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CITROEN XSARA PICASSO 1.6i 2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: Xsara Picasso Year: 2005 Engine: 1.6i (NFU / TU5JP4) Codes Chassis Code: N68 Engine Code Primary: NFU Engine Code Alternative: TU5JP4 👋 Introduction...
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CITROEN XSARA PICASSO 1.6i 2005 Full Service Repair ManualCITROEN XSARA PICASSO 1.6i 2005 Full Service Repair ManualCITROEN XSARA PICASSO 1.6i 2005 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Citroën
Model:
Xsara Picasso
Year:
2005
Engine:
1.6i (NFU / TU5JP4)
Codes
Chassis Code:
N68
Engine Code Primary:
NFU
Engine Code Alternative:
TU5JP4
👋 Introduction
Market Position
Vehicle Segment:
Compact MPV (Multi-Purpose Vehicle)
Target Audience:
Families seeking practical, spacious, and versatile transportation.
Competitive Analysis
Key Competitors:
Renault Scénic, Ford Focus C-Max, Opel Zafira, Volkswagen Touran
Key Features
Design Philosophy:
Characterized by its distinctive ‘cab-forward’ design, maximizing interior space and visibility. Emphasizes comfort and practicality.
Interior Versatility:
Modular seating system with three individual sliding and removable rear seats.
Driving Experience:
Known for its comfortable ride quality, often attributed to Citroën's signature suspension tuning.
📋 Manual Details
Coverage Areas
Manual Type:
Full Service & Repair Manual
Language:
English
Format:
Digital (PDF)
Page Count
Estimated Pages:
Over 1500
Manual Type Specific
Manual Scope:
Comprehensive Workshop Manual
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system
Transmission:
Manual transmission (ML5C), clutch system, driveshafts, differentials
Chassis:
Suspension (front & rear), steering system, braking system (front & rear discs, ABS), wheels and tires
Electrical:
Battery, charging system, starting system, lighting, instrument panel, body electricals, comfort systems, engine management electronics (ECU)
Bodywork Interior:
Body panels, doors, windows, seats, interior trim, climate control (HVAC)
Procedures Included
Maintenance:
Scheduled servicing, oil changes, filter replacements, spark plug replacement, brake fluid flush, coolant replacement
Troubleshooting:
Diagnostic flowcharts, common fault identification, error code interpretation
Repair:
Engine overhaul, transmission repair, suspension component replacement, brake caliper overhaul, electrical component diagnosis and replacement
Diagnostics:
OBD-II diagnostics, sensor testing, actuator testing, ECU programming (mention of tools may be present)
Technical Depth
Depth:
Extensive, covering routine maintenance to complete engine and transmission rebuilds.
Detail Level:
Detailed step-by-step instructions, torque specifications, special tool requirements, wiring diagrams, exploded views, and diagnostic procedures.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans, optimized for readability and searchability. May include vector diagrams.
Print Quality
Printability:
Printable pages, suitable for home or professional printing.
Binding Type
Digital Format Details:
Adobe Acrobat PDF, compatible with most devices. Searchable text and bookmarking capabilities.
