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CITROEN C4 1.6 16V HDi 2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Citroën Model: C4 Year: 2004 Engine: 1.6 16V HDi Codes Engine Code Prefix: DV6 👋 Introduction Market Position Segment: Compact family car (C-segment) Target Audience:...
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🏷️ Basic Information
Identification
Make:
Citroën
Model:
C4
Year:
2004
Engine:
1.6 16V HDi
Codes
Engine Code Prefix:
DV6
👋 Introduction
Market Position
Segment:
Compact family car (C-segment)
Target Audience:
Technicians and DIY mechanics seeking in-depth repair information
Competitive Analysis
Competitors 2004:
Volkswagen Golf, Ford Focus, Vauxhall/Opel Astra, Renault Mégane, Peugeot 307
Key Features
Format Advantage:
Instant download accessibility for immediate repairs
Content Depth:
Factory-level detail, enabling professional-grade repairs
Visuals:
Top-quality diagrams and exploded views for clarity
📋 Manual Details
Coverage Areas
Engine Mechanical:
Yes
Engine Electrical:
Yes
Fuel System:
Yes
Exhaust System:
Yes
Cooling System:
Yes
Transmission Manual:
Yes
Transmission Automatic:
Yes
Drivetrain:
Yes
Suspension:
Yes
Steering:
Yes
Brakes:
Yes
Electrical System:
Yes
Body And Chassis:
Yes
Interior Trim:
Yes
HVAC System:
Yes
Safety Systems:
Yes
Diagnostics And Troubleshooting:
Yes
Wiring Diagrams:
Yes
Page Count
Estimated Pages:
Hundreds
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Management System:
Covers Bosch EDC16 or similar ECU systems
Common Rail Injection:
Detailed information on common rail system operation, diagnosis, and repair
Turbocharger And Intercooler:
Maintenance and repair of the turbocharging system
Emission Control Systems:
Includes information on EGR, DPF (if applicable for early models), and catalytic converter systems
Anti Lock Braking System:
Diagnosis and repair of ABS components and sensors
Electronic Stability Program:
Covers ESP system operation and troubleshooting
Power Steering System:
Hydraulic power steering system maintenance and repair
Climate Control System:
Manual and automatic climate control system servicing
Lighting System:
Headlights, taillights, interior lighting, and bulb replacement
Instrument Panel And Gauges:
Diagnosis of dashboard warning lights and instrument cluster issues
Body Control Module:
Basic BCM functions and troubleshooting
Procedures Included
Engine Overhaul:
Complete engine disassembly, inspection, and reassembly procedures
Timing Belt Replacement:
Step-by-step instructions for timing belt and associated component replacement
Fuel Injector Service:
Removal, testing, and installation of fuel injectors
Turbocharger Rebuild:
Procedures for turbocharger maintenance and potential rebuilds
Brake Pad And Rotor Replacement:
Front and rear brake component replacement
Suspension Component Replacement:
Strut, shock absorber, control arm, and ball joint replacement
Clutch Replacement:
Procedures for manual transmission clutch service
Radiator And Coolant Hoses:
Replacement of cooling system components and fluid flushing
Oil And Filter Changes:
Detailed instructions for routine oil and filter maintenance
Spark Plug Replacement:
Not applicable to HDi diesel model
Accessory Belt Replacement:
Serpentine or V-belt replacement
Battery Testing And Replacement:
Battery maintenance and replacement procedures
Bodywork Repair Guides:
Minor body panel repair and adjustment
Interior Trim Removal:
Door panel, dashboard, and seat removal procedures
Troubleshooting Charts:
Diagnostic flowcharts for common issues
Torque Specifications:
Essential torque values for various fasteners
Technical Depth
Depth:
Comprehensive, from basic maintenance to in-depth engine and electrical system repair
