Citroen Jumpy 1.9 D 2004 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: Jumpy Year: 2004 Engine Type: Diesel Engine Displacement: 1.9 Liters Codes Platform Code: U64 Generation Generation: First Generation (Type U64) 👋 Introduction Market...

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Sku: 434561

Tags: 2004 Car Cars Citroen Jumpy

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Description

🏷️ Basic Information

Identification

Make:

Citroën

Model:

Jumpy

Year:

Engine Type:

Diesel

Engine Displacement:

1.9 Liters

Codes

Platform Code:

Generation

Generation:

First Generation (Type U64)

👋 Introduction

Market Position

Vehicle Segment:

Light Commercial Vehicle (LCV), Panel Van, MPV

Competitive Analysis

Key Competitors 2004:

Renault Trafic, Ford Transit, Volkswagen Transporter (T4/T5), Fiat Scudo, Peugeot Expert

Key Features

Manual Usability:

Easy-to-read text, step-by-step instructions, detailed diagrams.

Target Audience:

Do-it-yourself enthusiasts and professional mechanics.

Manual Value Proposition:

Saves time and money on repairs, provides accurate technical information.

📋 Manual Details

Coverage Areas

Covered Regions:

Global

Page Count

Estimated Page Count:

300-600 pages (typical for comprehensive service manuals)

Manual Type

Manual Classification:

Full Service and Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and overhaul procedures for the 1.9 D engine.

Engine Management System:

Fuel injection system (indirect injection), ignition timing, sensors, actuators, and diagnostic trouble codes (DTCs).

Cooling System:

Radiator, water pump, thermostat, hoses, coolant specifications, and troubleshooting.

Lubrication System:

Oil pump, oil filter, oil pressure, oil specifications, and oil change procedures.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), muffler, pipes, and emissions control.

Fuel System:

Fuel tank, fuel lines, fuel filter, injection pump, injectors, and troubleshooting fuel delivery issues.

Transmission Manual:

Gearbox overhaul, clutch operation, gear shift mechanism, and transmission fluid specifications.

Transmission Automatic:

N/A for the 1.9 D variant.

Drivetrain:

Front-wheel drive system, driveshafts, CV joints, and differential.

Suspension Front:

MacPherson strut, wishbones, anti-roll bar, bushings, and wheel bearing replacement.

Suspension Rear:

Torsion beam suspension (common on this platform), shock absorbers, and rear axle components.

Steering System:

Steering rack, power steering pump, fluid specifications, and troubleshooting.

Braking System:

Front disc brakes, rear drum brakes (common), brake fluid specifications, bleeding procedures, and ABS system (if equipped).

Electrical System Power:

Battery, alternator, starter motor, charging system diagnostics.

Electrical System Lighting:

Headlights, taillights, interior lighting, bulb replacement, and wiring diagrams.

Electrical System Instruments:

Dashboard gauges, warning lights, and instrument cluster.

Body Exterior:

Body panel removal and installation, door mechanisms, glass replacement, bumpers, and trim.

Body Interior:

Seat removal, dashboard components, interior trim panels, and carpet.

HVAC System:

Heating, ventilation, and air conditioning (HVAC) system operation, components, and refrigerant servicing (if applicable).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections.

Troubleshooting:

Diagnostic flowcharts for common problems, symptom-based troubleshooting guides.

Repair Procedures:

Step-by-step instructions for component replacement and repair.

Rebuilds:

Detailed procedures for engine and transmission rebuilds.

Electrical Diagnostics:

Wiring diagrams, circuit testing, and component testing.

Body Repair:

Panel alignment, dent repair, rust prevention, and sealant application.

Technical Depth

Diagnostic Capabilities:

Advanced diagnostics with detailed explanations of sensor data and control module functions.

Reconstruction Level:

Complete disassembly and reassembly of all major vehicle systems.

Diagram Quality:

High-quality diagrams, exploded views, and detailed illustrations.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, suitable for printing and digital viewing.

Print Quality

Printability:

Fully printable

Binding Type

Binding Method:

Digital (PDF Download)

Paper Type

Digital Format Notes:

Downloadable, instant access, no physical paper.

