CITROEN XSARA 1.4 HDi 2005 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: Xsara Engine Variant: 1.4 HDi Year: 2005 Codes Engine Code: DV4TD (8HX/8HZ) 👋 Introduction Market Position Segment: Compact family car (supermini/small family car)...

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标签: 2005 Car Cars Citroen XSARA XSARA 1.4 HDi

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Description

🏷️ Basic Information

Identification

Make:

Citroën

Model:

Xsara

Engine Variant:

1.4 HDi

Year:

Codes

Engine Code:

DV4TD (8HX/8HZ)

👋 Introduction

Market Position

Segment:

Compact family car (supermini/small family car)

Citroen Strategy:

Citroën typically aimed for comfort, practicality, and innovative design in this segment.

Competitive Analysis

Key Competitors:

Ford Focus, Volkswagen Golf, Vauxhall/Opel Astra, Renault Mégane, Peugeot 307.

Key Features

Design Philosophy:

Known for distinctive French styling, comfortable ride quality (often with hydropneumatic-inspired suspension tuning), and practical interior packaging.

📋 Manual Details

Coverage Areas

Manual Type:

Full Service and Repair Manual

Language:

English

Format:

Digital (Likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, block assembly, pistons, connecting rods, crankshaft, valve train, timing belt/chain replacement, oil pump, cooling system.

Engine Management:

Fuel injection system (HDi common rail), glow plug system, ignition timing (diesel), sensor data interpretation, ECU diagnostics, emission control systems (EGR).

Transmission Manual:

Clutch replacement, gearbox disassembly and reassembly, gear shift mechanism, driveshafts, bearings, seals.

Transmission Automatic:

Not applicable for 1.4 HDi variant.

Brakes:

Hydraulic system, brake fluid replacement, caliper overhaul, disc and pad replacement, ABS system diagnostics and repair, parking brake.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, bushings, wheel alignment procedures, steering system.

Electrical System:

Battery, charging system (alternator), starter motor, lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams for all circuits.

Bodywork And Interior:

Body panel removal and installation, door mechanisms, glass replacement, interior trim, seating, dashboard assembly, HVAC system (heating, ventilation, air conditioning).

Diagnostics And Troubleshooting:

OBD-II fault codes interpretation, diagnostic procedures for common faults, symptom-based troubleshooting guides.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, coolant checks and changes, spark plug (if applicable, though unlikely for HDi) inspection/replacement, brake fluid flush.

Component Replacement:

Detailed step-by-step guides for replacing virtually all major and minor components.

Diagnostic Testing:

Procedures for testing sensors, actuators, electrical components, and mechanical systems.

Rebuild Procedures:

Comprehensive instructions for rebuilding major assemblies like the engine and gearbox.

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete engine and transmission overhauls, including detailed wiring diagrams and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable (assuming OCR'd original)

Print Quality

Resolution:

High resolution suitable for clear viewing of diagrams and text.

Binding Type

Binding:

Not applicable (Digital Format)

Paper Type

Paper:

Not applicable (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Turbocharged Direct Injection Diesel (HDi)

Displacement:

1398 cc (1.4 Litre)

Bore X Stroke:

73.7 mm x 82 mm

Compression Ratio:

17.9:1 (Typical for DV4TD)

Performance

Horsepower:

68 bhp (50 kW) @ 4000 rpm

Torque:

150 Nm (111 lb-ft) @ 1750 rpm

Fuel System

Injection System:

Bosch Common Rail Direct Injection (CRDi)

Fuel Type:

Diesel

Cooling System

Coolant Type:

Antifreeze/Coolant (Glysantin G30 or equivalent, typically OAT-based, purple)

Coolant Capacity:

Approx. 5.5 Litres

Lubrication

Oil Grade:

ACEA B4 or C2 specification, typically 5W-30 or 5W-40 synthetic oil. Check specific manual for exact Citroën approval (e.g., B71 2297).