Diagnostics:
Advanced diagnostic procedures for engine, transmission, and ABS/ESP systems
Rebuilds:
Detailed rebuild procedures for major mechanical components
📊 Manual Specifications
File Format
Format:
PDF
Printable:
Yes, full printable
Searchable:
Likely text-searchable PDF (common for factory manuals)
Print Quality
Quality:
High quality diagrams and instructions
Binding Type
Binding:
Digital Download (N/A for physical binding)
Paper Type
Paper:
Digital Download (N/A for paper type)
Requirements
Reader Software:
Adobe PDF Reader
Extraction Software:
WinZip or similar file decompression utility
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder Turbocharged Diesel
Displacement:
1560 cc
Bore X Stroke:
75.3 mm x 88.3 mm
Compression Ratio:
Approx. 17.3:1
Valve Train:
DOHC, 16 valves (4 valves per cylinder)
Fuel System:
Common Rail Direct Injection (Bosch EDC16 or similar system)
Ignition System:
Compression Ignition (Diesel)
Performance
Horsepower Ps:
Approximately 110 PS (80 kW) at 4000 rpm
Torque Nm:
Approximately 240 Nm (177 lb-ft) at 1750 rpm
Fuel System
Fuel Type:
Diesel
Turbocharger:
Variable Geometry Turbocharger (VGT)
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission (AL4)
Features
Clutch Type:
Hydraulic, single dry plate
📐 Dimensions
Exterior
Body Style:
Hatchback (3-door and 5-door)
Length:
Approx. 4265 mm (5-door)
Width:
Approx. 1773 mm
Height:
Approx. 1460 mm
Weights
Curb Weight:
Approx. 1300-1350 kg (depending on specification)
🛡️ Safety Features
Ratings
Euro Ncap Initial Rating:
5 Stars (for the initial C4 generation)
Active Features
ABS:
Standard Anti-lock Braking System
Esp:
Optional Electronic Stability Program (ESP)
Emergency Brake Assist:
EBA included with ABS
Passive Features
Airbags:
Multiple airbags (driver, passenger, side, curtain)
Seat Belts:
Pre-tensioning seat belts with force limiters
Chassis Design:
Designed for improved crashworthiness
💡 Technology Features
Infotainment
Radio Options:
Factory fitted RDS radio with CD player
Navigation:
Optional factory navigation system
Driver Assistance
Cruise Control:
Optional cruise control with speed limiter
Parking Sensors:
Optional rear parking sensors
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 12,500 miles (20,000 km) or 1 year, whichever comes first (check manual for exact)
Timing Belt:
Crucial service item, generally around 120,000 miles (200,000 km) or 10 years (consult manual)
Air Filter:
Replace every 25,000 miles (40,000 km) or as needed
Fuel Filter:
Replace every 37,500 miles (60,000 km)
Fluid Specifications
Engine Oil Type:
API CF/CF-4/CG-4, ACEA B3/B4/B5, or specific PSA approval (e.g., PSA B71 2290 for low-SAP oils)
Engine Oil Capacity:
Approximately 3.75 liters
Coolant Type:
Ethylene glycol based antifreeze, meeting PSA S71 513 standard
Brake Fluid Type:
DOT 4
Power Steering Fluid:
ES-SO LV or equivalent (refer to manual)
Known Issues
Dpf Issues:
Potential DPF blockage if primarily used for short journeys without regeneration
Egr Valve Faults:
EGR valve clogging can lead to reduced performance and check engine lights
Injector Problems:
Diesel injectors can become faulty over time, requiring specialized testing
Glow Plug Failure:
Glow plugs can fail, affecting cold starting
Automatic Transmission Issues:
The AL4 automatic transmission is known for potential hydraulic issues and electronic control faults (if equipped)
📚 Vehicle History
Brand Heritage
Citroen Philosophy:
Known for innovation, comfort, and distinctive design
Model Evolution
C4 Introduction:
Launched in 2004 as a replacement for the Citroën Xsara
Platform:
Built on the PSA PF2 platform
Production
Manufacturing Locations:
Primarily manufactured in France (e.g., Mulhouse)