests, and module programming. 📊 Manual Specifications File Format File Format: PDF (Typically, allowing for bookmarking, searchability, and printing) Print Quality Print Quality: High-resolution scans or original manufacturer quality (for clarity of diagrams and text) Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format) Completeness Completeness: Explicitly stated to cover 'ALL MODELS & ALL REPAIRS A-Z', indicating a comprehensive and exhaustive scope. This is not a generic guide but vehicle-specific. ⚙️ Engine Specifications Primary Engine Primary Engine: 1.6 HDi (DV6) Diesel Engine Primary Engine Petrol: 1.6i 16V (TU5JP4/ET3) Petrol Engine Other Engines: Other engines include 1.4 HDi, 2.0 HDi, 1.4 VTi petrol, 1.6 VTi petrol, 2.0 VTi petrol, and the performance-oriented 1.6 THP (Prince engine). Performance 1 6 Hdi Power: 90 PS (66 kW; 89 hp) and 110 PS (81 kW; 109 hp) variants 1 6 Hdi Torque: 200 Nm (148 lb-ft) at 1,750 rpm (90 PS), 240 Nm (177 lb-ft) at 1,750 rpm (110 PS) 1 6I 16V Petrol Power: 110 PS (81 kW; 109 hp) 1 6I 16V Petrol Torque: 147 Nm (108 lb-ft) at 4,000 rpm 2 0 Hdi Power: 138 PS (101 kW; 136 hp) 2 0 Hdi Torque: 320 Nm (236 lb-ft) at 2,000 rpm Fuel System 1 6 Hdi Fuel System: Common Rail Direct Injection (CRDi) with variable geometry turbocharger (VGT) on 110 PS variant 1 6I 16V Petrol Fuel System: Multi-point Fuel Injection (MPI) 2 0 Hdi Fuel System: Common Rail Direct Injection (CRDi) with variable geometry turbocharger (VGT) Engine Codes Engine Codes Petrol: NFU (1.6i 16v TU5JP4), 8FS (1.4 VTi ET3), EP6 (1.6 VTi Prince) Engine Codes Diesel: 8HZ...
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Mots clés: 2004 C4 I Car Citroen
2004 Citroen C4 I Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Citroen
Model:
C4 I
Year:
2004
Generation:
First Generation (2004-2010)
Codes
Chassis Code:
LC
👋 Introduction
Market Position
Market Position:
The Citroën C4 I, launched in 2004, was positioned as a significant contender in the highly competitive compact family car segment, aiming to blend distinctive French styling with practicality and innovative features. It succeeded the Xsara and aimed to appeal to buyers seeking comfort, technology, and a unique design proposition.
Competitive Analysis
Competitive Analysis:
Key competitors for the C4 I included the Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Renault Mégane, and Peugeot 307. The C4 differentiated itself with its avant-garde interior design (e.g., the fixed-hub steering wheel), comfort-oriented suspension, and emphasis on safety.
Key Features
Key Features:
Distinctive 'V-shaped' styling, innovative fixed-center steering wheel, spacious and comfortable interior, advanced safety features, a range of efficient petrol and diesel engines, and a focus on ride quality.
📋 Manual Details
Coverage
Coverage Areas:
All models and all repairs A-Z
Page Count
Page Count:
Comprehensive (Specific count not provided, but described as extensive for A-Z repairs)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English (Assumed for global distribution, actual language may vary by specific product listing)
Format
Format:
Digital (Likely PDF, enabling searchability and easy access)
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, Engine management and diagnostics, Fuel system, Cooling system, Lubrication system, Exhaust system, Ignition system, Clutch, Manual transmission, Automatic transmission, Driveshafts, Axles, Suspension (front and rear), Steering system, Brakes (hydraulic and pneumatic), ABS, ESP, Bodywork and exterior, Interior trim, Electrical system (wiring diagrams, components), Air conditioning, Heating system, SRS airbag system, Immobilizer, Radio and navigation systems, Emission control systems
Electrical System Detail:
Extensive coverage of the electrical system, including detailed wiring diagrams for all circuits, location of electrical components, diagnostic procedures for faults, and explanations of control modules (e.g., BSI - Body Style Interface).
Chassis Systems Detail:
Detailed procedures for suspension component replacement (shock absorbers, springs, control arms, bushes), steering rack overhaul, and brake system servicing (pad/disc replacement, caliper overhaul, bleeding procedures for ABS systems).
Procedures Included
Procedures Included:
Routine maintenance, Scheduled servicing, Troubleshooting, Diagnostic procedures, Component removal and installation, Overhaul and repair of major sub-assemblies, Electrical troubleshooting, Wiring harness repair, Body panel repair, Interior component repair, Software updates and coding (where applicable)
Troubleshooting Methodology:
Structured troubleshooting guides based on symptoms, diagnostic trouble codes (DTCs) provided by OBD-II scanners, and step-by-step diagnostic flowcharts.
