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2004 Citroen C4 1.6L Service & Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: C4 Model Generation: First Generation (Type 1) Model Year: 2004 Engine Variant Covered: 1.6L Codes Chassis Code Prefix: RHF Engine Code Example: NFU (EC5) 👋 Introduction Market Position Segment: Compact family hatchback (C-segment) Target Audience: Families, commuters, general consumers seeking practical and stylish transport Competitive Analysis Key Competitors 2004: Volkswagen Golf, Ford Focus, Opel Astra, Renault Mégane, Peugeot 307 Key Features Design Philosophy: Avant-garde styling, unique 'mistral' central fixed steering wheel hub (discontinued in later models), emphasis on comfort and practicality Platform: PSA PF2 platform (shared with Peugeot 307) 📋 Manual Details Coverage Areas Overall Coverage: Comprehensive A-Z for all models and all repairs Page Count Estimated Page Count: Extensive (typically 1500+ pages for comprehensive workshop manuals) Manual Type Type: Service and Repair Manual Language Language: English (assumed, typical for international sales) Format Format: Digital (PDF) or Printed (assumed based on product description implying technician use) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, oil pump, lubrication system Engine Management: Fuel injection, ignition system, emissions control, ECU diagnostics, sensors, actuators Transmission Manual: Clutch, gearbox assembly, shifting mechanisms, bearings, seals Transmission Automatic: If applicable to the 1.6L variant, typically covering AT variants Braking System: Front and rear brakes, ABS, EBD, brake hydraulics, parking brake Suspension And Steering: Front and rear suspension components, shock absorbers, springs, steering rack, power steering system Electrical System: Battery, charging system, starter motor, lighting, wiring diagrams, fuses, relays, body control modules Body And Chassis: Body panels, doors, hoods, trunk, interior trim, chassis components, rust prevention Climate Control: HVAC system, air conditioning, heater core, blower motor, controls Safety Systems: Airbags, seatbelts, ABS, traction control (if equipped) Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation Major Repairs: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul Component Replacement: Step-by-step instructions for replacing common parts (e.g., alternator, starter, radiator, water pump, fuel pump) Electrical Diagnostics: Wiring diagrams interpretation, circuit testing, component testing using multimeters and oscilloscopes Body Repair: Panel alignment, dent repair, rust treatment, trim piece removal and installation Air Conditioning Service: Refrigerant handling, system evacuation and recharging, leak detection Technical Depth Depth Of Information: Factory-level technical data and procedures Diagnostic Codes: Includes specific OBD-II (On-Board Diagnostics II) fault codes and their meanings Torque Specifications: Precise torque values for all critical fasteners Special Tools: Lists and descriptions of special tools required for specific repairs Wiring Diagrams: Detailed, system-specific wiring schematics Illustrations And Diagrams: Clear, exploded views and step-by-step photographic or illustrative guidance 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - commonly used for ease of distribution and searchability Print Quality Image Resolution: High resolution for clear viewing of diagrams and text Binding Type Printed Binding: Coil-bound or perfect-bound for lay-flat usability in a workshop environment (if applicable) Paper Type Printed Paper: Durable, high-quality paper suitable for workshop use (if applicable) ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, naturally aspirated petrol Engine Code Common: TU5JP4 (1.6i 16V) Displacement: 1587 cc Bore X Stroke: 78.5 mm x 82 mm Performance Horsepower Ps: 110 PS (approx. 108 hp) at 6000 rpm Torque Nm: 147 Nm (approx. 108 lb-ft) at 4000 rpm Fuel System Fuel Delivery: Multi-point electronic fuel injection (MPI) Fuel Type: Unleaded petrol (RON 95 recommended) Emission Control Emission Standard: Euro 3 / Euro 4 compliant (depending on market and specific variant) 🔧 Transmission Standard Type: 5-speed Manual Transmission (e.g., BE4/5) Optional Type: 4-speed Automatic Transmission (AL4/DP0, often referred to as Tiptronic) Features Manual Gear Ratios: Specific gear ratios provided in manual for optimization and repair Automatic Transmission Features: Sequential shifting mode, adaptive learning 📐 Dimensions Exterior Body Styles: 5-door hatchback, 3-door hatchback, 4-door coupe (C4 'Lounge') Length: 4260 mm (5-door hatchback) Width: 1773 mm Height: 1488 mm Weights Curb Weight: Approx. 1200-1300 kg (depending on specification) 🛡️ Safety Features Ratings Euro Ncap Rating: 5 Stars (achieved in 2005 for the first generation C4) Active Features ABS: Standard Anti-lock Braking System Ebd: Standard Electronic Brakeforce Distribution Esp Optional: Optional Electronic Stability Program (ESP) / Traction Control System (ASR) Passive Features Airbags: Multiple airbags including front, side, and curtain airbags Seatbelts: Pretensioner seatbelts with force limiters Child Seat Anchors: ISOFIX mounting points 💡 Technology Features Infotainment Audio System: Factory fitted CD player, radio, optional MP3 compatibility Display: Digital display for climate control and audio settings Driver Assistance Cruise Control: Optional cruise control and speed limiter Connectivity Bluetooth: Optional Bluetooth hands-free system (may be part of upgraded audio packages) 🔧 Maintenance Service Intervals Oil Change Interval: Every 15,000 km or 1 year, whichever comes first (or as per manufacturer's specific recommendation) Timing Belt Interval: Typically every 120,000 km or 5 years (critical component,...
