Holden Barina Complete Workshop Service Repair Manual 2004 2005 2006

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The Barina, specifically the XC generation produced from 2004 to 2006, is a subcompact vehicle offered in 3-door hatchback, 5-door hatchback, and 4-door sedan body styles. Powered by a 1.4-liter...

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Type: Car

Vendor:

Sku: 75132

Tags: 2004 2005 2006 Barina Car Cars Holden

Product variants

Description

The Barina, specifically the XC generation produced from 2004 to 2006, is a subcompact vehicle offered in 3-door hatchback, 5-door hatchback, and 4-door sedan body styles. Powered by a 1.4-liter Z14XEP Ecotec inline 4-cylinder engine, it was engineered as an affordable and practical city car, competing with other entry-level vehicles of its era. This generation, based on the Opel Corsa C platform, offered a balance of fuel efficiency and utility, making it a sensible choice for daily commuting and urban driving. This comprehensive workshop service and repair manual provides detailed information for the Barina XC models from 2004 to 2006. It covers all engines, trims, and transmissions, offering in-depth guidance on routine maintenance, troubleshooting, and repair procedures. Essential sections include engine mechanicals, fuel and ignition systems, transmission overhauls, brake and suspension systems, electrical diagnostics, HVAC, and bodywork. Technical specifications, wiring diagrams, and diagnostic trouble code information are also included, empowering owners and technicians to maintain and restore the vehicle effectively.

🏷️ Basic Information

Identification

Make:

Holden

Model:

Barina

Model Code:

XC Barina

Model Generation:

Third Generation (XC)

Model Years Covered:

2004, 2005, 2006

👋 Introduction

Market Position

Market Segment:

Subcompact hatchback and sedan, positioned as an affordable and practical city car.

Competitive Analysis

Key Competitors:

Toyota Echo/Yaris, Honda Jazz/Fit, Ford Fiesta, Hyundai Getz, Mazda2.

Key Features

Ownership Benefit:

Empowers owners to perform their own maintenance and repairs, saving significant costs.

Accessibility:

Downloadable to multiple devices (PC, Mac, tablet, smartphone) and printable for easy access in the workshop.

Content Depth:

Extremely detailed, covering virtually all service and repair procedures from basic maintenance to complex diagnostics and overhauls.

📋 Manual Details

Coverage Areas

All Models Engines Trims Transmissions:

Page Count

Estimated Page Count:

Varies by specific edition, typically 1000+ pages for a complete workshop manual

Manual Type

Type:

Complete Workshop Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, camshaft, timing, lubrication, cooling, fuel, emissions control

Engine Performance:

Diagnosis, tuning, power output specifications, knock control

Fuel System:

Fuel injection, fuel pump, fuel filter, fuel lines, evaporative emissions control (EVAP)

Ignition System:

Spark plugs, ignition coils, ignition timing, distributor (if applicable), ECU control

Transmission Manual:

Clutch system, gearbox overhaul, gearshift linkage, final drive

Transmission Automatic:

Transmission overhaul, torque converter, valve body, transmission control module (TCM)

Brake System:

Disc brakes, drum brakes, hydraulic system, ABS (Anti-lock Braking System), parking brake

Suspension System:

Front suspension (struts, control arms), rear suspension (torsion beam, trailing arms), shock absorbers, springs, alignment specifications

Steering System:

Power steering pump, steering rack, steering column, tie rod ends

Electrical System:

Battery, charging system (alternator), starter motor, lighting system, wiring diagrams, fuses and relays

Body And Interior:

Body panels, doors, hood, trunk, interior trim, seats, glass, seals

HVAC System:

Air conditioning (refrigerant, compressor, condenser, evaporator), heating, ventilation, blower motor

Safety Systems:

Airbag system, seat belts, pre-tensioners

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotations, spark plug replacement, belt inspections

Troubleshooting Diagnostics:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical system diagnosis

Engine Repair:

Engine removal and installation, cylinder head gasket replacement, piston ring replacement, bearing replacement, timing belt/chain replacement

Transmission Repair:

Clutch replacement, transmission fluid service, manual gearbox overhaul, automatic transmission repair

Brake System Repair:

Brake pad and rotor replacement, brake fluid flush, caliper and wheel cylinder service, ABS component replacement

Suspension Steering Repair:

Strut and shock absorber replacement, ball joint and tie rod end replacement, power steering pump and rack service, wheel alignment procedures

Electrical Diagnostics Repair:

Wiring harness repair, component testing, starter and alternator testing, lighting circuit repair

Bodywork Repair:

Panel replacement, door hinge adjustment, glass replacement, seal replacement

HVAC Repair:

AC system recharge, compressor replacement, heater core replacement, blower motor replacement

Safety System Repair:

Airbag system component replacement, seat belt repair

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring schematics.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High quality, suitable for printing individual pages or entire sections. Often includes clear diagrams and illustrations.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Z14XEP (Ecotec)

Engine Type:

Inline 4-cylinder, DOHC, 16-valve, Naturally Aspirated

Displacement:

1.4 Liters (1389 cc)

Performance

Horsepower:

Approx. 90 PS (66 kW) @ 6000 rpm (varies slightly by market/tuning)

Torque:

Approx. 123 Nm (91 lb-ft) @ 4400 rpm (varies slightly by market/tuning)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (Petrol)

Engine Features

Emission Standard:

Euro III / Euro IV compliant (depending on market and specific model year)

🔧 Transmission

Standard

Type:

5-Speed Manual Transmission

Optional

Type:

4-Speed Automatic Transmission (Optional)

Features

Clutch Type:

Dry single plate, hydraulically operated

📐 Dimensions

Exterior

Body Styles:

3-Door Hatchback, 5-Door Hatchback, 4-Door Sedan

Length:

Approx. 3880 mm (Hatchback), 4260 mm (Sedan)

Width:

Approx. 1670 mm

Height:

Approx. 1480 mm

Weights

Curb Weight:

Approx. 950 kg - 1050 kg (depending on body style and equipment)

Gross Vehicle Weight:

Approx. 1400 kg - 1500 kg

🛡️ Safety Features

Ratings

Ancap Rating:

Likely 3-4 stars (for Australian market, based on contemporary models). Specific official ratings for all configurations may vary.

Active Features

Anti-lock Braking System (Optional on some trims, standard on higher trims)

Electronic Brake-force Distribution (EBD) (often linked with ABS)

Passive Features

Airbags:

Driver and Front Passenger Airbags (Standard on most models), Side Airbags (Optional on some trims)

Seat Belts:

Front and Rear Seat Belts with Pretensioners (Driver and Front Passenger)

Child Seat Anchors:

ISOFIX mounting points

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player, potentially with steering wheel controls on higher trims. AUX input may be absent on base models.

Display:

Basic LCD display for radio and clock functions.

Driver Assistance

Cruise Control:

Optional on higher trims.

Connectivity

Phone Integration:

No native Bluetooth or smartphone integration on most models from this era. Aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 15,000 km or 12 months, whichever comes first. Always consult the manual for specific recommendations.

Air Filter Replacement:

Every 30,000 km or as per manual inspection/recommendation.

Spark Plug Replacement:

Typically 60,000 km for standard spark plugs, or longer for iridium/platinum plugs.

Coolant Flush:

Every 2 years or 60,000 km.

Brake Fluid Flush:

Every 2 years.

Fluid Specifications

Engine Oil Type:

SAE 5W-30, API SM or higher (e.g., Dexos1 Gen 2 is often backward compatible and recommended for modern oil standards)

Engine Oil Capacity:

Approx. 3.5 Liters (with filter change)

Coolant Type:

GM-specific orange silicate-free long-life coolant (or equivalent OAT/HOAT coolant)

Transmission Fluid Manual:

API GL-4, SAE 75W-80 or 75W-90 Gear Oil

Transmission Fluid Automatic:

GM Dexron III / Dexron VI ATF (Automatic Transmission Fluid)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Common Problems:

Rear axle bushes wear, occasional ignition coil failure, exhaust manifold cracks, power steering pump leaks, ABS sensor issues, water ingress into cabin (door seals).

📚 Vehicle History

Brand Heritage

Brand Origin:

Holden is an Australian automotive manufacturer, a subsidiary of General Motors (GM).

Model Evolution

Model Lineage:

The Barina nameplate has been used by Holden since the early 1980s, often as a rebadged version of a Suzuki or Opel/Vauxhall model. The XC generation (2004-2006) was based on the Opel Corsa C platform.

Production

Manufacturing Location:

Primarily manufactured in Spain (for Opel Corsa C) and then distributed globally, including Australia under the Holden brand.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

No specific major awards are widely recognized for the 2004-2006 Holden Barina. It was generally considered a competent, if unexciting, entry-level vehicle.