CITROEN SAXO XSARA PICASSO BERLINGO Technical Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Models Covered: Saxo, Xsara, Xsara Picasso, Berlingo, C2, C3, C3 Pluriel Applicable Years: 2001, 2002, 2003, 2004, 2005 Engine Coverage: All engines Codes Product Name: CITROEN SAXO XSARA PICASSO BERLINGO Technical Service Repair Manual 👋 Introduction Market Position Vehicle Segment: Citroën Saxo: Supermini; Citroën Xsara/Xsara Picasso: Small Family Car/Compact MPV; Citroën Berlingo: Compact MPV/Leisure Activity Vehicle; Citroën C2/C3/C3 Pluriel: Supermini/City Car. These vehicles generally occupied the budget-friendly to mainstream segments of the European automotive market. Competitive Analysis Key Competitors Era: Saxo: Peugeot 106, Ford Fiesta, Vauxhall Corsa. Xsara: Ford Focus, Volkswagen Golf, Renault Mégane. Xsara Picasso: Renault Scénic, Ford Focus C-Max. Berlingo: Peugeot Partner, Renault Kangoo. C2/C3: Peugeot 206/207, Renault Clio, Ford Fiesta, Fiat Punto. Key Features Citroen Philosophy: Citroën vehicles from this era were known for their emphasis on comfort (e.g., Hydractive suspension on some models, though less common in these specific models), innovative design, and often practical features, particularly the MPVs. Vehicle Diversity: This manual covers a diverse range of Citroën vehicles, from the compact city car (Saxo, C2, C3) to versatile MPVs (Xsara Picasso, Berlingo) and the family car (Xsara), highlighting the breadth of Citroën's offerings in the early 2000s. 📋 Manual Details Coverage Areas Manual Type: Technical Service Repair Manual / Workshop Manual Language: English Format: Likely digital (PDF) given industry trends for workshop manuals of this era, but could also be physical print. Target Audience: Trained automotive repair personnel, professional vehicle repairers Page Count Estimated Page Count: Likely several hundred pages, potentially over 1000 pages if it's a comprehensive collection covering all models and variants with detailed schematics. 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, engine management, fuel injection, ignition system, cooling system, lubrication system, exhaust system Drivetrain: Clutch, manual transmission, automatic transmission (if applicable to models/years), transaxle, driveshafts, CV joints Chassis: Front axle, rear axle, suspension systems (front and rear), steering system, wheel bearings Braking System: Front brakes, rear brakes, parking brake, ABS (Anti-lock Braking System) if equipped Electrical System: Battery, charging system (alternator, starter), lighting systems (headlights, taillights, interior), wiring diagrams, fuses, relays, ECUs (Electronic Control Units) Climate Control: Air conditioning system (refrigerant, components, diagnosis), heating system, ventilation Bodywork And Interior: Body panels, doors, trim, seats, airbags (if applicable) Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections Engine Repair: Engine overhaul, piston ring replacement, valve adjustments, gasket replacement, timing belt/chain service Fuel System Repair: Fuel pump replacement, injector cleaning/replacement, fuel filter replacement, fuel pressure testing Ignition System Repair: Ignition coil testing/replacement, spark plug wire testing/replacement, distributor service (if applicable) Transmission Service: Clutch replacement, transmission fluid change, seal replacement, gearbox overhaul Suspension And Steering Repair: Shock absorber/strut replacement, ball joint replacement, tie rod end replacement, power steering system service Brake System Repair: Brake pad replacement, brake rotor replacement, brake caliper overhaul, brake fluid flush, ABS component testing Electrical Diagnostics: Troubleshooting electrical faults, component testing, wiring harness repair, ECU diagnostics Air Conditioning Service: Refrigerant charging, leak detection, component replacement (compressor, condenser), system evacuation Troubleshooting: Diagnostic charts, symptom-based troubleshooting guides, fault code interpretation Body Repair: Procedures for body panel replacement, door adjustments, and potentially structural repair guidelines, including welding and adhesive bonding where applicable. Technical Depth Level Of Detail: Comprehensive, suitable for professional mechanics, including detailed diagrams, torque specifications, and diagnostic procedures. Diagnostic Capabilities: Includes fault finding charts and procedures, often requiring specific diagnostic tools (e.g., Lexia/PP2000 for Citroën specific codes and parameter reading) for more advanced electronic issues. 📊 Manual Specifications File Format Digital Format Details: Likely PDF with high-resolution schematics, searchable text, and bookmarking capabilities for easy navigation. May include interactive elements if a modern digital format. Searchability: If PDF, expect excellent searchability for keywords, part numbers, and technical terms, greatly aiding diagnostic and repair processes. Print Quality Print Quality Notes: If physical, expect clear printing of text and diagrams, often on durable paper suitable for workshop environments. Color sections for wiring diagrams or specific components are common. Binding Type Binding Type Notes: If physical, likely spiral-bound or professionally bound to lay flat for ease of use in a workshop setting. Paper Type Paper Type Notes: If physical, often printed on heavier weight paper stock to withstand repeated use in a garage environment. ⚙️ Engine Specifications Primary Engine Example Saxo Engine Type Saxo 1.1: 8-valve SOHC 4-cylinder Displacement Saxo 1.1: 1124 cc Power Saxo 1.1: Approx. 60 PS (59 bhp / 44 kW) Primary Engine Example Xsara Picasso Engine Type Xsara Picasso 1.6: 8-valve SOHC 4-cylinder (TU5JP) Displacement Xsara Picasso 1.6: 1587 cc Power Xsara Picasso 1.6: Approx. 95 PS (94 bhp / 70 kW) Primary Engine Example Berlingo Engine Type Berlingo 1.9D: Naturally Aspirated Diesel, 8-valve SOHC 4-cylinder (XUD9A or DW8) Displacement Berlingo 1.9D: 1905 cc Power Berlingo 1.9D: Approx. 70 PS (69 bhp / 51...

