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
Power unit Citroen Berlingo I
Step-by-step instructions on "Power unit" for Citroen Berlingo I (1996–2002). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Articles in this section
- Presentation: DW8 (WJZ) engine (DW8, DW8B)
- Tightening torques: DW8B engine type (DW8B)
- Checking and adjusting values: DW8 engine type (DW8, DW8B)
- Checking and adjusting values: engine types DW10TD - DW10ATED4 (DW10TD)
- Data: engine suspension (TU3JP, 1.1 i (TU1M+))
- Data: engine (TU3JP, 1.1 i (TU1M+))
- Data: engine suspension (XUD9, 1.8 D)
- Data: engine (XUD9, 1.8 D)
- Identification: engine
- Tightening torques: engine
- Data: engine (1.4)
- Data: engine (XU7JB)
- Data: power unit suspension (XU7JB)
- Data: engine (SA18)
- Identification: engine — variant 2
- Tightening torques: DW8 engine (DW8)
- Identification - data: DW8 engine (DW8)
- Data: engine suspension (DW8B, DW8)
- Data: tightening torque (DW8)
- Data: DW10 engine (DW10TD)
- Tightening torques: power unit suspension (DW10TD)
- Tightening torques: DW10 engine (DW10TD)
- Identification: engine — variant 3
- Identification: engine — variant 4
- Tightening torques: TU5JP4 engines (TU5JP4)
- Identification: engine — variant 5
- Tightening torques: tu engines (8 valves) (TU3JP, 1.4, TU1JP)
- Identification: tooling (engine reconditioning) (1.4, TU1JP, TU3JP)
- Identification: engine — variant 6
- Tightening torques: tu engine (16 valves) (TU5JP4)
- Identification: ENGINE TOOLS (TU5JP4)
- Check: electric motor brushes (SA18)
- Check: engine compression ratio (DW10TD)
- Removing - refitting: ancillary drive belt (XUD9, 1.8 D)
- Removing - refitting: ancillary drive belt (TU3JP, 1.1 i (TU1M+))
- Removing - refitting: power unit (TU3JP, 1.1 i (TU1M+))
- Removing - refitting: engine and gearbox assembly (1.8 D, XUD9)
- Dismantling: engine
- Refitting: engine
- Removing - refitting: engine/gearbox assembly (XU7JB)
- Removing - refitting: ancillary drive belt (XU7JB)
- Uncoupling - coupling: engine - motor (SA18)
- Removing - refitting: power unit (SA18)
- Dismantling: engine — variant 2
- Refitting: engine — variant 2
- Removing - refitting: engine and gearbox assembly (DW8B, DW8)
- Removing - refitting: ancillary drive belt (DW8, DW8B)
- Removing - refitting: engine/gearbox assembly (DW10TD)
- Removing - refitting: ancillary drive belt (DW10TD)
- Dismantling: DW10 engine (DW10TD)
- Refitting: DW10 engine (DW10TD)
- Dismantling: engine — variant 3
- Refitting: engine — variant 3
- Refitting: engine (cast iron cylinder block) (TU1JP, 1.4, 1.1 i (TU1M+), TU3JP)
- Dismantling: engine — variant 4
- Refitting: engine (aluminium block) (TU3JP, 1.4, TU1JP)
- Dismantling: engine — variant 5
- Refitting: engine — variant 4
- Replacement: electric motor brushes (SA18)
- Cleaning: engine (SA18)
- Activation: power unit (SA18)
- Prohibited operations: HDI direct injection system
- Prohibited operations: HDI direct injection system (SIEMENS) (DW10TD)
- Prohibited operations: HDI direct injection system — variant 2
- Fitting: engine on stand (DW8B, DW8)
- Fitting: engine on stand (DW10TD)
- Fitting: engine on stand (TU5JP4)
- Fitting: engine on stand (1.1 i (TU1M+), TU5JP4, 1.4, TU1JP, TU3JP)
- Modification: Siemens injection DW10TD (adaptation of the fuel high pressure common injection rail) (DW10TD)
- Modification: modernised TU1M+ engine (1.1 i (TU1M+))
- Modification: TU3JP+ /L3 engine (TU3JP)
- Modification: TU3JP /IFL4 engine (TU3JP)
- Modification: DW8 engine (DW8B)
- Modification: tightening of the accessories pulley screw (DW10TD)
- Checking for leaks: battery cooling system (SA18)
- Operating methods: TU3JP - TU5JP - XU7JP4 - XU10J4R (BOSCH MP7.2 - MP7.3) engines (Summary) (TU3JP)
- Operating methods: DW10TD engine - HDI direct injection system (BOSCH) (Summary) (DW10TD)
- Operating methods: (engine DW10TD) hdi direct injection system (SIEMENS SID 801) (Summary) (DW10TD)
- General: diesel injection
- Presentation: injection MAGNETI MARELLI 1.AP (TU3JP, XU7JB)
- Description: fuel supply system (petrol) (XU7JB, TU3JP)
- Description: air supply circuit (TU3JP, XU7JB)
- Description: ignition system (TU3JP, XU7JB)
- General principal: injection MAGNETI MARELLI 1.AP (TU3JP, XU7JB)
- Function: components of the system (XU7JB, TU3JP)
- Principles of operation: injection MAGNETI MARELLI 1.AP (TU3JP, XU7JB)
- Presentation: injection BOSCH MA 3.1 (1.1 i (TU1M+))
- Description: fuel supply system (petrol) (1.1 i (TU1M+))
- Description: air supply circuit (1.1 i (TU1M+))
