CITROEN C4 1.6i 16V 2004 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: C4 Year: 2004 Engine Variant: 1.6i 16V Codes Engine Code Identifier: TU5JP4 (likely, common for this engine) 👋 Introduction Market Position Vehicle Segment:...

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Type: Car

Vendor:

Sku: 460099

Tags: 2004 C4 Car Cars Citroen

Product variants

Description

🏷️ Basic Information

Identification

Make:

Citroën

Model:

Year:

Engine Variant:

1.6i 16V

Codes

Engine Code Identifier:

TU5JP4 (likely, common for this engine)

👋 Introduction

Market Position

Vehicle Segment:

Compact family car (C-segment).

Target Audience:

Individuals and families seeking a stylish, comfortable, and practical European hatchback.

Competitive Analysis

Key Competitors:

Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Renault Mégane.

Key Features

Design Philosophy:

Emphasized aerodynamic styling, innovative interior design, and driver comfort.

Manual Utility:

Empowers owners and technicians with factory-level knowledge for efficient and accurate repairs and maintenance.

📋 Manual Details

Coverage Areas

Model Years Covered:

2004 (primarily, with potential relevance to early C4 models)

Engine Variants Covered:

1.6i 16V (TU5JP4/EP6 - clarification needed on specific engine code if provided by manufacturer, but 1.6i 16V points to a specific family)

Trim Levels Covered:

All applicable trim levels for the 1.6i 16V engine variant

Page Count

Estimated Page Count:

Hundreds (as stated, typical for a complete factory manual)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Delivery Format:

Instant Download (Digital PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnostics, timing belt, cooling system, lubrication, fuel injection, ignition system, exhaust system, engine management system (ECU).

Transmission:

Manual transmission (likely, given engine) - removal, installation, internal components, fluid specifications, clutch operation and replacement.

Brakes:

Hydraulic system, ABS, brake pad and disc replacement, caliper overhaul, bleeding procedures, parking brake.

Electrical:

Wiring diagrams, battery, charging system (alternator, starter), lighting, fuses and relays, power windows, central locking, dashboard instruments, diagnostic connector (OBD-II).

Suspension:

Front and rear suspension components, shock absorbers, springs, ball joints, bushings, wheel alignment specifications.

Steering:

Power steering system (hydraulic), steering rack, tie rod ends, steering column.

Bodywork:

Exterior panel removal and installation, interior trim, door mechanisms, hood and trunk operation, glass replacement.

HVAC:

Air conditioning system, heater core, ventilation system, refrigerant handling (with safety precautions).

Procedures Included

Maintenance:

Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, brake fluid flush, coolant replacement.

Troubleshooting:

Diagnostic procedures for common faults, symptom-based troubleshooting guides, error code interpretation.

Repair:

Step-by-step repair instructions for all major components and systems, including detailed disassembly and reassembly processes.

Installation:

Installation procedures for replacement parts and accessories.

Diagnostics:

On-board diagnostics (OBD-II), sensor testing, actuator testing, fault finding.

Technical Depth

Depth Of Coverage:

Comprehensive (Factory-level detail for professional technicians and advanced DIYers).

Diagrams Illustrations:

High-quality diagrams, exploded views, and detailed illustrations for clarity of procedures.

Specifications:

Critical torque specifications, clearances, fluid capacities, and other vital data.

📊 Manual Specifications

File Format

File Format:

Compatibility:

All versions of Windows & Mac

Requirements:

Adobe PDF Reader & WinZip (for potential archive extraction if zipped)

Print Quality

Printability:

Full Printable

Zoom Functionality:

YES (Zoom IN/OUT functionality

Binding Type

Binding Type:

Digital Download (No physical binding)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated Inline-4

Displacement:

1587 cc (1.6 Liters)

Bore X Stroke:

78.5 mm x 82.0 mm (typical for TU5JP4)

Compression Ratio:

10.2:1 (typical for TU5JP4)

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 109 PS (107 bhp; 80 kW) at 6000 rpm (typical for TU5JP4 in this application)

Torque:

Approximately 147 Nm (108 lb-ft) at 4000 rpm (typical for TU5JP4 in this application)

Fuel System

Fuel Delivery:

Multi-point fuel injection (MPFI)

Fuel Type:

Unleaded gasoline (RON 95 recommended)

Emission Control:

Catalytic converter, Euro 3/4 compliant (depending on market)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

Likely a 4-speed Automatic Transmission (AL4) available on some models, but the manual is specified.

Features

Clutch Type:

Hydraulically operated diaphragm spring clutch

📐 Dimensions

Exterior

Body Styles:

Hatchback (3-door and 5-door)

Length:

Approx. 4,260 mm (for 5-door hatchback)

Width:

Approx. 1,773 mm

Height:

Approx. 1,460 mm

Weights

Curb Weight:

Approx. 1200 - 1300 kg (depending on equipment)

🛡️ Safety Features

Ratings

Euroncap Rating:

5 Stars (for the C4 model generally, verified for Euro NCAP crash tests of the era)

Active Features

Standard (Anti-lock Braking System)

Optional (Electronic Stability Program), potentially available on higher trims.

Passive Features

Airbags:

Multiple airbags (front, side, curtain) depending on trim level.

Seatbelts:

Pre-tensioned seatbelts with force limiters, ISOFIX child seat anchors.

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player with steering wheel controls.

Navigation:

Optional factory navigation system.

Driver Assistance

Cruise Control:

Optional cruise control and speed limiter.

Parking Sensors:

Optional rear parking sensors.

Connectivity

Bluetooth:

Rare for 2004 models as standard, likely an aftermarket addition or available on later revisions/higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 20,000 km or 1 year, whichever comes first (check manual for specific oil type).

Timing Belt Replacement:

Typically 120,000 km or 5 years (critical item for this engine family; consult manual for exact interval).

Fluid Specifications

Engine Oil Type:

Refer to manual; likely Total Quartz INEO ECS 5W-30 or a compatible API SN/ACEA C2 specification oil.

Engine Oil Capacity:

Approx. 3.2 Liters with filter change (verify in manual).

Coolant Type:

Antifreeze/Coolant (e.g., Citroën Blue Antifreeze) - ethylene glycol based, typically orange or red hue.

Brake Fluid Type:

DOT 4

Transmission Fluid Type:

Refer to manual; manual gearbox oil specification (e.g., API GL-4).

Known Issues

Ignition Coils:

Can be prone to failure, leading to misfires.

Electric Power Steering:

Early models could have issues with the EPS system, though this engine is more likely to have hydraulic power steering.

Thermostat:

Can fail to open or close correctly, affecting engine temperature regulation.

Egr Valve:

Can become clogged with carbon deposits, affecting engine performance and emissions.

📚 Vehicle History

Brand Heritage

Citroen Philosophy:

Known for innovation, avant-garde design, and comfort-oriented engineering.

Model Evolution

C4 Introduction:

Launched in 2004 as a successor to the Citroën Xsara, based on the PSA Platform 2.

Generation:

First Generation (2004-2010)

Production

Manufacturing Locations:

Primarily produced in France (e.g., Aulnay-sous-Bois) and Spain.

🏆 Awards & Recognition

Recognitions

Safety Award:

Euro NCAP 5 Star Safety Rating (Significant achievement for a 2004 vehicle)