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Description

🏷️ Basic Information

Identification

Make:

Citroën

Models Covered:

Saxo, Xsara, Xsara Picasso, Berlingo, C2, C3, C3 Pluriel

Applicable Years:

2001, 2002, 2003, 2004, 2005

Engine Coverage:

All engines

Codes

Product Name:

CITROEN SAXO XSARA PICASSO BERLINGO Technical Service Repair Manual

👋 Introduction

Market Position

Vehicle Segment:

Citroën Saxo: Supermini; Citroën Xsara/Xsara Picasso: Small Family Car/Compact MPV; Citroën Berlingo: Compact MPV/Leisure Activity Vehicle; Citroën C2/C3/C3 Pluriel: Supermini/City Car. These vehicles generally occupied the budget-friendly to mainstream segments of the European automotive market.

Competitive Analysis

Key Competitors Era:

Saxo: Peugeot 106, Ford Fiesta, Vauxhall Corsa. Xsara: Ford Focus, Volkswagen Golf, Renault Mégane. Xsara Picasso: Renault Scénic, Ford Focus C-Max. Berlingo: Peugeot Partner, Renault Kangoo. C2/C3: Peugeot 206/207, Renault Clio, Ford Fiesta, Fiat Punto.

Key Features

Citroen Philosophy:

Citroën vehicles from this era were known for their emphasis on comfort (e.g., Hydractive suspension on some models, though less common in these specific models), innovative design, and often practical features, particularly the MPVs.

Vehicle Diversity:

This manual covers a diverse range of Citroën vehicles, from the compact city car (Saxo, C2, C3) to versatile MPVs (Xsara Picasso, Berlingo) and the family car (Xsara), highlighting the breadth of Citroën's offerings in the early 2000s.

📋 Manual Details

Coverage Areas

Manual Type:

Technical Service Repair Manual / Workshop Manual

Language:

English

Format:

Likely digital (PDF) given industry trends for workshop manuals of this era, but could also be physical print.

Target Audience:

Trained automotive repair personnel, professional vehicle repairers

Page Count

Estimated Page Count:

Likely several hundred pages, potentially over 1000 pages if it's a comprehensive collection covering all models and variants with detailed schematics.

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, engine management, fuel injection, ignition system, cooling system, lubrication system, exhaust system

Drivetrain:

Clutch, manual transmission, automatic transmission (if applicable to models/years), transaxle, driveshafts, CV joints

Chassis:

Front axle, rear axle, suspension systems (front and rear), steering system, wheel bearings

Braking System:

Front brakes, rear brakes, parking brake, ABS (Anti-lock Braking System) if equipped

Electrical System:

Battery, charging system (alternator, starter), lighting systems (headlights, taillights, interior), wiring diagrams, fuses, relays, ECUs (Electronic Control Units)

Climate Control:

Air conditioning system (refrigerant, components, diagnosis), heating system, ventilation

Bodywork And Interior:

Body panels, doors, trim, seats, airbags (if applicable)

Procedures Included

General Maintenance:

Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt inspections

Engine Repair:

Engine overhaul, piston ring replacement, valve adjustments, gasket replacement, timing belt/chain service

Fuel System Repair:

Fuel pump replacement, injector cleaning/replacement, fuel filter replacement, fuel pressure testing

Ignition System Repair:

Ignition coil testing/replacement, spark plug wire testing/replacement, distributor service (if applicable)

Transmission Service:

Clutch replacement, transmission fluid change, seal replacement, gearbox overhaul

Suspension And Steering Repair:

Shock absorber/strut replacement, ball joint replacement, tie rod end replacement, power steering system service

Brake System Repair:

Brake pad replacement, brake rotor replacement, brake caliper overhaul, brake fluid flush, ABS component testing

Electrical Diagnostics:

Troubleshooting electrical faults, component testing, wiring harness repair, ECU diagnostics

Air Conditioning Service:

Refrigerant charging, leak detection, component replacement (compressor, condenser), system evacuation

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides, fault code interpretation

Body Repair:

Procedures for body panel replacement, door adjustments, and potentially structural repair guidelines, including welding and adhesive bonding where applicable.

Technical Depth

Level Of Detail:

Comprehensive, suitable for professional mechanics, including detailed diagrams, torque specifications, and diagnostic procedures.

Diagnostic Capabilities:

Includes fault finding charts and procedures, often requiring specific diagnostic tools (e.g., Lexia/PP2000 for Citroën specific codes and parameter reading) for more advanced electronic issues.

📊 Manual Specifications

File Format

Digital Format Details:

Likely PDF with high-resolution schematics, searchable text, and bookmarking capabilities for easy navigation. May include interactive elements if a modern digital format.

Searchability:

If PDF, expect excellent searchability for keywords, part numbers, and technical terms, greatly aiding diagnostic and repair processes.

Print Quality

Print Quality Notes:

If physical, expect clear printing of text and diagrams, often on durable paper suitable for workshop environments. Color sections for wiring diagrams or specific components are common.

Binding Type

Binding Type Notes:

If physical, likely spiral-bound or professionally bound to lay flat for ease of use in a workshop setting.

Paper Type

Paper Type Notes:

If physical, often printed on heavier weight paper stock to withstand repeated use in a garage environment.

⚙️ Engine Specifications

Primary Engine Example Saxo

Engine Type Saxo 1.1:

8-valve SOHC 4-cylinder

Displacement Saxo 1.1:

1124 cc

Power Saxo 1.1:

Approx. 60 PS (59 bhp / 44 kW)

Primary Engine Example Xsara Picasso

Engine Type Xsara Picasso 1.6:

8-valve SOHC 4-cylinder (TU5JP)

Displacement Xsara Picasso 1.6:

1587 cc

Power Xsara Picasso 1.6:

Approx. 95 PS (94 bhp / 70 kW)

Primary Engine Example Berlingo

Engine Type Berlingo 1.9D:

Naturally Aspirated Diesel, 8-valve SOHC 4-cylinder (XUD9A or DW8)

Displacement Berlingo 1.9D:

1905 cc

Power Berlingo 1.9D:

Approx. 70 PS (69 bhp / 51 kW)

Fuel System

Fuel Injection Type:

Bosch Motronic, Siemens or Lucas multi-point fuel injection (MPI) for petrol engines. Lucas DPC, Bosch VP30 or common rail (HDi) for diesel engines.

Engine Variety

Petrol Engines:

TU series (1.1, 1.4, 1.6) - 8v and 16v, EW series (1.8, 2.0 on Xsara) - 16v.

Diesel Engines:

XUD (1.9D, 1.9TD), DW8 (1.9D), HDi (2.0 common rail diesel).

🔧 Transmission

Standard Transmission

Manual Gearbox:

4-speed or 5-speed manual transaxle, often BE series (e.g., BE3, BE4).

Optional Transmission

Automatic Gearbox:

AL4 4-speed automatic transmission was an option on many petrol models.

Features

Clutch Type:

Dry single-plate clutch, hydraulically actuated.

📐 Dimensions

Exterior Saxo

Length Saxo:

Approx. 3,732 mm

Exterior Xsara Picasso

Length Xsara Picasso:

Approx. 4,274 mm

Exterior Berlingo

Length Berlingo:

Approx. 4,137 mm (standard wheelbase)

Weights Saxo

Kerb Weight Saxo:

Approx. 950-1050 kg, depending on engine and specification.

