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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标签: 2004 C4 C4 1.6 16V HDi Car Cars Citroen

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Description

🏷️ Basic Information

Identification

Make:

Citroën

Model:

Year:

Engine:

1.6 16V HDi

Codes

Engine Code Prefix:

👋 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:

Engine Electrical:

Fuel System:

Exhaust System:

Cooling System:

Transmission Manual:

Transmission Automatic:

Drivetrain:

Suspension:

Steering:

Brakes:

Electrical System:

Body And Chassis:

Interior Trim:

HVAC System:

Safety Systems:

Diagnostics And Troubleshooting:

Wiring Diagrams:

Page Count

Estimated Pages:

Hundreds

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

📖 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:

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

Standard Anti-lock Braking System

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)