Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Dashboard
- Driver information
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Other
- Panel on dashboard
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear door trim
- Rear door windows
- Rear parcel tray
- Rear section
- Rear shock absorbers
- Rear springs
- Roof panel
- Side structure
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Citroen Berlingo I
Step-by-step instructions on "Engine" for Citroen Berlingo I (1996–2002). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Data: reciprocating gear
- Data: conrods
- Data: liners - pistons - piston rings
- Data: conrods — variant 2
- Data: crankshaft (DW8, DW8B)
- Data: pistons - piston rings - the piston shaft
- Data: conrods — variant 3
- Data: pistons-gudgeon pins-rings (DW10TD)
- Data: crankshaft - crankshaft bearing shells (DW10TD)
- Data: conrods — variant 4
- Data: pistons - piston rings - the piston shaft — variant 2
- Data: half shells
- Data: conrods — variant 5
- Data: pistons - piston rings (TU3JP, TU1JP, 1.4)
- Data: crankshaft - crankshaft half shells (1.4, TU3JP, TU1JP)
- Data: conrods — variant 6
- Data: half shells — variant 2
- Data: pistons - piston rings - the piston shaft — variant 3
- Data: crankshaft (TU5JP4)
- Check: liner protrusion (aluminium block) (TU3JP, 1.4, 1.1 i (TU1M+), TU1JP)
- Removing - refitting: ancillary drive belt (without air conditioning and with power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (with air conditioning and without power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (with air conditioning and with power steering) (TU5JP4)
- Removing - refitting: ancillary drive belt (without power steering and without air conditioning) (TU5JP4)
- Dismantling - re-assembly: pistons/con.rods
- Check: liner protrusion
- Matching: bearing shells
- Dismantling - re-assembly: conrods - pistons (TU3JP, TU5JP4, 1.4, TU1JP, 1.1 i (TU1M+))
- Matching: crankshaft bearing shells (1.1 i (TU1M+), 1.4, TU1JP, TU3JP)
- Dismantling - re-assembly: dynamic seals - tu engine - 8 valves (1.4, TU1JP, TU3JP, 1.1 i (TU1M+))
- Dismantling - re-assembly: dynamic seals (tu 16 -valve engine) (TU5JP4)
- Modification: engine flywheel (engine DW8B) (DW8, DW8B)
Timing gear
- Modification: new timing system (DW10TD)
- Data: camshafts
- Data: camshaft
- Data: timing gear (DW8B, DW8)
- Data: camshaft — variant 2
- Data: camshaft — variant 3
- Data: camshafts (TU3JP, 1.4, TU1JP)
- Data: valve rockers (TU3JP, 1.4, TU1JP)
- Data: camshaft — variant 4
- Removal - refitting: ancillary drive belt
- Removing - refitting: camshaft seal (timing gear side)
- Removing - refitting: camshaft
- Removing - refitting: camshaft — variant 2
- Removing - refitting: camshaft seal
- Removing - refitting: camshaft seal (timing side) (XUD9, 1.8 D)
- Removal - refitting: camshaft seal (timing side)
- Removing - refitting: camshaft — variant 3
- Removal - refitting: camshaft
- Removing - refitting: camshaft — variant 4
- Removal - refitting: camshaft — variant 2
- Removing - refitting: camshaft seal (TU3JP, 1.1 i (TU1M+))
- Removal - refitting: camshaft seal
- Removing - refitting: camshaft seal (XU7JB)
- Removing - refitting: camshafts (XU7JB)
- Removing - refitting: camshaft seal (DW8B, DW8)
- Removing - refitting: camshaft — variant 5
- Removing - refitting: camshaft seal (DW10TD)
- Removing - refitting: camshaft — variant 6
- Check: setting the valve timing
- Check: setting the valve timing — variant 2
- Check: setting the valve timing — variant 3
- Check: valve timing
- Check: setting the valve timing — variant 4
- Check: valve timing — variant 2
- Check: setting the valve timing — variant 5
- Check: setting the valve timing — variant 6
- Check: setting the valve timing — variant 7
- Removing - refitting: timing belt
- Removing - refitting: timing belt — variant 2
- Removing - refitting: timing belt — variant 3
