🏷️ Basic Information

Make:

Citroën

Model:

Xsara

Year:

2005

Engine Variant:

2.0 HDi

Engine Code Prefix:

RHZ

Chassis Code:

N1

👋 Introduction

Vehicle Segment:

Compact family car, often positioned as a practical and comfortable alternative to hatchbacks and MPVs of its era.

Key Competitors:

Ford Focus, Volkswagen Golf, Peugeot 307, Renault Mégane.

Manufacturer Philosophy:

Citroën's characteristic focus on ride comfort, innovative suspension (though the Xsara moved away from hydropneumatics), and distinctive styling.

Manual Value Proposition:

Provides essential technical knowledge for maintaining and repairing the popular and robust 2.0 HDi diesel engine, covering a critical period for this model.

📋 Manual Details

Manual Type:

Full Service & Repair Manual

Language:

English

Format:

Digital (likely PDF)

Page Count:

Estimated 2000+ pages (typical for comprehensive manuals of this era and scope)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, piston rings, bearings, valve guides, timing belt replacement, oil pump, cylinder head assembly, gaskets, seals.

Engine Management:

Fuel injection system (common rail), glow plug system, ECU diagnostics, sensor testing (MAP, MAF, crankshaft, camshaft), exhaust gas recirculation (EGR).

Transmission:

Manual gearbox (ML5C, BE3/4), clutch assembly, gear linkage, gearbox oil change and level check, common faults and repairs.

Brakes:

Front and rear disc brake systems, ABS (Anti-lock Braking System) components, brake fluid change, caliper overhaul, handbrake mechanism.

Suspension:

Front MacPherson struts, rear torsion beam axle, control arms, ball joints, bushings, shock absorber replacement, wheel alignment specifications.

Steering:

Hydraulic power steering system, steering rack, tie rod ends, fluid replacement, troubleshooting steering column issues.

Electrical System:

Battery, charging system (alternator), starter motor, lighting (headlights, taillights, interior), fuse box diagrams, wiring harnesses, relay identification.

Body And Chassis:

Body panel removal and installation, door mechanisms, hinges, locks, window regulators, glass replacement, corrosion protection.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, refrigerant recharge, blower motor, cabin filter replacement, control panel operation.

Safety Systems:

Airbag system (SRS) component location, diagnostics, and replacement precautions, seatbelt mechanisms.

Maintenance:

Scheduled maintenance intervals, oil and filter changes, air filter replacement, fuel filter replacement, coolant service, spark plug replacement (if applicable, though HDi is diesel), brake fluid flush.

Troubleshooting:

Systematic diagnostic flowcharts for common drivability issues, electrical faults, starting problems, and performance complaints.

Repair:

Step-by-step instructions for component removal, repair, and reinstallation across all major vehicle systems.

Diagnostics:

OBD-II (On-Board Diagnostics) code interpretation, specific fault code procedures, sensor data analysis.

Specifications:

Torque specifications for all fasteners, fluid capacities, diagnostic trouble codes (DTCs), wiring diagrams, component dimensions.

Depth:

Comprehensive, covering from basic maintenance to advanced engine and transmission overhauls. Suitable for professional mechanics and dedicated DIY enthusiasts.

📊 Manual Specifications

File Type:

Likely PDF, ensuring searchability and easy navigation.

Image Resolution:

High resolution for clear diagrams and illustrations.

Binding:

N/A (Digital Format)

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

DW10TD (or similar variant of the DW10 HDi family)

Engine Configuration:

Inline 4-cylinder, turbocharged, direct injection diesel

Displacement:

1997 cc

Bore X Stroke:

85.0 mm x 88.0 mm

Compression Ratio:

18.0:1 (approximate)

Valve Train:

DOHC (Double Overhead Camshaft), 2 valves per cylinder

Fuel System:

Bosch Common Rail Direct Injection (CRDi)

Ignition System:

Compression ignition (Diesel)

Horsepower:

90 PS (66 kW) @ 4000 rpm (typical for this engine variant)

Torque:

205 Nm (151 lb-ft) @ 1750 rpm (typical for this engine variant)

🔧 Transmission

Transmission Type:

5-speed Manual Transmission (ML5C or similar)

Transmission Type:

4-speed Automatic Transmission (AL4 or similar, less common with HDi)

Clutch Type:

Hydraulically operated single dry plate clutch

Gear Ratios:

Specific ratios for each gear and final drive would be detailed in the manual.