Weights Xsara Picasso

Kerb Weight Xsara Picasso:

Approx. 1,350-1,450 kg.

🛡️ Safety Features

Ratings Euro Ncap

Euro Ncap Saxo:

3 stars (early models, later improved). Frontal impact protection was a focus.

Euro Ncap Xsara Picasso:

4 stars (Good level of protection for its class).

Active Features

Optional or standard on higher trims, particularly on Xsara and later models.

Passive Features

Airbags:

Driver airbag standard, passenger airbag optional or standard on higher trims. Side airbags available on some models.

💡 Technology Features

Infotainment Era

Audio Systems:

Basic radio cassette players or CD players, often with optional steering wheel remote controls. Early models may have simpler analogue systems.

Driver Assistance

Driver Aids:

ABS was an option on most models. Cruise control was less common in this era for the smaller vehicles but available on higher trims of Xsara and Picasso. Parking sensors were a later addition/option.

Connectivity

Connectivity Features:

Limited connectivity for the era. Bluetooth hands-free was a rare option. Typically no integrated navigation or advanced smartphone integration.

🔧 Maintenance

Service Intervals Engine Oil

Oil Change Interval:

Typically every 10,000-15,000 miles (16,000-24,000 km) or 12-24 months, depending on engine type and driving conditions (refer to specific model for exact recommendation).

Service Intervals Timing Belt

Timing Belt Replacement:

Crucial for petrol engines with timing belts (e.g., TU series). Typically every 60,000-80,000 miles (100,000-130,000 km) or 5-7 years. Failure can cause catastrophic engine damage.

Fluid Specifications Engine Oil

Engine Oil Specification:

Petrol engines: SAE 5W-40 or 10W-40, meeting ACEA A3/B3 or API SL/CF specifications. Diesel engines: SAE 5W-40 or 10W-40, meeting ACEA B3/B4 or VW 505.00 specifications. Always consult the manual for the precise grade.

Fluid Specifications Coolant

Coolant Specification:

Ethylene glycol based, long-life coolant (often pink or orange). Capacity varies by model, typically 5-7 liters. Citroën recommends specific types like 'Citroën Coolant Organic'.

Fluid Specifications Brake Fluid

Brake Fluid Specification:

DOT 3 or DOT 4. Should be flushed and replaced every 2-3 years to maintain performance and prevent moisture absorption.

Known Issues

Common Saxo Issues:

Rear axle beam wear (causing alignment issues), electrical gremlins (especially related to multiplexed systems on later models), exhaust system corrosion, clutch wear.

Common Xsara Picasso Issues:

Rear suspension component wear (e.g., torsion bar issues), electronic faults (e.g., BSI module), clutch slave cylinder failure, AC compressor issues.

Common Berlingo Issues:

Rear axle beam issues (similar to Saxo), starter motor failure, DMF (Dual Mass Flywheel) issues on HDi models, clutch wear, exhaust manifold cracks on HDi.

Common C3 Issues:

Electronic issues (BSI, UCH), suspension wear, engine management light illuminated due to lambda sensors or ignition coils (especially 1.4 16v and 1.6 16v).

📚 Vehicle History

Brand Heritage

Citroen Philosophy History:

Citroën has a long history of innovation, particularly in suspension technology (Hydropneumatic) and aerodynamic design, often prioritizing comfort and practicality.

Model Evolution Saxo

Saxo Introduction:

Launched in 1996 as a replacement for the Citroën AX, sharing a platform with the Peugeot 106. Known for its agile handling and affordable running costs.

Model Evolution Xsara

Xsara Introduction:

Introduced in 1997 as the successor to the Citroën ZX. Available as hatchback, estate (Break), and coupe. The Xsara Picasso, launched in 1999, was a highly successful compact MPV variant.

Model Evolution Berlingo

Berlingo Introduction:

Launched in 1996, it pioneered the leisure activity vehicle segment, offering a versatile and practical solution for families and light commercial use.

Model Evolution C3

C3 C3 Pluriel Introduction:

The C3 and C3 Pluriel were introduced around 2001/2002, replacing the Saxo and evolving Citroën's small car offering with more modern styling and features.

Production Locations

Manufacturing Plants:

Primary production for these models was primarily in France (e.g., Aulnay-sous-Bois for some models), Spain, and the UK. Some components may have been sourced globally.