🏷️ Basic Information

Make:

Citroen

Model:

Jumpy

Year:

2004

Engine Variant:

2.0i 16V Petrol

Product Name:

Citroen Jumpy 2.0i 16V Petrol 2004 Full Service Repair Manual

Engine Code Likely:

EW10J4 (or similar PSA 2.0L I4)

👋 Introduction

Vehicle Segment:

Light Commercial Vehicle (LCV) / Panel Van / MPV

Target Audience:

Small businesses, tradespeople, families requiring versatile transport.

Key Competitors:

Ford Transit, Renault Trafic, Fiat Scudo, Volkswagen Transporter, Peugeot Expert.

Design Philosophy:

Practicality, versatility, comfort, and modularity, characteristic of Citroën's design heritage.

Manual Benefit:

Empowers owners and mechanics with professional-level diagnostic and repair capabilities, saving time and money.

📋 Manual Details

Coverage Scope:

Comprehensive service, maintenance, and troubleshooting

Estimated Page Count:

Highly comprehensive, likely exceeding 1500 pages based on typical professional manuals for this vehicle class.

Manual Type:

Full Service Repair Manual

Language:

English

File Format:

PDF

Delivery Method:

Instant Download

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for disassembly, assembly, inspection, and repair of the 2.0i 16V petrol engine, including cylinder head, pistons, crankshaft, camshafts, timing system, lubrication, cooling, and fuel injection.

Engine Electrical:

Wiring diagrams, ignition system, starter motor, alternator, battery, sensors (crankshaft position, camshaft position, coolant temperature, oxygen sensors, etc.), and engine control unit (ECU) diagnostics.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, injectors, throttle body, and emissions control systems.

Transmission:

Manual transmission (likely BE4/MA gearbox variant) servicing, clutch replacement, gear linkage adjustments, and lubrication.

Drivetrain:

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

Brakes:

Front and rear brake systems (discs and pads), hydraulic system, ABS (if equipped), parking brake, and bleeding procedures.

Suspension:

Front suspension (MacPherson struts), rear suspension (torsion beam or similar), shock absorbers, springs, bushings, and wheel alignment specifications.

Steering:

Power steering system (hydraulic), steering rack, tie rods, and steering column.

Electrical Body:

Lighting system (headlights, taillights, interior lights), wipers, washers, horn, central locking, power windows, and accessory circuits.

Climate Control:

Heating, ventilation, and air conditioning (HVAC) system diagnosis and repair (if covered).

Bodywork:

Body panel removal/installation, door mechanisms, tailgate, bumpers, and interior trim.

Scheduled Maintenance:

Detailed guidance on routine servicing tasks, including oil changes, filter replacements, spark plug replacement, and visual inspections.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common faults and performance issues, including symptom-based guides.

Component Replacement:

Step-by-step instructions for replacing major and minor components across all vehicle systems.

Adjustments:

Procedures for making critical adjustments, such as clutch cable, handbrake, and ignition timing (if applicable).

Rebuilding:

Complete overhaul procedures for engines, transmissions, and other major assemblies.

Diagnostic Capabilities:

Advanced diagnostic information, including OBD-II codes, sensor readings, and potential fault causes.

Diagrams Illustrations:

High-quality exploded diagrams, schematics, and line drawings to aid in repair and assembly.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

📊 Manual Specifications

File Format:

PDF

Printability:

Full Printable

Zoom Capability:

YES

Binding Type:

Digital (PDF)

Paper Type:

N/A (Digital)

Software Requirements:

Adobe PDF Reader & WinZip

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft), 16 valves

Engine Displacement:

1997 cc (2.0 Liters)

Bore X Stroke:

Approx. 85.0 mm x 88.0 mm (typical for EW10J4)

Compression Ratio:

Approx. 10.8:1 (typical for EW10J4)

Horsepower:

Approx. 136 PS (134 bhp / 100 kW) at 6000 rpm

Torque:

Approx. 192 Nm (142 lb-ft) at 4100 rpm

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Petrol (Gasoline)

Ignition System:

Electronic Ignition with Coil-on-Plug (COP) or distributorless ignition system (DIS)

Cooling System:

Liquid-cooled, pressurized system with thermostatically controlled fan.

Lubrication System:

Pressurized wet sump system with oil pump and oil filter.

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Optional Transmission:

Likely a 4-speed Automatic Transmission (AL4 or similar) was an option on some models/markets.

Gearbox Model Likely:

BE4/MA

Clutch Type:

Hydraulic operation

📐 Dimensions

Length:

Variable based on configuration (e.g., L1, L2 standard/long wheelbase)

Width:

Approx. 1815 mm (excluding mirrors)

Height:

Approx. 1890 mm (standard roof)

Cargo Volume:

Variable based on wheelbase and configuration (e.g., 3.0 m³ to 4.0 m³ approx.)

Gross Vehicle Weight:

Varies by configuration, typically around 2000-2500 kg

Curb Weight:

Varies by configuration, typically around 1400-1600 kg

🛡️ Safety Features

Euro Ncap Rating:

Likely 3 or 4 stars for passenger variants (Euro NCAP 2004-2007 tests for Eurovan 3 platform vehicles).

ABS:

Standard or optional depending on trim level.

Esp:

Likely optional or not available on all models in 2004.

Airbags:

Driver and front passenger airbags standard. Side airbags optional.

Seatbelts:

3-point seatbelts with pretensioners.

💡 Technology Features

Infotainment System:

Basic radio/cassette player or CD player, possibly with auxiliary input. Limited advanced infotainment features expected for 2004.

Cruise Control:

Optional on higher trims.

Connectivity Features:

Basic connectivity options, potentially including Bluetooth hands-free if equipped as an option.

🔧 Maintenance

Oil Change Interval:

Typically 10,000-15,000 miles or 1 year, whichever comes first (refer to manual for exact specification).

Timing Belt Interval:

For the EW10J4 engine, this is crucial. Typically around 75,000-90,000 miles or 5-6 years. Crucial to replace preventatively.

Engine Oil Type:

Likely a synthetic oil, e.g., 5W-40 or 5W-30, meeting PSA specifications (e.g., ACEA A3/B4 or C3).

Coolant Type:

Antifreeze/coolant concentrate, typically blue or purple, meeting PSA specifications (e.g., PSA S71 3320).

Brake Fluid Type:

DOT 4

Transmission Fluid Type:

Manual: GL-4 75W-80 or 75W-90 synthetic gear oil. Automatic: ATF type as specified by PSA (e.g., LT71141 for AL4).

Common Issues:

Potential issues may include suspension wear (bushings, ball joints), clutch wear, EGR valve issues, ignition coil failures, and occasional electrical gremlins, typical for LCVs of this era.

Maintenance Focus:

Regular maintenance of the timing belt, coolant system, and suspension components is vital for longevity.

📚 Vehicle History

Citroen Heritage:

Citroën has a long history of producing innovative and practical vehicles, including commercial vans and MPVs.

Platform Sharing:

The Jumpy (also known as Citroën Dispatch, Fiat Scudo, Peugeot Expert, and Lancia Zeta) is part of the 'Eurovan 3' platform project developed by PSA Peugeot Citroën and Fiat.

Production Period:

First generation produced from 1994 to 2006. The 2004 model falls within this first generation.

Manufacturing Location:

Primarily manufactured in France (Sevel Nord plant).

🏆 Awards & Recognition

Industry Awards:

The Jumpy/Expert/Scudo platform has historically received positive reviews for its practicality and payload capacity, often being recognized within the LCV market.

Reliability Ratings:

Reliability can vary; thorough maintenance as outlined in this manual is key to ensuring dependable operation.