⚙️ Engine Specifications

Primary Engine

Engine Code:

DW8 (typically)

Engine Configuration:

Inline 4-cylinder, naturally aspirated diesel

Bore X Stroke:

82.2 mm x 92 mm (typical for DW8)

Compression Ratio:

19.5:1 (typical)

Horsepower Output:

69 hp (51 kW) at 4600 rpm (typical)

Torque Output:

124 Nm (91 lb-ft) at 2000 rpm (typical)

Fuel System

Fuel Type:

Diesel

Injection Type:

Indirect Injection (IDI) with rotary injection pump

Glow Plugs:

Equipped with glow plug system for cold starting.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Optional Transmission:

Not commonly available for the 1.9 D variant.

Features

Clutch Type:

Hydraulically operated single dry plate clutch

📐 Dimensions

Exterior

Length:

4.27 m (approx. for short wheelbase)

Width:

1.81 m

Height:

1.89 m

Cargo

Cargo Volume:

Approx. 3-4.5 m³ depending on configuration

Weights

Gross Vehicle Weight Rating:

Approx. 2200-2500 kg

Curb Weight:

Approx. 1500-1600 kg

Towing Capacity:

Approx. 1500 kg (braked)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

Variable based on year and exact specification, typically 3-4 stars for passenger variants.

Active Features

Optional or standard depending on trim and market. The manual would cover its diagnosis and operation.

Electronic Stability Control:

Rare on this specific 1.9 D 2004 model.

Passive Features

Airbags:

Driver airbag standard, passenger airbag optional.

Seatbelts:

All seating positions equipped with seatbelts, often with pre-tensioners.

💡 Technology Features

Infotainment

Audio System:

Basic radio/cassette or CD player with optional speakers. Manual will cover basic operation and speaker wiring.

Driver Assistance

Cruise Control:

Rarely fitted on the 1.9 D models, but if present, the manual would detail its operation and diagnostics.

Connectivity

Remote Central Locking:

Optional feature, manual covers key fob battery replacement and system troubleshooting.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 miles or 12 months, whichever comes first (check manual for exact specification).

Air Filter Replacement:

Every 20,000-30,000 miles or as per manual recommendations.

Fuel Filter Replacement:

Every 30,000-40,000 miles.

Timing Belt Replacement:

Critical: Typically 75,000-90,000 miles or 5-7 years for the DW8 engine. Failure can lead to severe engine damage.

Fluid Specifications

Engine Oil Specification:

API CD/CE/CF or ACEA E2/E3, SAE 15W-40 or 10W-40 (check manual for specific viscosity and grade).

Coolant Specification:

Ethylene glycol based antifreeze, typically a pink or blue type. Capacity around 7.5 liters.

Brake Fluid Specification:

DOT 4

Transmission Fluid Specification:

API GL-4, SAE 75W-90 or 80W-90 manual transmission fluid. Capacity around 2.2 liters.

Known Issues

Common Faults Engine:

Glow plug failure leading to hard starting in cold weather, potential for injector pump leaks, exhaust manifold gasket leaks.

Common Faults Transmission:

Wear in synchromesh rings causing difficult gear changes, clutch wear.

Common Faults Suspension:

Front suspension bushings wear, leading to knocking noises and poor handling. Rear axle mounting points can corrode.

Common Faults Electrical:

Corroded earth points, failure of dashboard warning lights, issues with central locking system.

📚 Vehicle History

Brand Heritage

Citroen Lcav Heritage:

Citroën has a long history of producing practical and innovative light commercial vehicles, dating back to models like the Citroën Type H.

Model Evolution

Jumpy First Generation:

The first generation Jumpy (also known as Dispatch in the UK and Synergie/Evasion in some markets) was launched in 1994 as part of a joint venture with Fiat, Peugeot, and Lancia (Sevel Nord platform).

2004 Facelift Impact:

The 2004 model year falls within the initial production run of the first generation, which received a facelift around 2000, offering updated styling and minor mechanical improvements.

Production

Manufacturing Location:

Sevel Nord plant in Hordain, France.

🏆 Awards & Recognition

Recognitions

Van Of The Year Awards:

The Jumpy/Dispatch/Expert platform as a whole has received various 'Van of the Year' awards in its various iterations and markets.