- Removal - refitting: timing belt
- Removing - refitting: timing belt — variant 4
- Removal - refitting: timing belt — variant 2
- Removing - refitting: timing belt — variant 5
- Removing - refitting: timing belt — variant 6
- Removing - refitting: timing belt — variant 7
- Removing - refitting: timing belt (from RPO No. 9128) (DW10TD)
- Modification: removal of the crankshaft pulley bolt (DW10TD)
Lubrication
- Engine oil capacities: (96 - 97 Model Year)
- Engine oil capacities: (1999 Model Year)
- Engine oil capacities: 2000 model year
- Summary: engine oil filter cartridges (05.1999–12.2001)
- Summary: engine oil filter cartridges (05.2000–12.2001)
- Engine oil capacities: 2001 model year
- Summary: engine oil filter cartridges (year 2002)
- Summary: engine oil filter cartridges (year 2003)
- Check: oil pressure (TU3JP, 1.1 i (TU1M+))
- Check: oil pressure (XUD9, 1.8 D)
- Check: oil pressure (XU7JB)
- Check: oil pressure (DW8B, DW8)
- Check: oil pressure (DW10TD)
- Modification: dipstick - dipstick guide tube (1.1 i (TU1M+), TU3JP)
- Modification: oil filter (TU3JP, 1.1 i (TU1M+))
- Modification: oil sump fixing
- Maintenance: TOTAL recommended lubricants
- Lubrication: engine oil
- Maintenance: recommended ingredients, year 2006
Engine block
- Data: cylinder housings of aluminium alloy
- Data: cylinder block
- Data: cylinder block — variant 2
- Data: cylinder block — variant 3
- Data: dynamic seals (TU1JP, TU5JP4, 1.4, TU3JP)
- Data: aluminium cylinder block (1.1 i (TU1M+), TU3JP, 1.4, TU1JP)
- Data: cast cylinder block (TU1JP, 1.4, 1.1 i (TU1M+), TU3JP)
- Data: cylinder block — variant 4
Cylinder head
- Data: identification of the cylinder head
- Data: valves
- Data: valve springs
- Data: valve guides
- Data: valve seats
- Data: cylinder head gasket
- Data: cylinder head
- Data: swirl chambers (DW8B, DW8)
- Data: valves and valve springs
- Data: valve seats and guides
- Data: cylinder head gasket (DW8, DW8B)
- Data: cylinder head bolts - cylinder head tightening (DW8B, DW8)
- Data: valves and valve springs — variant 2
- Data: valve seats and guides — variant 2
- Data: cylinder head gasket (DW10TD)
- Data: cylinder head — variant 2
- Data: cylinder head bolts - cylinder head tightening (DW10TD)
- Data: valves and valve springs — variant 3
- Data: valve seats and guides — variant 3
- Data: cylinder head gasket (TU5JP4)
- Data: cylinder head bolts - cylinder head tightening (TU5JP4)
- Data: cylinder head — variant 3
- Data: valves and valve springs — variant 4
- Data: valve seats and guides — variant 4
- Data: cylinder head — variant 4
- Data: cylinder head — variant 5
- Data: valve seats and guides — variant 5
- Data: valves and valve springs — variant 5
- Stripping - re-assembling: cylinder head
- Stripping-assembling: cylinder head (DW8, DW8B)
- Stripping-assembling: cylinder head (DW10TD)
- Stripping - re-assembling: cylinder head (TU5JP4)
- Stripping-assembling: cylinder head (TU3JP, TU1JP, 1.4, 1.1 i (TU1M+))
- Stripping - re-assembling: engine (TU3JP, 1.1 i (TU1M+), TU1JP, 1.4)
- Stripping-assembling: cylinder head (TU5JP4)
- Removing - refitting: cylinder head (on vehicle) (TU3JP, 1.1 i (TU1M+))
- Removing - refitting: cylinder head (on the vehicle) (1.8 D, XUD9)
- Removing - refitting: cylinder head on the vehicle (XU7JB)
- Removing - refitting: cylinder head (on vehicle) (DW8B, DW8)
- Removing - refitting: cylinder head (DW10TD)
- Modification: cylinder head gasket (1.8 D, XUD9)
- Modification: cylinder head (XUD9, 1.8 D)
- Modification: engines TU petrol all types (TU3JP, 1.4, 1.1 i (TU1M+))
- Modification: cylinder head cover (1.1 i (TU1M+), TU3JP)
- Presentation: tool 4533-T (1.4)
Cooling system
- Repair operation: temperature sensor (SA18)
- Data: cooling system (TU3JP, 1.1 i (TU1M+))
- Data: cooling system (XUD9, 1.8 D)
- Data: cooling system (1.4)
- Data: cooling system (XU7JB)
- Data: battery cooling system (SA18)
