🏷️ Basic Information

Make:

Citroën

Model:

C5

Year:

2004

Engine Variant:

2.0 16V HPi

Engine Code:

EW10D (HPi)

👋 Introduction

Target Audience:

Professional automotive technicians, experienced DIY mechanics, and Citroën C5 owners seeking in-depth repair knowledge.

Value Proposition:

Provides factory-level repair and maintenance data, enabling owners to perform complex tasks and make informed decisions, saving on labor costs.

Manual Advantage:

Offers the same detailed information as traditional factory manuals, but with the convenience of instant digital access and printability.

Content Structure:

Step-by-step instructions, critical specifications, high-quality diagrams, troubleshooting guides, and maintenance schedules.

Accessibility:

Instant download eliminates shipping delays and costs, allowing immediate access to repair information.

📋 Manual Details

Manual Type:

Complete Official Full Factory Service Repair Manual

Language:

English

Format:

PDF

Delivery Method:

Instant Download

Printability:

Full Printable

Zoom Functionality:

Yes

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, assembly, inspection, and repair of all engine components including cylinder head, block, pistons, crankshaft, camshafts, valves, and timing systems.

Fuel System:

Detailed coverage of the HPi direct injection system, fuel pump, injectors, fuel pressure regulator, fuel filter, and evaporative emission control system.

Ignition System:

Ignition coil pack operation, spark plug replacement, ignition timing and control.

Cooling System:

Radiator, thermostat, water pump, cooling fan operation, coolant specifications, and bleeding procedures.

Exhaust System:

Catalytic converter, exhaust manifold, mufflers, oxygen sensors, and emission control components.

Transmission Manual:

Detailed repair and overhaul procedures for manual transmissions, including clutch, gearbox internals, synchronizers, and shift linkages.

Transmission Automatic:

Coverage for automatic transmission (if applicable to specific variant, though HPi is typically manual) including torque converter, valve body, gear sets, and electronic control.

Drivetrain And Axles:

Front-wheel drive system, CV joints, drive shafts, differential, and wheel bearings.

Suspension System:

Front and rear suspension components, springs, shock absorbers, control arms, anti-roll bars, and hydraulic suspension system (Hydractive) details.

Steering System:

Power steering system, pump, rack and pinion, steering column, and wheel alignment specifications.

Brake System:

Front and rear brake components, disc brakes, pads, calipers, brake lines, master cylinder, ABS system, and brake fluid specifications.

Electrical System:

Complete wiring diagrams, battery, charging system (alternator), starter motor, lighting systems, and accessory circuits.

Body And Chassis:

Body panel removal and installation, door mechanisms, glass replacement, interior trim, and structural components.

Climate Control HVAC:

Air conditioning system, heater core, blower motor, refrigerant, and control modules.

Infotainment And Electronics:

Radio, CD player, navigation system, dashboard instrumentation, and control units.

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections and replacement.

Troubleshooting:

Diagnostic procedures for common issues, fault code interpretation, and symptom-based troubleshooting guides.

Engine Repair:

Complete engine rebuild, head gasket replacement, piston ring replacement, bearing checks, timing belt/chain replacement.

Transmission Repair:

Clutch replacement, gearbox internal repairs, seal replacement, gear oil changes.

Brake System Repair:

Brake pad and rotor replacement, caliper overhaul, brake line bleeding, ABS sensor replacement.

Suspension Component Replacement:

Replacement of shock absorbers, struts, ball joints, control arms, and bushings.

Electrical Diagnostics:

Tracing electrical faults, checking circuits, replacing sensors, modules, and actuators.

Bodywork And Interior Repair:

Panel alignment, door lock and window regulator repair, interior trim piece replacement.

Diagnostic Tool Usage:

Information on using diagnostic equipment for engine management and other vehicle systems.

Depth Level:

Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.

Diagnostics:

Advanced diagnostic procedures, including sensor data interpretation, fault code analysis, and live data stream interpretation.

Specifications:

Extensive torque specifications, clearances, pressures, electrical values, and other critical technical data.

Rebuild Procedures:

Detailed step-by-step instructions for complete disassembly and reassembly of major mechanical and electrical components.

