1997-2000 CITREON XSARA Service Repair Manual (Covers Coupe Hatchback and Estate Models with Petrol and Diesel Engines)
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🏷️ Basic Information Identification Make: Citroën Model: Xsara Model Variants: Coupe, Hatchback, Estate Production Years Covered: 1997, 1998, 1999, 2000 Codes Platform Code: PSA Peugeot-Citroën Type 3 👋 Introduction Market Position Market Position: Compact family car, competing with Ford Focus, VW Golf, Renault Mégane Competitive Analysis Key Strengths: Comfortable ride (hydropneumatic-inspired suspension), spacious interior, practical estate variant Key Weaknesses: Perceived build quality issues compared to some rivals, electrical gremlins in some early models Key Features Design Philosophy: Emphasis on ride comfort and practicality Innovations: Advanced suspension design for its class 📋 Manual Details Coverage Areas Covered Regions: Global (primarily European market focus) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF likely) 📖 Manual Coverage Systems Covered Engine Mechanical: All petrol and diesel engine variants (e.g., TU series, XUD series, DW series) Engine Management: Fuel injection systems (Bosch, Lucas), ignition systems, emissions control Transmission Manual: Manual gearboxes (e.g., BE series) Transmission Automatic: Automatic transmission (if applicable to specified years/models) Drivetrain: Clutch, driveshafts, differentials Suspension: Front (MacPherson struts), Rear (Trailing arm with torsion bars/coil springs) Steering: Hydraulic power steering system Brakes: Front discs (ventilated/solid), Rear discs/drums, ABS (Anti-lock Braking System) Electrical System: 12V system, battery, alternator, starter motor, lighting, instrumentation Body And Chassis: Body construction, panels, doors, windows, seats, interior trim HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system Safety Systems: Airbags, seatbelts, ABS Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, spark plug replacement Engine Repair: Engine overhaul, head gasket replacement, timing belt/chain service Transmission Repair: Clutch replacement, gearbox rebuild, automatic transmission service Brake System Repair: Brake pad/disc replacement, caliper servicing, bleeding procedures Suspension And Steering Repair: Component replacement (struts, ball joints, tie rods), power steering pump and rack service Electrical Troubleshooting: Wiring diagrams, component testing, fault diagnosis Bodywork Repair: Panel replacement, dent repair, door and window mechanism repair HVAC System Service: Refrigerant charging, component replacement (compressor, evaporator) Diagnostic Procedures: OBD-II (On-Board Diagnostics) troubleshooting and error code interpretation Technical Depth Depth Of Coverage: Comprehensive; from basic maintenance to complete engine and transmission rebuilds Diagnostic Capabilities: Detailed diagnostic flowcharts, common fault symptoms, and solutions Special Tools: Identification and usage of specific Citroën special tools for various procedures Torque Specifications: Precise torque settings for all critical fasteners Wiring Diagrams: Detailed electrical system schematics for accurate diagnosis and repair 📊 Manual Specifications File Format File Format: PDF Searchability: Searchable text content for quick information retrieval Print Quality Print Quality: High-resolution scans for clear diagrams and text Binding Type Binding Type: Digital (N/A for printed) Paper Type Paper Type: Digital (N/A for printed) ⚙️ Engine Specifications Primary Engine Petrol Engine Options: 1.4L (TU3), 1.6L (TU5), 1.8L (XU7), 2.0L (XU10), 16V variants Diesel Engine Options: 1.9L (XUD7, XUD9 naturally aspirated and turbocharged), 2.0L (DW8, DW10 common rail) Performance Typical Horsepower Range: 60 hp (1.4i) to 135 hp (2.0i 16V) Typical Torque Range: 110 Nm to 190 Nm Fuel System Fuel Delivery: Multi-point fuel injection (MPI) for petrol, Direct Injection (DI) or Common Rail (HDI) for diesel Emission Standards: Euro 2, some later models Euro 3 🔧 Transmission Standard Standard Transmission: 5-speed Manual (e.g., BE3/BE4) Optional Optional Transmission: 4-speed Automatic (e.g., AL4) Features Gear Ratios: Specific ratios available in manual for different engines (detailed in manual) Clutch Type: Single dry plate clutch, hydraulically actuated 📐 Dimensions Exterior Wheelbase: Approx. 