Bodywork Repair:
Detailed instructions for body panel alignment, dent repair, rust prevention and treatment, and replacement of external trim components. Includes specific instructions for bumpers, doors, hoods, and tailgates.
Interior Trim Removal:
Step-by-step guides for removing and refitting interior panels, seats, dashboard components, and roof lining, crucial for accessing other systems or performing repairs.
Technical Depth
Technical Depth:
Complete rebuilds, Advanced diagnostics, Detailed component specifications, Torque values, Clearances, Timing procedures, Diagnostic trouble codes (DTCs) and their interpretations, Schematics and wiring diagrams
Engine Diagnostics:
In-depth diagnostics for engine management systems, including fuel injection timing, ignition timing, sensor data interpretation, and actuator testing for both petrol and diesel engines.
Diagnostic Tools:
Information on required diagnostic tools, including specific Peugeot/Citroën diagnostic software (e.g., DIAGBOX/PP2000) for advanced parameter reading, actuator tests, and module programming.
📊 Manual Specifications
File Format
File Format:
PDF (Typically, allowing for bookmarking, searchability, and printing)
Print Quality
Print Quality:
High-resolution scans or original manufacturer quality (for clarity of diagrams and text)
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format)
Completeness
Completeness:
Explicitly stated to cover 'ALL MODELS & ALL REPAIRS A-Z', indicating a comprehensive and exhaustive scope. This is not a generic guide but vehicle-specific.
⚙️ Engine Specifications
Primary Engine
Primary Engine:
1.6 HDi (DV6) Diesel Engine
Primary Engine Petrol:
1.6i 16V (TU5JP4/ET3) Petrol Engine
Other Engines:
Other engines include 1.4 HDi, 2.0 HDi, 1.4 VTi petrol, 1.6 VTi petrol, 2.0 VTi petrol, and the performance-oriented 1.6 THP (Prince engine).
Performance
1 6 Hdi Power:
90 PS (66 kW; 89 hp) and 110 PS (81 kW; 109 hp) variants
1 6 Hdi Torque:
200 Nm (148 lb-ft) at 1,750 rpm (90 PS), 240 Nm (177 lb-ft) at 1,750 rpm (110 PS)
1 6I 16V Petrol Power:
110 PS (81 kW; 109 hp)
1 6I 16V Petrol Torque:
147 Nm (108 lb-ft) at 4,000 rpm
2 0 Hdi Power:
138 PS (101 kW; 136 hp)
2 0 Hdi Torque:
320 Nm (236 lb-ft) at 2,000 rpm
Fuel System
1 6 Hdi Fuel System:
Common Rail Direct Injection (CRDi) with variable geometry turbocharger (VGT) on 110 PS variant
1 6I 16V Petrol Fuel System:
Multi-point Fuel Injection (MPI)
2 0 Hdi Fuel System:
Common Rail Direct Injection (CRDi) with variable geometry turbocharger (VGT)
Engine Codes
Engine Codes Petrol:
NFU (1.6i 16v TU5JP4), 8FS (1.4 VTi ET3), EP6 (1.6 VTi Prince)
Engine Codes Diesel:
8HZ (1.4 HDi DV4), 9HX (1.6 HDi DV6), 9HY/9HZ (1.6 HDi DV6), RHR (2.0 HDi DW10BTED)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission (AL4), 6-speed Automated Manual Transmission (EGS - Electronic Gearbox System)
Features
Transmission Features:
The AL4 automatic was known for its comfort but could be hesitant; the EGS offered fuel economy benefits but was often criticized for its jerky shifts. The manual transmissions were generally well-regarded for their smoothness.
📐 Dimensions
Exterior
Exterior Dimensions Length:
4,260 mm (167.7 in)
Exterior Dimensions Width:
1,773 mm (69.8 in)
Exterior Dimensions Height:
1,455 mm (57.3 in)
Cargo
Cargo Volume:
Approx. 320 liters (11.3 cu ft) (hatchback)
Weights
Curb Weight:
Starting from approx. 1,200 kg (2,646 lb)
Wheelbase
Wheelbase:
2,608 mm (102.7 in)
Track Width
Front Track:
1,516 mm (59.7 in)
Rear Track:
1,521 mm (59.9 in)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (Euro NCAP 2005)
Active Features
Active Features:
ABS with EBD (Electronic Brakeforce Distribution), Emergency Brake Assist (EBA), ESP (Electronic Stability Program) available on higher trims, Cruise control
Passive Features
Passive Features:
Up to 7 airbags (front, side, curtain, driver's knee), ISOFIX child seat anchorage points, pretensioner seatbelts, crumple zones, reinforced passenger cell
Safety Equipment
Safety Equipment Standard:
Driver and front passenger airbags, ABS, power steering, electric front windows, remote central locking.