📐 Dimensions

Body Styles:

Hatchback (3-door, 5-door), Estate (Break/SW)

Length:

Approximately 4138 mm (5-door Hatchback), 4277 mm (Estate)

Width:

Approximately 1716 mm

Height:

Approximately 1437 mm (Hatchback), 1478 mm (Estate)

Kerb Weight:

Approx. 1200 - 1300 kg depending on body style and equipment.

Gross Vehicle Weight:

To be specified in manual.

🛡️ Safety Features

Euro Ncap Rating:

4 stars (for the Xsara model range, specific year may vary slightly but generally consistent)

ABS:

Standard on many 2.0 HDi models, detailed system coverage in the manual.

Esp Traction Control:

Optional or standard on higher trims, check specific vehicle. Manual would cover its diagnostics.

Airbags:

Front airbags, optional side airbags. Manual covers SRS system maintenance and diagnostics.

Seatbelts:

Pre-tensioning seatbelts with force limiters for front occupants.

💡 Technology Features

Audio System:

Factory fitted radio/CD player with steering wheel controls. Manual may cover basic radio code retrieval or speaker replacement.

Cruise Control:

Optional on some variants. Manual would cover installation and troubleshooting if applicable.

Connectivity Options:

Limited by era; may include basic hands-free calling (Bluetooth) on later models. Manual would cover any integrated systems.

🔧 Maintenance

Oil Change Interval:

Typically 15,000 km (9,300 miles) or 1 year, whichever comes first. Manual will confirm exact interval.

Timing Belt Interval:

Critical service item for the DW10TD engine. Usually around 120,000 km (75,000 miles) or 5 years. Manual will specify exact interval and replacement parts.

Engine Oil Specification:

ACEA B3/B4 or API CF/CG-4. Viscosity typically 5W-40 or 10W-40 synthetic or semi-synthetic. Manual will provide exact specification and capacity (approx. 5.5 litres).

Coolant Specification:

Propylene glycol based coolant, meeting PSA Peugeot Citroën specification (e.g., Type D). Manual will specify capacity and correct type.

Brake Fluid Specification:

DOT 4.

Transmission Oil Specification:

Specific gear oil grade (e.g., 75W-80 GL-4). Manual will provide capacity and part number.

Engine:

Potential for turbocharger wear, injector issues (especially with poor fuel quality), EGR valve clogging, and swirl flap issues in later iterations. Timing belt tensioner failure can be catastrophic.

Suspension:

Rear axle pivot wear leading to alignment issues and handling problems. Worn front suspension bushings and drop links.

Electrical:

Intermittent dashboard warning lights, issues with central locking and window regulators can occur. Poor earth connections.

Exhaust:

DPF (Diesel Particulate Filter) issues if fitted on this specific variant (less common on early 90hp versions, but check), exhaust manifold cracks.

Oil Filter:

Typical part numbers: Mann-Filter W940/24, Mahle OX116D, Bosch 0986452077 (Manual will confirm specific OE number).

Air Filter:

Typical part numbers: Mann-Filter C30153, Mahle LX585, Bosch 1457433703 (Manual will confirm specific OE number).

Fuel Filter:

Critical for HDi. Typical part numbers: Mann-Filter WK821, Mahle KL73, Bosch 0450906449 (Manual will confirm specific OE number and replacement procedure).

📚 Vehicle History

Manufacturer History:

Citroën, a French manufacturer with a long history of innovation in automotive engineering, known for comfort-focused vehicles and unique designs.

Xsara Generation:

The Xsara (N1/N2/N68) replaced the Citroën ZX and was produced from 1997 to 2006. The 2005 model falls into the later part of its production run, often incorporating minor updates.

Production Period:

1997 – 2006

Manufacturing Locations:

Primarily France, but also Spain, and potentially other PSA Peugeot Citroën plants.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the 2005 Xsara 2.0 HDi are not widely publicized as standout accolades, the Xsara range generally received positive reviews for its comfort and practicality within its class during its production run.