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CITROEN C15 1.9 D 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: C15 Year: 2004 Engine Code: DJY (XUD7) Codes Vehicle Type: Light Commercial Vehicle (LCV) / Panel Van / Combi Van 👋 Introduction Market...
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Mots clés: 2004 C15 Car Cars Citroen
CITROEN C15 1.9 D 2004 Full Service Repair ManualCITROEN C15 1.9 D 2004 Full Service Repair ManualCITROEN C15 1.9 D 2004 Full Service Repair ManualCITROEN C15 1.9 D 2004 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Citroën
Model:
C15
Year:
2004
Engine Code:
DJY (XUD7)
Codes
Vehicle Type:
Light Commercial Vehicle (LCV) / Panel Van / Combi Van
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, independent repair shops, fleet maintenance.
Competitive Analysis
Manual Advantage:
Provides dealer-level information for DIY use, comprehensive coverage, cost savings over dealership service.
Key Features
Ease Of Use:
Easy-to-read text, high-quality diagrams, step-by-step instructions.
Practicality:
Downloadable format allows for on-the-spot access via smartphones/tablets for field repairs.
📋 Manual Details
Coverage Areas
Geographic Coverage:
Global (primarily Europe)
Page Count
Estimated Pages:
High (typically 500+ pages for full service manuals)
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
Digital Format:
PDF
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip/equivalent extraction software
Compatibility
Operating Systems:
All Windows and Mac versions
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (1.9 D XUD7), Fuel System, Cooling System, Exhaust System, Ignition System (if applicable, though diesel), Starting System, Charging System
Transmission:
Manual Transmission (gearbox), Clutch System, Driveshafts
Chassis:
Suspension (Front & Rear), Steering System, Braking System (Front Disc, Rear Drum), Wheels and Tires
Electrical:
12V Electrical System, Battery, Alternator, Starter Motor, Lighting System, Instrumentation, Wiper System, Fuses and Relays, Engine Control Unit (ECU) diagnostics (basic)
Body:
Bodywork Repair, Doors, Windows, Interior Trim, Seats, Bumpers, Body Sealing
Procedures Included
Maintenance:
Scheduled Maintenance, Oil Changes, Filter Replacements, Fluid Checks and Top-ups, Spark Plug/Glow Plug Replacement, Belt Inspection/Replacement
Repair:
Engine Overhaul, Transmission Rebuild, Brake System Repairs, Suspension Component Replacement, Electrical Component Diagnosis and Repair, Body Panel Repair
Troubleshooting:
Diagnostic Flowcharts, Common Faults and Solutions, Symptom-based Diagnosis
Technical Depth
Depth:
Comprehensive: From basic maintenance to complete engine and transmission rebuilds, detailed diagnostics, and body repair.
Manual Content Type
Content Focus:
Step-by-step instructions, exploded diagrams, torque specifications, wiring diagrams (likely included).
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Capability:
Yes (Zoom IN/OUT)
Binding Type
Binding:
Digital (N/A for PDF, but printable for physical binding)
Paper Type
Paper Quality:
N/A (Digital - designed to be printed on standard paper)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Diesel
Engine Family:
PSA XUD
Displacement:
1.9 Liters (1905 cc)
Cylinders:
4
Bore X Stroke:
83.0 mm x 88.0 mm (typical for XUD7)
Compression Ratio:
23.0:1 (typical for XUD7)
Performance
Horsepower:
60-69 PS (44-51 kW) at approximately 4000-4600 rpm (depending on specific tuning for C15)
Torque:
114-120 Nm (84-89 lb-ft) at approximately 2000-2500 rpm (depending on specific tuning for C15)
Fuel System
Fuel Injection:
Indirect Injection (IDI) with Bosch VE Rotary Injection Pump
Glow Plugs:
Yes, for cold starting
Engine Cooling
Cooling Type:
Water-cooled, pressurized system
🔧 Transmission
Standard
Transmission Type:
5-speed Manual
Optional
Optional Transmission:
Not typically available for the 1.9 D variant in this model year.
Features
Clutch Type:
Dry, single-plate, diaphragm spring
📐 Dimensions
Exterior
Length:
Approx. 4035 mm
Width:
Approx. 1630 mm (excluding mirrors)
Height:
Approx. 1820 mm
Cargo
Cargo Volume:
Highly variable depending on configuration (panel van vs. combi), typically around 3 cubic meters.
Weights
Curb Weight:
Approx. 1000-1100 kg
Gross Vehicle Weight Rating Gvw:
Approx. 1700-1900 kg
Towing Capacity:
Approx. 750 kg (unbraked), 1100 kg (braked) - Consult vehicle plate for exact figures.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Limited specific official crash test data available for this era of LCV; generally considered basic safety standards of its time.
Active Features
Braking System:
Front ventilated discs, rear drum brakes. Power assisted.
Steering:
Rack and pinion, typically unassisted (power steering not standard/common on this variant).
Passive Features
Airbags:
Driver airbag typically optional or standard depending on market/trim. Passenger airbag uncommon.
Seatbelts:
Front: 3-point inertia reel. Rear (combi): 2-point or 3-point depending on seating arrangement.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM Radio, optional CD player. Speakers typically located in doors or dashboard.
Driver Assistance
Driver Aids:
Limited to basic safety features like ABS (optional on some later models), but not standard on this 2004 1.9 D.
Connectivity
Connectivity Features:
None (no Bluetooth, USB, or smartphone integration in this model).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 10,000-15,000 km or 12 months, whichever comes first. Consult manual for exact specification.
Timing Belt Replacement:
Every 60,000 - 80,000 km or 5 years. Crucial for the XUD engine; failure can cause severe damage.
Fluid Specifications
Engine Oil Grade:
API CD/CE or ACEA B2/B3, typically SAE 10W-40 or 15W-40. Consult manual for precise specifications and ambient temperature suitability.
Coolant Type:
Ethylene Glycol based antifreeze/coolant, typically 50% mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Transmission Fluid Type:
Manual Transmission Fluid (MTF), typically API GL-4, SAE 75W-80 or 75W-90.
Known Issues
Common Problems:
Corrosion (especially around wheel arches, sills, and rear door), injector pump leaks, glow plug issues, exhaust manifold cracks, suspension wear (bushings, ball joints), occasional electrical gremlins (e.g., dashboard lights).
Engine Reliability:
The XUD7 engine is known for its robustness and longevity if properly maintained. However, like all diesels of this era, it requires diligent maintenance, especially regarding the timing belt and oil changes.
📚 Vehicle History
Brand Heritage
Citroen Legacy:
Citroën has a long history of producing robust and practical light commercial vehicles, known for their innovative designs and durability.
Model Evolution
C15 Lineage:
The C15 (also known as the Citroën VÉNA / Citroën Evasion in some markets) is based on the Peugeot 205 platform, inheriting its reliable mechanicals. It was produced for a very long production run, evolving through various engine options and facelifts.
Production
Production Period:
1984 - 2005
Manufacturing Location:
Primarily France.
🏆 Awards & Recognition
Recognitions
Industry Awards:
While the C15 itself didn't receive specific 'car of the year' type awards, it was highly regarded within the LCV sector for its practicality, load-carrying capacity, and affordability, earning it a loyal customer base and significant sales success across Europe.
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