Safety Equipment Optional:
Side airbags, curtain airbags, driver's knee airbag, ESP, rear electric windows, panoramic glass roof.
💡 Technology Features
Infotainment
Infotainment Features:
Optional RDS radio with CD player, MP3 compatibility, steering wheel-mounted controls. Some higher trims featured a more advanced system with a larger display and navigation. The fixed-center steering wheel housed many of these controls.
Driver Assistance
Driver Assistance Features:
Cruise control, speed limiter, parking sensors (optional), automatic windscreen wipers and headlights (optional).
Connectivity
Connectivity Features:
Bluetooth hands-free system available on later models and higher trims. Aux-in port for audio devices.
🔧 Maintenance
Service Intervals
Service Intervals Petrol:
1.6i 16V: Oil and filter change every 12,500 miles (20,000 km) or 1 year. Timing belt replacement every 75,000 miles (120,000 km) or 5 years. Spark plug replacement every 37,500 miles (60,000 km) or 3 years.
Service Intervals Diesel:
1.6 HDi: Oil and filter change every 12,500 miles (20,000 km) or 1 year. Timing belt replacement every 150,000 miles (240,000 km) or 10 years (with recommended interim inspection). Fuel filter replacement every 37,500 miles (60,000 km).
Fluid Specifications
Engine Oil Specification:
For 1.6 HDi: PSA Peugeot Citroën B71 2290 (Low SAPS) specification, typically 0W-30 or 5W-30 synthetic oil. For 1.6i 16V: ACEA A3/B4 or API SL specification, typically 5W-30 or 5W-40 synthetic oil.
Coolant Specification:
PSA Peugeot Citroën B71 5100 (Green or Blue type, extended life antifreeze/coolant)
Brake Fluid Specification:
DOT 4
Transmission Fluid Manual:
API GL-4, SAE 75W-80 (e.g., Total Transmission BV)
Transmission Fluid Automatic Al4:
LT 71141 specification (e.g., Esso LT 71141 or equivalent)
Power Steering Fluid:
Specific hydraulic fluid for power steering system (check manual for exact specification, often PSA standard)
Air Conditioning Refrigerant:
R134a (for the 2004 model year)
Known Issues
Known Issues Diesel:
1.6 HDi: Injector seal leaks, EGR valve clogging, diesel particulate filter (DPF) issues (especially on early models or short-trip usage), turbocharger problems (wastegate actuator), glow plug issues.
Known Issues Petrol:
1.6i 16V: Ignition coil failures, oil leaks from crankcase seals, thermostat issues, potential carbon build-up on intake valves.
Known Issues General:
Electrical gremlins, issues with the fixed-center steering wheel controls, wear on suspension components, automatic transmission (AL4) issues, early EGS gearbox reliability concerns.
Known Issues Fixed Steering Wheel:
Wear on the contact rings within the fixed-center steering wheel (clock spring mechanism) can lead to non-functional steering wheel controls and airbag warning lights. Repair requires replacement of the steering column module.
Fluid Capacities
Engine Oil Capacity 1 6 Hdi:
Approx. 3.75 liters (4.0 US qt) with filter change
Engine Oil Capacity 1 6I 16V:
Approx. 3.25 liters (3.4 US qt) with filter change
Coolant Capacity:
Approx. 7.5 liters (7.9 US qt)
Brake Fluid Capacity:
Approx. 0.75 liters (0.79 US qt)
📚 Vehicle History
Brand Heritage
Brand Heritage:
Citroën, a French automotive manufacturer founded in 1919, has a long history of innovation, particularly in ride comfort and avant-garde design. Brands like the Traction Avant, DS, and SM cemented its reputation for forward-thinking engineering.
Model Evolution
Model Evolution:
The C4 I replaced the well-established Xsara. Its design language was a significant departure, aiming for a more modern and distinctive identity. It was also produced as a sporty 3-door hatchback (C4 Coupé) and later a sedan variant in some markets.
Production
Production Period:
2004-2010 (First Generation)
Manufacturing Locations:
Primarily manufactured in France (Aulnay-sous-Bois and Rennes-Planck) and also in other Stellantis (formerly PSA Peugeot Citroën) plants globally.
Model Variants
Model Variants:
Available as a 5-door hatchback and a 3-door coupé. Later models introduced the C4 Picasso (a compact MPV based on the C4 platform) which is distinct but shares some technologies.
🏆 Awards & Recognition
Recognitions
Recognitions:
The Citroën C4 received a 5-star Euro NCAP safety rating, highlighting its strong performance in occupant protection. It was also praised for its comfortable ride and distinctive design elements.
Ratings
Ratings:
Consistently ranked well for ride comfort and interior space within its class during its production run.
Certifications
Certifications:
Compliant with European emissions standards (Euro 4 for most engines in 2004).
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