📊 Manual Specifications

File Type:

PDF

Requirements:

Adobe PDF Reader, WinZip (for potential archive extraction)

Compatibility:

All Versions of Windows & Mac

Print Capability:

Printable

Diagram Quality:

Top quality diagrams and illustrations, including exploded views.

Binding:

Digital Download (PDF)

Paper Equivalent:

Equivalent to a professionally printed workshop manual.

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, 16-valve, Naturally Aspirated with Direct Injection

Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

85.0 mm x 88.0 mm (typical for EW10 series)

Compression Ratio:

10.8:1 (typical for EW10D)

Valve Train:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

Horsepower Max:

136 PS (134 hp / 100 kW) at 6000 rpm (approximate)

Torque Max:

192 Nm (142 lb-ft) at 4000 rpm (approximate)

Fuel Delivery:

Multi-point Direct Injection (HPi)

Fuel Type:

Unleaded gasoline (RON 95 recommended)

Emissions Control:

Euro 3/4 compliant, featuring catalytic converter and lambda sensors.

🔧 Transmission

Type:

5-speed Manual Transmission (ML5C or similar)

Type:

4-speed Automatic Transmission (AL4, though less common with HPi)

Clutch:

Hydraulically operated, dry single-plate clutch.

Gear Ratios:

Specific gear ratios for manual transmission detailed in the manual.

Transmission Fluid:

Specific manual transmission fluid specification (e.g., PSA B71 2310 or equivalent API GL-4).

📐 Dimensions

Length:

4,772 mm (approx.)

Width:

1,783 mm (approx.)

Height:

1,475 mm (approx.)

Curb Weight:

1450 - 1550 kg (depending on equipment, approximate)

Gross Vehicle Weight:

2000 - 2100 kg (approximate)

🛡️ Safety Features

Euro Ncap Rating:

5 Stars (for overall safety, specific model year testing)

ABS:

Standard Anti-lock Braking System

Esp:

Optional Electronic Stability Program (ESP)

Brake Assist:

Standard Electronic Brake Force Distribution (EBD) and Brake Assist (EBA).

Airbags:

Driver, passenger, side airbags, and curtain airbags (depending on trim).

Seatbelts:

Pretensioning front seatbelts with force limiters.

💡 Technology Features

Audio System:

Standard CD player with radio, optional premium sound system, steering wheel controls.

Navigation:

Optional factory navigation system.

Cruise Control:

Standard or optional cruise control and speed limiter.

Parking Assistance:

Optional rear parking sensors.

Connectivity Options:

Limited to basic auxiliary input for audio on some models, Bluetooth hands-free was introduced later in the generation.

🔧 Maintenance

Oil Change Interval:

Every 20,000 km or 1 year, whichever comes first (or as specified by Citroën depending on driving conditions).

Spark Plug Replacement:

Every 60,000 km or 4 years (for Iridium type, check manual for specifics).

Timing Belt Replacement:

Every 120,000 km or 5 years (critical for EW engines, check manual for exact interval and component kit).

Engine Oil Specification:

Synthetic engine oil, typically meeting PSA B71 2296 or ACEA A3/B4 specifications, viscosity 5W-40 or 0W-40 (refer to manual for exact grade).

Coolant Specification:

Antifreeze/coolant meeting PSA B71 5100 standard, typically a long-life organic acid technology (OAT) coolant.

Brake Fluid Specification:

DOT 4 brake fluid.

Common Problems:

Potential issues include Hydractive suspension system faults (spheres, pressure regulators), electronic control unit (ECU) problems, coil pack failures, and HPi direct injection system issues (injector clogging, fuel pump wear).

Maintenance Focus:

Regularly checking and replacing timing belt and associated components, maintaining the suspension system, and ensuring proper fuel system maintenance are key to longevity.

📚 Vehicle History

Manufacturer:

Citroën (French manufacturer known for innovation in suspension and comfort).

Generation:

First Generation Citroën C5 (Type R1/R2), launched in 2000.

Facelift:

The 2004 model year would have been part of the initial production run, potentially with minor updates.

Manufacturing Plant:

Rennes-la-Janais, France