Vehicle Class:
Compact family car (Hatchback and Estate/Wagon variants).
Key Competitors:
Volkswagen Golf, Ford Focus, Opel/Vauxhall Astra, Renault Mégane, Peugeot 307.
Vehicle Highlights:
Comfortable ride (Citroën's renowned hydro-pneumatic suspension on some variants, though less common on 1.6i), practical interior, distinctive styling.
Utility:
Essential resource for accurate diagnosis, repair, and maintenance, ensuring the longevity and optimal performance of the 2005 Citroën Xsara 1.6i 16V.
Coverage Scope:
Comprehensive service and repair for all major mechanical and electrical systems.
Body Repair:
Bodywork repair techniques, panel alignment, rust prevention, window replacement.
Paint Code Info:
May include information on locating paint codes.
Type:
Full Service & Repair Manual
Content Type:
Workshop Manual / Service Manual
Searchability:
Fully searchable text within the PDF document.
Viewing Requirements:
Requires a PDF reader (e.g., Adobe Acrobat Reader).
Engine Management:
Engine mechanicals, fuel injection, ignition system, emissions control.
Transmission:
Manual gearbox (BE4/ML), clutch system, gearbox overhaul.
Chassis:
Suspension (front & rear independent), steering, brakes (front discs, rear drums/discs), ABS.
Electrical:
Complete wiring diagrams, ECU, lighting, instrumentation, comfort systems, body electronics.
Body And Interior:
Body panel repair, interior trim, seating, HVAC system.
Maintenance Procedures:
Routine maintenance (oil changes, filter replacements, spark plugs), scheduled servicing.
Diagnostic Procedures:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation.
Repair Procedures:
Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhaul, brake caliper replacement.
Diagnostics Electrical:
Detailed diagnostic flowcharts for electrical faults, including BSI (Body Style Integration) module troubleshooting, CAN bus communication issues.
Diagnostics Engine:
Engine performance diagnostics, fuel system pressure testing, ignition timing checks, lambda sensor testing.
Depth:
Detailed technical specifications, torque values, clearances, diagnostic procedures, and overhaul instructions suitable for professional mechanics and advanced DIYers.
Engine Rebuild:
Includes piston ring replacement, bearing checks, cylinder head gasket replacement, valve grinding, timing chain/belt installation.
Brake System Overhaul:
Detailed procedures for brake pad/disc replacement, caliper servicing, brake line bleeding, ABS hydraulic unit diagnosis.
Suspension Repair:
Focus on common rear torsion beam axle repair, front suspension component replacement (ball joints, wishbones, shock absorbers).
Engine Type:
Naturally Aspirated Inline-4
Bore X Stroke:
78.5 mm x 82.0 mm
Compression Ratio:
10.8:1
Valvetrain:
DOHC, 16 Valves
Horsepower:
110 PS (108 bhp / 81 kW) at 6000 rpm
Torque:
150 Nm (111 lb-ft) at 4000 rpm
Fuel Delivery:
Multi-point Fuel Injection (MPI), Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Petrol (95 RON recommended)
Emission Control:
Catalytic Converter, Euro 3 compliant
Oil Capacity With Filter:
3.5 Litres (approx.)
Recommended Oil Grade:
5W-40 or 10W-40 API SL/CF or ACEA A3/B3
Transmission Type:
5-Speed Manual
Automatic Transmission Availability:
Yes, AL4 4-speed Automatic (less common on this specific engine variant in all markets, but available).
Clutch Type:
Hydraulic, Single Dry Plate
Gearbox Oil Grade:
SAE 75W-80 GL-4
Gearbox Oil Capacity:
2.1 Litres (approx.)
Euro Ncap Rating:
4 Stars (for the model generation, specific scores vary by year and equipment)
ABS:
Standard on most 2005 models, with EBD (Electronic Brakeforce Distribution).
Traction Control:
Optional on some higher trims.
Airbags:
Driver, passenger, side airbags standard on many models; curtain airbags optional.
Seatbelts:
Pre-tensioning seatbelts with force limiters.
Oil And Filter Change:
Every 15,000 km or 12 months, whichever comes first.
Spark Plug Replacement:
Every 60,000 km or 4 years (depending on plug type).
Air Filter Replacement:
Every 30,000 km or 24 months.
Timing Belt Replacement:
Every 90,000 km or 5 years (critical interval for the TU5JP4 engine).
Coolant Type:
Antifreeze/Coolant, ethylene glycol based, purple/pink colour (PSA specification).
Common Problems:
Rear suspension beam wear (needs refurbishing/replacement), ABS sensor failure, ECU issues, ignition coil failure, water ingress into fuse box.
Engine Reliability:
The TU5JP4 engine is generally robust but can suffer from oil leaks (e.g., camshaft seal) and sticky throttle bodies if not maintained.
Citroen Legacy:
Citroën, a French manufacturer known for innovation, comfort, and distinctive design, with a rich history dating back to 1919.
Xsara Generation:
The Xsara (introduced in 1997) was the successor to the Citroën ZX and was built on the PSA PF2 platform (shared with Peugeot 307). The 2005 model is part of the second phase (Phase 2) facelift.
Production Period:
1997-2006 (for Xsara hatchback/estate); Xsara Picasso continued longer.