Paper Type
Original Manual Type:
Typically provided as a digital download; original factory manuals were paper-based.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-cylinder, naturally aspirated petrol
Displacement:
1587 cc (1.6 Liters)
Bore X Stroke:
78.5 mm x 82.0 mm
Compression Ratio:
10.8:1
Performance
Horsepower:
109 PS (108 bhp; 80 kW) @ 5750 rpm (approximate)
Torque:
147 Nm (108 lb-ft) @ 3750 rpm (approximate)
Fuel System
Fuel Delivery:
Multi-point fuel injection (Bosch Motronic or similar)
Fuel Type:
Unleaded Petrol (RON 95 recommended)
Engine Management
Ignition System:
Distributorless ignition system (DIS) with coil-on-plug or coil packs
Emission Control:
Catalytic converter, Euro 3 / Euro 4 compliance (depending on market)
🔧 Transmission
Standard
Type:
5-speed Manual
Gearbox Code:
ML5C (or similar PSA 5-speed manual)
Optional
Type:
4-speed Automatic (AL4 / DP0 - less common for 1.6i)
Features
Clutch Type:
Hydraulically operated, dry single-plate clutch
Fluid Specifications
Manual Gearbox Oil:
SAE 75W-80 GL-5 (e.g., Total Transmission Gear 80W-80 or equivalent)
📐 Dimensions
Exterior
Length:
4276 mm (168.3 in)
Width:
1755 mm (69.1 in)
Height:
1654 mm (65.1 in)
Wheelbase:
2760 mm (108.7 in)
Interior
Seating Capacity:
5
Cargo
Boot Volume Seats Up:
550 liters (19.4 cu ft)
Boot Volume Seats Down:
Up to 1970 liters (70 cu ft) with rear seats removed
Weights
Kerb Weight:
1305 kg (2877 lbs) (approximate)
Wheels Tires
Standard Wheel Size:
15-inch or 16-inch alloy or steel wheels
Standard Tire Size:
195/65 R15 or 205/55 R16 (varies by trim)
Bolt Pattern:
5x108
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 stars (tested in 2001 for an earlier model, but indicative)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Electronic Brakeforce Distribution
Esp:
Optional Electronic Stability Programme (ESP)
Passive Features
Airbags:
Driver, front passenger, and front side airbags standard. Optional curtain airbags.
Seatbelts:
3-point seatbelts with pretensioners and load limiters (front and rear)
Child Safety:
ISOFIX child seat mounting points on rear outer seats
💡 Technology Features
Infotainment
Head Unit:
Factory fitted radio/CD player with steering wheel controls. May feature a dashboard-integrated display for radio/climate settings.
Display:
Central dashboard display for audio, clock, and trip computer. Some models may have a monochrome LCD.
Driver Assistance
Parking Sensors:
Optional rear parking sensors available on higher trims.
Comfort Features
Climate Control:
Manual air conditioning standard, optional automatic climate control on some trims.
Cruise Control:
Optional cruise control and speed limiter.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 15,000 miles or 12 months, whichever comes first (or as per specific driving conditions)
Spark Plug Replacement:
Approximately every 40,000 - 60,000 miles (depending on plug type, e.g., platinum)
Timing Belt Replacement:
Crucial: Every 75,000 miles or 5 years for the 1.6i (NFU) engine. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Capacity:
Approximately 3.5 - 4.0 liters (including filter)
Engine Oil Grade:
SAE 5W-40 or 10W-40, API SN/SM/SL or ACEA A3/B4, C3 (check manual for exact specification/approval)
Coolant Type:
Ethylene glycol based antifreeze with corrosion inhibitors (e.g., PSA Group Type D - blue or pink)
Coolant Capacity:
Approximately 6.0 liters
Brake Fluid Type:
DOT 4
Power Steering Fluid:
LHM or LDS fluid is NOT used. Typically uses Dexron III or equivalent ATF (check manual).
Known Issues
Common Complaints:
Ignition coil failure, premature wear of front suspension components (wishbone bushes, drop links), minor electrical gremlins, rear axle pivot wear (leading to 'tuck-in'), catalytic converter failure, clutch slave cylinder leaks.
Timing Belt Risk:
High risk of engine damage if timing belt is not replaced at the specified interval. Often includes replacement of the water pump and tensioners at the same time.
Filter Part Numbers Example
Oil Filter:
Mann-Filter HU719/3X, Bosch 0 986 452 030, Purflux EP202 (verify specific fitment)
📚 Vehicle History
Brand Heritage
Citroen Legacy:
Citroën has a long history of innovation in automotive design, comfort, and suspension technology, dating back to André Citroën's pioneering work.
Model Evolution
Origin:
Developed from the Citroën Xsara hatchback, launched in 1997. The Picasso MPV variant debuted in 1999.
Facelift:
Received a significant facelift in 2004, which includes the 2005 model year.
Production
Production Period:
1999 – 2010 (for the original Xsara Picasso)
Manufacturing Plant:
Vigo, Spain (PSA Group plant)
🏆 Awards & Recognition
Recognitions
General Reputation:
Praised for its practicality, comfort, and spacious interior, making it a popular family car.
Market Reception:
Was a strong seller in the compact MPV segment across Europe.
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