CITROEN C5 2.2 HDi 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Citroen Model: C5 Year: 2004 Engine: 2.2 HDi Codes Engine Code Prefix: DW12 👋 Introduction Market Position Positioning: Comprehensive DIY and professional workshop resource for...

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Type: Car

Vendor:

Sku: 484570

Tags: 2004 C5 C5 2.2 HDi Car Cars Citroen

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Description

🏷️ Basic Information

Identification

Make:

Citroen

Model:

Year:

Engine:

2.2 HDi

Codes

Engine Code Prefix:

👋 Introduction

Market Position

Positioning:

Comprehensive DIY and professional workshop resource for the Citroen C5 2.2 HDi.

Competitive Analysis

Advantage:

Direct factory information, superior to generic manuals, cost-effective for vehicle owners.

Key Features

Detail Level:

Factory-level detail, step-by-step instructions, diagrams, schematics.

Diy Focus:

Empowers owners to perform maintenance and repairs, saving money and enhancing vehicle knowledge.

Professional Use:

Equally valuable for independent workshops and mobile mechanics.

Format Benefit:

Printable pages allow for easy workshop use, reducing wear on the digital file.

📋 Manual Details

Coverage Areas

Primary Coverage:

2004 Citroen C5 2.2 HDi

Page Count

Estimated Page Count:

High (Full Service Manual - typically 1000+ pages)

Manual Type

Type:

Official Factory Service and Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, diagnostics, fuel system, cooling system, lubrication system, emission control, timing, turbocharger, intercooler.

Transmission:

Manual and Automatic transmission repair, clutch, gearbox, drivetrain components, differential.

Chassis And Suspension:

Hydropneumatic suspension system (Hydractive 3+), steering, front and rear suspension components, wheel alignment, shock absorbers, springs, anti-roll bars.

Brakes:

Brake system diagnosis, repair, ABS, EBD, brake fluid specifications, master cylinder, calipers, pads, discs, parking brake.

Electrical System:

Full wiring diagrams, lighting, ignition, starting system, charging system, battery, fuses, relays, ECU diagnostics, body control modules.

Bodywork And Interior:

Body panel repair, doors, windows, mirrors, seats, dashboard, climate control system, interior trim, sound insulation.

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), use of diagnostic tools, component testing procedures.

Procedures Included

Maintenance:

Routine maintenance schedules, oil changes, filter replacements, fluid checks, belt inspections, tune-ups.

Repair:

Detailed step-by-step repair instructions for all major and minor components.

Disassembly And Assembly:

Comprehensive guides for removing and refitting all vehicle parts and systems.

Specifications And Tolerances:

Torque values, clearances, measurements, and critical specifications for all repairs.

Technical Depth

Depth:

Extremely High (Factory Level Detail)

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Full Printable (High Resolution)

Binding Type

Binding:

N/A (Digital File)

Paper Type

Paper:

N/A (Digital File)

Features

Zoom Functionality:

Yes (Enlarged images and diagrams)

Searchability:

Likely Searchable Text within PDF

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (for extraction if zipped)

Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-4 Turbocharged Diesel (HDi)

Displacement:

2.2 Liters (2179 cc)

Bore X Stroke:

85.0 mm x 96.0 mm (Typical for DW12TED4)

Compression Ratio:

17.7:1 (Typical for DW12TED4)

Valve Train:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

Fuel Delivery:

Common Rail Direct Injection (CRDi) with high-pressure fuel pump and injectors.

Turbocharger:

Variable Geometry Turbocharger (VGT) with intercooler.

Performance

Horsepower:

Approximately 136 PS (134 bhp; 100 kW) at 4000 rpm (Typical for 2004 2.2 HDi)

Torque:

Approximately 317 Nm (234 lb-ft) at 1750 rpm (Typical for 2004 2.2 HDi)

Fuel System

Fuel Type:

Diesel

Emissions Control:

Euro 3/Euro 4 compliant, likely incorporating EGR (Exhaust Gas Recirculation).