2605 mm Length: Hatchback: ~4138 mm, Coupe: ~4138 mm, Estate: ~4410 mm Width: Approx. 1719 mm Height: Hatchback: ~1427 mm, Estate: ~1476 mm Cargo Cargo Volume Hatchback: Approx. 354 litres (seats up) Cargo Volume Estate: Approx. 517 litres (seats up) Weights Curb Weight: Approx. 1100-1300 kg depending on engine and body style 🛡️ Safety Features Ratings Euroncap Rating: Achieved 3 stars in early Euro NCAP tests (results varied by test year and configuration) Active Features Active Safety: ABS (optional on some models), Power Assisted Steering Passive Features Passive Safety: Driver and front passenger airbags, three-point seatbelts with pre-tensioners, ISOFIX child seat anchor points (on some models) 💡 Technology Features Infotainment Infotainment System: Basic radio cassette/CD player, often with steering wheel mounted controls on higher trims. Driver Assistance Driver Assistance Features: ABS (optional on many variants), rear parking sensors were a rare dealer-fit option. Connectivity Connectivity Features: Limited to basic auxiliary inputs for aftermarket head units. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 10,000-15,000 km or 1 year, whichever comes first (varies by engine and oil type) Timing Belt Interval: Generally 60,000-120,000 km or 5-6 years for petrol engines (XU/TU series), crucial to check for specific engine. DW diesel engines use timing chains or belts with longer intervals. Fluid Specifications Engine Oil Specification: API SG/SH or ACEA A2/A3, viscosity typically 5W-40 or 10W-40 depending on climate (refer to manual for exact grade) Coolant Specification: Ethylene glycol based, long-life coolant (e.g., Citroën type or...
1.9L (XUD7, XUD9 naturally aspirated and turbocharged), 2.0L (DW8, DW10 common rail)
Performance
Typical Horsepower Range:
60 hp (1.4i) to 135 hp (2.0i 16V)
Typical Torque Range:
110 Nm to 190 Nm
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) for petrol, Direct Injection (DI) or Common Rail (HDI) for diesel
Emission Standards:
Euro 2, some later models Euro 3
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual (e.g., BE3/BE4)
Optional
Optional Transmission:
4-speed Automatic (e.g., AL4)
Features
Gear Ratios:
Specific ratios available in manual for different engines (detailed in manual)
Clutch Type:
Single dry plate clutch, hydraulically actuated
📐 Dimensions
Exterior
Wheelbase:
Approx. 2605 mm
Length:
Hatchback: ~4138 mm, Coupe: ~4138 mm, Estate: ~4410 mm
Width:
Approx. 1719 mm
Height:
Hatchback: ~1427 mm, Estate: ~1476 mm
Cargo
Cargo Volume Hatchback:
Approx. 354 litres (seats up)
Cargo Volume Estate:
Approx. 517 litres (seats up)
Weights
Curb Weight:
Approx. 1100-1300 kg depending on engine and body style
🛡️ Safety Features
Ratings
Euroncap Rating:
Achieved 3 stars in early Euro NCAP tests (results varied by test year and configuration)
Active Features
Active Safety:
ABS (optional on some models), Power Assisted Steering
Passive Features
Passive Safety:
Driver and front passenger airbags, three-point seatbelts with pre-tensioners, ISOFIX child seat anchor points (on some models)
💡 Technology Features
Infotainment
Infotainment System:
Basic radio cassette/CD player, often with steering wheel mounted controls on higher trims.
Driver Assistance
Driver Assistance Features:
ABS (optional on many variants), rear parking sensors were a rare dealer-fit option.
Connectivity
Connectivity Features:
Limited to basic auxiliary inputs for aftermarket head units.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 10,000-15,000 km or 1 year, whichever comes first (varies by engine and oil type)
Timing Belt Interval:
Generally 60,000-120,000 km or 5-6 years for petrol engines (XU/TU series), crucial to check for specific engine. DW diesel engines use timing chains or belts with longer intervals.
Fluid Specifications
Engine Oil Specification:
API SG/SH or ACEA A2/A3, viscosity typically 5W-40 or 10W-40 depending on climate (refer to manual for exact grade)
Coolant Specification:
Ethylene glycol based, long-life coolant (e.g., Citroën type or equivalent) with anti-corrosion inhibitors
Brake Fluid Specification:
DOT 4
Transmission Oil Manual:
API GL-4, typically SAE 75W-80 or 75W-90
Transmission Oil Automatic:
Specific ATF fluid (e.g., LT 71141 or equivalent for AL4 gearbox)