🏷️ Basic Information

Make:

Citroën

Model:

Xsara

Year:

2005

Engine:

1.6i 16V

Engine Code Prefix:

NFU (often associated with EW10J4, but 1.6 16V is typically the TU5JP4 or similar)

👋 Introduction

Target Audience:

Professional technicians and do-it-yourself (DIY) mechanics with adequate data for most tasks.

Value Proposition:

Provides factory-level repair information, enabling informed maintenance and repair decisions, saving costs compared to professional servicing.

Accessibility:

Instant download, immediate access for immediate repairs.

Content Quality:

Easy to read text, top-quality diagrams, step-by-step instructions, highly detailed exploded pictures.

Completeness:

Covers every single detail, based on complete disassembly.

📋 Manual Details

Overall Coverage:

Complete workshop service and repair information for the specified model.

Estimated Pages:

Hundreds of pages (exact number not specified, but implies comprehensive content).

Type:

Factory Service Repair Manual / Workshop Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, assembly, inspection, repair, torque specifications, timing, cylinder head, pistons, crankshaft, camshafts.

Engine Electrical:

Ignition system, fuel injection system (ECU, sensors, actuators), starting system, charging system, wiring diagrams.

Transmission:

Manual transmission (disassembly, assembly, repair, fluid specifications, troubleshooting).

Drivetrain:

Clutch, drive shafts, CV joints, wheel bearings.

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, ball joints, steering linkage.

Brakes:

Brake system components (master cylinder, calipers, pads, rotors), ABS system, hydraulic lines, bleeding procedures.

Steering:

Power steering system, steering rack, column, tie rod ends.

Cooling System:

Radiator, thermostat, water pump, hoses, coolant specifications, fan operation.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, hangers.

Electrical Body:

Lighting system, interior controls, power windows, central locking, wipers, horn.

HVAC:

Heating, Ventilation, and Air Conditioning system components and operation.

Body And Chassis:

Body panel removal and installation, chassis components, corrosion protection.

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspection/replacement.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, error code interpretation.

Repair Procedures:

Step-by-step instructions for disassembly, repair, and reassembly of all major vehicle components.

Rebuilding Procedures:

Detailed guidance for engine and transmission rebuilding.

Electrical Troubleshooting:

Schematic interpretation, component testing, fault finding within electrical systems.

Component Replacement:

Instructions for replacing specific parts such as alternators, starters, fuel pumps, sensors, etc.

Alignment And Adjustment:

Wheel alignment procedures, steering wheel centering, handbrake adjustment.

Special Tools:

Identification and usage of specialized tools required for certain procedures.

Depth:

Comprehensive, covering everything from basic maintenance to complete overhaul and diagnostics, suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

Type:

PDF

Compatibility:

All versions of Windows & Mac

Requirements:

Adobe PDF Reader & WinZip (for download/extraction)

Printability:

Full Printable (allows printing of entire manual or selected pages).

Zoom Capability:

YES (Zoom IN/OUT functionality for diagrams and text).

Type:

Digital Download (PDF format, no physical binding).

Type:

Not Applicable (Digital product).

⚙️ Engine Specifications

Engine Type:

Inline 4-cylinder, DOHC (Double Overhead Camshaft), 16 valves

Displacement:

1.6 Liters (approx. 1587 cc)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Horsepower Estimate:

Approximately 108-110 PS (Pferdestärke) or 106-108 bhp (brake horsepower) at around 6000 rpm (exact figures depend on specific tuning and market).

Torque Estimate:

Around 147-150 Nm (Newton-meters) or 108-111 lb-ft at around 4000 rpm (exact figures depend on specific tuning and market).

Fuel Type:

Unleaded gasoline (Petrol)

Valve Actuation:

Timing belt driven camshafts.

🔧 Transmission

Type:

5-speed Manual Transmission

Type:

4-speed Automatic Transmission (likely available on some variants).

Fluid Type Manual:

Refer to manual for specific gear oil specification (e.g., API GL-4, SAE 75W-80).

Fluid Type Automatic:

Refer to manual for specific ATF specification (e.g., LT 71141 or equivalent).

📐 Dimensions

Body Styles:

Hatchback (3-door and 5-door), Estate (Station Wagon), Coupe (often referred to as the 'Picasso' MPV, but the standard Xsara also had coupe variants).

Wheelbase Approx:

2500 - 2550 mm (depending on body style)

Track Width Front Approx:

1470 - 1500 mm

Track Width Rear Approx:

1450 - 1470 mm

🛡️ Safety Features

Euro Ncap Rating:

The Citroën Xsara generally achieved a 4-star Euro NCAP rating for adult occupant protection (results may vary slightly by specific model year and testing criteria).

ABS:

Anti-lock Braking System (ABS) often standard or optional on this model.

Esp:

Electronic Stability Program (ESP) may be available on higher trims or as an option, but less common on base 1.6 models of this era.

Airbags:

Front airbags for driver and passenger, side airbags (optional on some trims).

Seatbelts:

Pre-tensioned seatbelts with force limiters.

💡 Technology Features

Audio System:

Factory fitted radio/CD player, often with steering wheel mounted controls on higher trims. Aux-in or USB connectivity may be limited on base models.

Cruise Control:

Available on some higher-spec models.

Remote Central Locking:

Standard feature, often with keyless entry.

🔧 Maintenance

Oil Change Interval:

Typically every 12,500 miles (20,000 km) or 1 year, whichever comes first. Consult manual for specific recommendation.

Timing Belt Replacement:

Crucial maintenance item. Typically recommended every 75,000 miles (120,000 km) or 5 years. Failure can cause catastrophic engine damage.

Spark Plug Replacement:

Generally around 60,000 miles (100,000 km) for platinum or iridium plugs.

Engine Oil:

Refer to manual for specific viscosity grade (e.g., 5W-40 or 10W-40) and ACEA specification (e.g., A3/B4).

Coolant:

Antifreeze/coolant concentrate, typically a long-life type, mixed 50/50 with distilled water. Refer to manual for specific type and capacity (e.g., PSA B71 5100).

Brake Fluid:

DOT 4 brake fluid.

Ignition Coils:

Can be a source of misfires, especially on older units.

Rear Suspension Torsion Bars:

Wear on torsion bars can lead to a lower rear ride height, though this is a design characteristic that can be adjusted or replaced if excessive.

Electric Window Motors:

Occasional failures of window regulator mechanisms or motors.

Exhaust Manifold Cracks:

Cast iron exhaust manifolds can develop cracks, leading to exhaust leaks and noise.

Thermostat Housing Leaks:

Plastic thermostat housings can become brittle and crack over time, causing coolant leaks.

📚 Vehicle History

Citroen Philosophy:

Citroën is renowned for its innovative engineering, often prioritizing ride comfort, advanced suspension systems (like hydropneumatic, though not on this specific model), and distinctive styling.

Xsara Generation:

The Xsara succeeded the Citroën ZX and was produced from 1997 to 2006. The 2005 model falls within the facelifted second generation (Phase II), which featured updated styling and interior refinements.

Production Period:

1997-2006 (with a significant facelift in 2000).

Manufacturing Locations:

Primarily manufactured in France, with potential production in other PSA Peugeot Citroën facilities.

🏆 Awards & Recognition

Euro Ncap:

4-star safety rating (as mentioned in safety section).

Model Reputation:

The Xsara was generally considered a comfortable and practical family car, with good ride quality for its class.