Oil Capacity W Filter:

Approx. 3.5 Litres

🔧 Transmission

Standard

Type:

5-speed Manual Transaxle

Gear Ratios 1St:

Approx. 3.45:1

Gear Ratios 2Nd:

Approx. 1.94:1

Gear Ratios 3Rd:

Approx. 1.28:1

Gear Ratios 4Th:

Approx. 0.93:1

Gear Ratios 5Th:

Approx. 0.77:1

Final Drive Ratio:

Approx. 3.40:1

Features

Clutch Type:

Hydraulically operated single dry plate clutch

Fluid Specifications

Gearbox Oil Type:

GL-4 75W-80 Synthetic Gear Oil (e.g., PSA S71 2360 specification)

Gearbox Oil Capacity:

Approx. 2.3 Litres

📐 Dimensions

Exterior

Body Styles:

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

Length:

Approx. 4133 mm (Hatchback)

Width:

Approx. 1717 mm

Height:

Approx. 1427 mm (Hatchback)

Wheelbase:

Approx. 2605 mm

Wheel Bolt Pattern:

4 x 108

Wheel Offset:

ET 18 to ET 27

Weights

Kerb Weight:

Approx. 1160 - 1250 kg (depending on body style and equipment)

Gross Vehicle Weight:

Approx. 1700 - 1750 kg

🛡️ Safety Features

Ratings

Euro Ncap Rating:

4 Stars (Adult Occupant Protection) for Xsara II (tested 2001 - relevant to 2005 model generation)

Active Features

Standard on most 2005 models, often with EBD (Electronic Brakeforce Distribution).

Traction Control:

Optional on some trims, known as ASR (Anti-Slip Regulation).

Passive Features

Airbags:

Driver, front passenger, front side airbags (standard on higher trims, optional on base models).

Seatbelts:

Pre-tensioning front seatbelts with force limiters, three-point rear seatbelts.

Child Seat Anchors:

ISOFIX mounting points for child seats (standard on rear outer seats).

💡 Technology Features

Infotainment

Audio System:

Factory fitted radio/CD player with steering wheel controls on higher trims. Standard speaker configuration.

Navigation:

Optional factory fitted satellite navigation system (RT2 system) on higher trim levels.

Driver Assistance

Cruise Control:

Optional feature on some variants.

Parking Sensors:

Optional rear parking sensors available on later models/higher trims.

Connectivity

Bluetooth:

Limited or no factory Bluetooth connectivity on standard 2005 models; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 20,000 km or 1 year, whichever comes first (or as per specific market/driving conditions, often 15,000 km in older recommendations).

Air Filter Replacement:

Every 40,000 km or 2 years.

Fuel Filter Replacement:

Every 60,000 km or 3 years.

Coolant Replacement:

Initial change at 120,000 km or 5 years, then every 60,000 km or 3 years thereafter.

Timing Belt Replacement:

Every 120,000 km or 6 years (crucial for this HDi engine, non-interference if timing belt fails, but severe damage possible).

Fluid Specifications

Brake Fluid Type:

DOT 4 (or DOT 3 if specified, but DOT 4 is common)

Power Steering Fluid:

PSA S71 2310 (often a mineral-based fluid, check manual)

Known Issues

Egr Valve Clogging:

Common in HDi engines due to soot buildup, leading to reduced power and rough running. Cleaning or replacement is often required.

Diesel Particulate Filter:

If fitted (less common on early 1.4 HDi), DPF regeneration issues can occur if the vehicle is only used for short trips.

Glow Plugs:

Can fail, impacting cold starting. Diagnosis involves checking resistance and voltage.

Suspension Wear:

Front suspension components (ball joints, drop links, bushings) can wear, leading to knocking noises and poor handling. The rear beam suspension can also require maintenance/reconditioning over time.

Electrical Gremlins:

As with many cars of this era, minor electrical faults (e.g., window regulators, central locking) can occur, often related to wiring or modules.

Fuel Injector Issues:

Can become clogged or fail, affecting performance and fuel economy. Requires specialized diagnostic equipment.

📚 Vehicle History

Brand Heritage

Citroen Legacy:

Citroën, a French manufacturer, has a long history of innovative automotive engineering, particularly known for its avant-garde designs and ride comfort (e.g., the DS).

Model Evolution

Xsara Lineage:

The Xsara succeeded the Citroën ZX and was part of Citroën's strategy to offer stylish, comfortable, and practical alternatives to more mainstream offerings. It was based on the PSA PF2 platform.

Generation:

The 2005 model falls within the second generation (Xsara II), which received a facelift in 2000, featuring updated styling, interior refinements, and improved safety features.

Production

Production Period:

1997 - 2006 (with Xsara II facelift in 2000)

Production Location

Manufacturing Sites:

Primarily manufactured at Citroën's plants in France (e.g., Aulnay-sous-Bois) and Spain (Vigo).

🏆 Awards & Recognition

Recognitions

European Design Awards:

While not specific to the 1.4 HDi variant, the Xsara range was recognized for its styling and comfort by various automotive publications in Europe.

Ratings

Consumer Reports Performance:

Reliability ratings for the Xsara varied by market and year, but the HDi engines were generally considered robust and economical if well-maintained.