- Data: cooling system (DW8B, DW8)
- Data: cooling system (DW10TD)
- Removing - refitting: coolant outlet housing (TU5JP4)
- Removing - refitting: water pumps (SA18)
- Removing - refitting: battery cooling radiator (SA18)
- Removing - refitting: engine cooling air blower (SA18)
- Drain and refill - refilling - bleeding: cooling system
- Filling and bleeding: battery cooling system (SA18)
- Principles of operation: additional and independent heating systems (DW10TD)
- Data - identification: heating unit (SA18)
- General: additional and independent heating systems (DW10TD)
- Data: additional heating (DW10TD)
- Removing - refitting: heating unit (SA18)
- Removing - refitting: fuel tank (SA18)
- Removing - refitting: coolant pump (SA18)
- Removing - refitting: air turbine (SA18)
- Removing - refitting: incandescent finger and flame controller (SA18)
- Removing - refitting: combustion boiler (SA18)
- Filling and bleeding: heater fluid system (SA18)
- Diagnostic: heating unit (SA18)
- Diagnostic: additional and independent heating systems (DW10TD)
- Diagnostic: cooling circuit check - during performance limitation by temperature (SA18)
- Presentation: passenger compartment heating (SA18)
Air and fuel supply
- Data - identification: SOLEX 32-34 Z2 carburettor reference 528-5 (1.4)
- Data - identification: SOLEX 32-34 Z2 carburettor reference 528-12 (1.4)
- Checks and adjustments: SOLEX 32-34 Z2 carburettor (1.4)
- Removing - refitting: fuel tank (TU3JP, 1.1 i (TU1M+))
- Removing - refitting: fuel tank (XUD9, 1.8 D)
- Removing - refitting: fuel tank (XU7JB)
- Removing - refitting: fuel pump and gauge assembly (DW8, DW8B)
- Removing - refitting: fuel tank (DW8B, DW8)
- Removing - refitting: fuel pump and gauge assembly (DW8B, DW8)
- Removing - refitting: cylindrical LPG tank (1.1 i (TU1M+))
- Removing - refitting: LPG gauge valve - safety solenoid valve (1.1 i (TU1M+))
- Removing - refitting: LPG gauge valve - safety solenoid valve (TU3JP, 1.1 i (TU1M+))
- Removing - refitting: cylindrical LPG tank (TU3JP, 1.1 i (TU1M+))
- Removing - refitting: fuel pump and gauge assembly (DW10TD)
- Removing - refitting: fuel filter (DW10TD)
- Removing - refitting: LPG gauge - safety solenoid valve (1.1 i (TU1M+), TU3JP)
- Removing - refitting: fuel filter (DW10TD) — variant 2
- Removing - refitting: LPG tank (TU3JP)
- Removing - refitting: solenoid valve piston kit GNV (TU3JP)
- Removing - refitting: CNG reservoir (TU3JP)
- Data: charging cord and socket (SA18)
- Removing - refitting: charging socket harness (SA18)
- Removing - refitting: charging flap locking device
- Removing - refitting: charging socket light bulb (SA18)
- Removing - refitting: lower part of the charging socket (SA18)
- Removing - refitting: charging flap sensor (SA18)
- Removing - refitting: charging cable plug body (SA18)
- Overhaul: extension charging cable for electric vehicles (SA18)
- Modification: mains filter (SA18)
- Data: nickel-cadmium traction battery (SA18)
- Check: sealing of the battery electrolyte topping up system (SA18)
- Removing - refitting: lower battery pack (front) (SA18)
- Removing - refitting: upper battery pack (SA18)
- Removing - refitting: central battery compartment (SA18)
- Removing - refitting: rear battery pack (SA18)
- Removing - refitting: filler connections (SA18)
- Replacement: cooling hoses - traction batteries (SA18)
- Topping up: nickel-cadmium battery electrolyte (SA18)
- Data: high voltage fuse circuit breaker (SA18)
- Data: electronic unit (SA18)
- Removing - refitting: electronic unit (SA18)
- Removing - refitting: computer (SA18)
- Battery voltage check: 12 volt battery - traction battery (SA18)
- Diagnostic: traction battery circuit check in the event of a cut-off (SA18)
- Diagnostic: procedure to be followed in the event of a loss of traction battery range (SA18)
- Diagnostic: traction battery charging procedures (SA18)