🔧 Transmission

Standard

Type:

6-speed Manual Transmission (ML6C)

Optional

Type:

6-speed Automatic Transmission (AL6)

Features

Drivetrain:

Front-Wheel Drive (FWD)

📐 Dimensions

Exterior

Length:

Approximately 4755 mm (187.2 in)

Width:

Approximately 1779 mm (70.0 in)

Height:

Approximately 1472 mm (57.9 in)

Wheelbase

Wheelbase:

Approximately 2725 mm (107.3 in)

Weights

Curb Weight:

Approximately 1550-1650 kg (3417-3638 lbs), depending on transmission and specification.

🛡️ Safety Features

Ratings

Euroncap:

5 Stars (for the Mk1 C5, typically awarded in 2001)

Active Features

Standard Anti-lock Braking System

Optional/Standard Electronic Stability Program (ESP)

Traction Control:

Standard Traction Control System (TCS)

Passive Features

Airbags:

Multiple airbags (front, side, curtain) as standard or optional.

Seatbelts:

Pretensioning seatbelts with load limiters.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player with steering wheel controls, optional navigation system (RT3).

Driver Assistance

Cruise Control:

Standard or optional cruise control with speed limiter.

Parking Sensors:

Optional rear parking sensors.

Connectivity

Bluetooth:

Available in later versions or as an aftermarket addition, but unlikely as standard on 2004 models.

Comfort Features

Climate Control:

Automatic dual-zone climate control.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Typically every 12,500 miles (20,000 km) or 1 year, whichever comes first. Consult manual for specific interval and driving conditions.

Fuel Filter:

Typically every 37,500 miles (60,000 km).

Air Filter:

Typically every 25,000 miles (40,000 km) or as needed based on condition.

Timing Belt:

Critical item. Typically every 75,000 miles (120,000 km) or 5 years. The manual will specify the exact interval and procedure.

Fluid Specifications

Engine Oil:

API CF or ACEA B3/B4 specification, viscosity grade typically 5W-40 or 10W-40. Refer to manual for exact Citroën approved specification (e.g., PSA B71 2290).

Coolant:

Ethylene glycol-based antifreeze, meeting PSA standards. Typically a pink or purple long-life coolant. Refer to manual for correct type and mixture ratio.

Brake Fluid:

DOT 4 standard.

Power Steering Fluid:

Refer to manual for specific type (often PSA specific or mineral oil based).

Hydropneumatic Fluid:

LHM PLUS (Citroën hydraulic fluid) is typically used for the suspension and steering systems of this era.

Known Issues

Suspension Height Sensors:

Common issues with height sensors and their wiring can affect ride height and comfort.

Suspension Spheres:

Hydropneumatic spheres may require periodic replacement or recharging.

Diesel Particulate Filter:

Early models might not have a DPF, or it could be a passive type. If fitted, regeneration issues can occur.

Glow Plugs:

Glow plug failure can lead to difficult cold starts.

Egr Valve:

EGR valve can become clogged with carbon, affecting engine performance and emissions.

📚 Vehicle History

Brand Heritage

Citroen Innovation:

Citroën is renowned for its pioneering spirit in automotive technology, particularly with hydropneumatic suspension systems and innovative designs.

Model Evolution

C5 Generation:

This manual covers the first generation (Mk1) Citroën C5, produced from 2000 to 2008.

C5 Platform:

Based on the PSA EW/DW platform, sharing some components with Peugeot models.

C5 Design:

Characterized by its distinctive 'swooping' lines and a focus on passenger comfort, especially via the Hydractive 3+ suspension.

Production

Manufacturing:

Primarily manufactured in Rennes, France.

🏆 Awards & Recognition

Recognitions

Euroncap Rating:

5 Stars (as mentioned in safety section, awarded to the initial Mk1 C5)