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Sku: 507573
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2004 Citroen C4 1.6L Service & Repair Manual
🏷️ Basic Information
Identification
Make:
Citroën
Model:
C4
Model Generation:
First Generation (Type 1)
Model Year:
2004
Engine Variant Covered:
1.6L
Codes
Chassis Code Prefix:
RHF
Engine Code Example:
NFU (EC5)
👋 Introduction
Market Position
Segment:
Compact family hatchback (C-segment)
Target Audience:
Families, commuters, general consumers seeking practical and stylish transport
Competitive Analysis
Key Competitors 2004:
Volkswagen Golf, Ford Focus, Opel Astra, Renault Mégane, Peugeot 307
Key Features
Design Philosophy:
Avant-garde styling, unique 'mistral' central fixed steering wheel hub (discontinued in later models), emphasis on comfort and practicality
Platform:
PSA PF2 platform (shared with Peugeot 307)
📋 Manual Details
Coverage Areas
Overall Coverage:
Comprehensive A-Z for all models and all repairs
Page Count
Estimated Page Count:
Extensive (typically 1500+ pages for comprehensive workshop manuals)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English (assumed, typical for international sales)
Format
Format:
Digital (PDF) or Printed (assumed based on product description implying technician use)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, valve train, crankshaft, pistons, connecting rods, oil pump, lubrication system
Engine Management:
Fuel injection, ignition system, emissions control, ECU diagnostics, sensors, actuators
Transmission Manual:
Clutch, gearbox assembly, shifting mechanisms, bearings, seals
Transmission Automatic:
If applicable to the 1.6L variant, typically covering AT variants
Braking System:
Front and rear brakes, ABS, EBD, brake hydraulics, parking brake
Suspension And Steering:
Front and rear suspension components, shock absorbers, springs, steering rack, power steering system
Electrical System:
Battery, charging system, starter motor, lighting, wiring diagrams, fuses, relays, body control modules
Body And Chassis:
Body panels, doors, hoods, trunk, interior trim, chassis components, rust prevention
Climate Control:
HVAC system, air conditioning, heater core, blower motor, controls
Safety Systems:
Airbags, seatbelts, ABS, traction control (if equipped)
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation
Major Repairs:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper overhaul
Component Replacement:
Step-by-step instructions for replacing common parts (e.g., alternator, starter, radiator, water pump, fuel pump)
Electrical Diagnostics:
Wiring diagrams interpretation, circuit testing, component testing using multimeters and oscilloscopes
Body Repair:
Panel alignment, dent repair, rust treatment, trim piece removal and installation
Air Conditioning Service:
Refrigerant handling, system evacuation and recharging, leak detection
Technical Depth
Depth Of Information:
Factory-level technical data and procedures
Diagnostic Codes:
Includes specific OBD-II (On-Board Diagnostics II) fault codes and their meanings
Torque Specifications:
Precise torque values for all critical fasteners
Special Tools:
Lists and descriptions of special tools required for specific repairs
Wiring Diagrams:
Detailed, system-specific wiring schematics
Illustrations And Diagrams:
Clear, exploded views and step-by-step photographic or illustrative guidance
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - commonly used for ease of distribution and searchability
Print Quality
Image Resolution:
High resolution for clear viewing of diagrams and text
Binding Type
Printed Binding:
Coil-bound or perfect-bound for lay-flat usability in a workshop environment (if applicable)
Paper Type
Printed Paper:
Durable, high-quality paper suitable for workshop use (if applicable)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, naturally aspirated petrol
Engine Code Common:
TU5JP4 (1.6i 16V)
Displacement:
1587 cc
Bore X Stroke:
78.5 mm x 82 mm
Performance
Horsepower Ps:
110 PS (approx. 108 hp) at 6000 rpm
Torque Nm:
147 Nm (approx. 108 lb-ft) at 4000 rpm
Fuel System
Fuel Delivery:
Multi-point electronic fuel injection (MPI)
Fuel Type:
Unleaded petrol (RON 95 recommended)
Emission Control
Emission Standard:
Euro 3 / Euro 4 compliant (depending on market and specific variant)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission (e.g., BE4/5)
Optional
Type:
4-speed Automatic Transmission (AL4/DP0, often referred to as Tiptronic)
Features
Manual Gear Ratios:
Specific gear ratios provided in manual for optimization and repair
Automatic Transmission Features:
Sequential shifting mode, adaptive learning
📐 Dimensions
Exterior
Body Styles:
5-door hatchback, 3-door hatchback, 4-door coupe (C4 'Lounge')
Length:
4260 mm (5-door hatchback)
Width:
1773 mm
Height:
1488 mm
Weights
Curb Weight:
Approx. 1200-1300 kg (depending on specification)
🛡️ Safety Features
Ratings
Euro Ncap Rating:
5 Stars (achieved in 2005 for the first generation C4)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brakeforce Distribution
Esp Optional:
Optional Electronic Stability Program (ESP) / Traction Control System (ASR)
Passive Features
Airbags:
Multiple airbags including front, side, and curtain airbags
Seatbelts:
Pretensioner seatbelts with force limiters
Child Seat Anchors:
ISOFIX mounting points
💡 Technology Features
Infotainment
Audio System:
Factory fitted CD player, radio, optional MP3 compatibility
Display:
Digital display for climate control and audio settings
Driver Assistance
Cruise Control:
Optional cruise control and speed limiter
Connectivity
Bluetooth:
Optional Bluetooth hands-free system (may be part of upgraded audio packages)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15,000 km or 1 year, whichever comes first (or as per manufacturer's specific recommendation)
Timing Belt Interval:
Typically every 120,000 km or 5 years (critical component, refer to manual for exact value)
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40, API SN/SM/SL or ACEA A3/B4 or C2/C3 (check specific requirement for emissions systems)
Coolant Type:
Antifreeze/Coolant (G12/G12+ or equivalent long-life coolant, typically purple or pink)
Brake Fluid Type:
DOT 4 (or DOT 4 LV for some systems)
Transmission Fluid Manual:
API GL-5, SAE 75W-80 synthetic (e.g., Total Transmission BV)
Transmission Fluid Automatic:
Specific ATF fluid for AL4/DP0 (e.g., LT 71141 or equivalent)
Known Issues
Ignition Coils:
Can be prone to failure, leading to misfires
Coil Pack Failures:
Common cause of rough running and Check Engine Light
Automatic Transmission Sluggishness:
AL4 gearbox can sometimes exhibit delayed shifts or harshness if fluid is degraded or valve body issues occur
Electronic Faults:
As with many modern vehicles, various sensors and control modules can develop faults
📚 Vehicle History
Brand Heritage
Citroen Legacy:
Known for innovative design, hydropneumatic suspension (though not on C4), and driver comfort
Model Evolution
Predecessor:
Citroën Xsara
Launch Year:
2004
Production
Manufacturing Locations:
Primarily France (Mulhouse), also other PSA plants globally
🏆 Awards & Recognition
Recognitions
Euro Ncap Award:
Achieved 5-star Euro NCAP safety rating, highlighting structural integrity and safety features.
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