- Description: ignition system (1.1 i (TU1M+))
- General principal: injection BOSCH MA 3.1 (1.1 i (TU1M+))
- Function: components of the system (1.1 i (TU1M+))
- Principles of operation: injection BOSCH MA 3.1 (1.1 i (TU1M+))
- General: HDI direct injection system (DW10TD)
- General synopsis: HDI direct injection system (DW10TD)
- Function: fuel supply (DW10TD)
- Function: air supply (DW10TD)
- Function: exhaust gas recycling (DW10TD)
- Function: HDI direct injection system (DW10TD)
- Function: pre-postheating (DW10TD)
- Function: engine cooling (integrated in the injection ECU) (DW10TD)
- Phases of operation: HDI direct injection system (DW10TD)
- Maintenance: HDI direct injection system (DW10TD)
- General: BOSCH MP7.2 and BOSCH MP7.3 injection systems (TU3JP)
- General synopsis: BOSCH MP7.2 and BOSCH MP7.3 injection systems (engine TU) (TU3JP)
- Function: fuel supply (TU3JP)
- Function: air supply (TU3JP)
- Function: ignition system (TU3JP)
- Function: injection (TU3JP)
- Function: air injection to the exhaust (TU3JP)
- Function: fuel vapour recycling (canister) (TU3JP)
- Function: diagnosis of depollution systems (EOBD) (TU3JP)
- Phases of operation: BOSCH MP7.2 and BOSCH MP7.3 injection systems (TU3JP)
- Maintenance: BOSCH MP7.2 and BOSCH MP7.3 injection systems (TU3JP)
- General: DELPHI DCN 2.2 diesel indirect injection system (DW8B)
- General synopsis: DELPHI DCN 2.2 diesel indirect injection system (DW8B)
- Function: air supply (DW8B)
- Function: DELPHI DCN 2.2 diesel indirect injection system (DW8B)
- Function: pre-postheating (DW8B)
- Function: cooling requirement for the air conditioning (BRAC) (integrated in the injection ECU) (DW8B)
- Function: engine cooling (integrated in the injection ECU) (DW8B)
- Phases of operation: DELPHI DCN 2.2 diesel indirect injection system (DW8B)
- Maintenance: DELPHI DCN 2.2 diesel indirect injection system (DW8B)
- General: HDI direct injection system (SIEMENS SID 801) (DW10TD)
- General synopsis: HDI direct injection system (SIEMENS SID 801) (DW10TD)
- Function: fuel supply (SIEMENS SID 801) (DW10TD)
- Function: air supply (SIEMENS SID 801) (DW10TD)
- Function: exhaust gas recycling (SIEMENS SID 801) (DW10TD)
- Function: HDI direct injection system (SIEMENS SID 801) (DW10TD)
- Function: pre-postheating (SIEMENS SID 801) (DW10TD)
- Function: engine cooling (FRIC) (integrated in the injection ECU) (SIEMENS SID 801) (DW10TD)
- Function: cooling requirement for the air conditioning (BRAC) (integrated in the injection ECU) (SIEMENS SID 801) (DW10TD)
- Phases of operation: HDI direct injection system (SIEMENS SID 801) (DW10TD)
- Maintenance: HDI direct injection system (SIEMENS SID 801) (DW10TD)
- Data: MAGNETI multipoint injection system - MARELLI 1AP40 (TU3JP)
- Data: BOSCH type MA 3.1 monopoint injection system (1.1 i (TU1M+))
- Data: (BOSCH) injection pump XUD9/L3 engine (XUD9, 1.8 D)
- Data: lucas diesel injection pump (XUD9, 1.8 D)
- Data: injectors ((BOSCH)) (XUD9, 1.8 D)
- Data: injectors (LUCAS DIESEL) (XUD9, 1.8 D)
- Diagnostic: injection system BOSCH MA3.1 (1.1 i (TU1M+))
- Diagnostic: injection system MAGNETI - MARELLI 1.AP (TU3JP)
- Data: MAGNETI-MARELLI 1 AP 20 multipoint injection system (XU7JB)
- Data: injection system BOSCH (DW8)
- Data: injection system LUCAS DIESEL (DW8)
- Data: petrol/LPG dual fuel system (1.1 i (TU1M+))
- Specifications of the LPG supply circuit: petrol/LPG dual fuel vehicle (van 1.1i) (1.1 i (TU1M+))
- Data: petrol/LPG dual fuel system (TU3JP)
- Data: HDI direct injection system BOSCH (DW10TD)
- Data: air supply circuit (DW10TD)
- Data: petrol/LPG dual fuel system EURO 3 (TU3JP)
- Data: HDI direct injection system (SIEMENS) (DW10TD)
- Data: petrol/natural gas (CNG) dual fuel system (TU3JP)
- Check: fuel high pressure supply circuit (BOSCH assembly) (DW10TD)
- Check: fuel supply system (high pressure) (SIEMENS assembly) (DW10TD)
- Check: air supply circuit (DW10TD)
- Check: low pressure fuel supply circuit (DW10TD)
- Check: high pressure fuel circuit (DW10TD, 09.1999+)
- Check: low pressure fuel supply circuit (DW10TD) — variant 2
- Tightening procedure: GNV supply unions (TU3JP)
- Checking-adjusting: CNG supply pressure (TU3JP)
- Checking the seals: mechanical units ° C (TU3JP)
- Checking the seals: mechanical units (CNG)
- Check: high pressure fuel circuit (DW10TD)
- Check: operation of the lambda signal emulation (TU3JP)
- Check - timing: injection pump (XUD9, 1.8 D)
- Checks and adjustments: (LUCAS DIESEL) injection pump (XUD9, 1.8 D)
- Checks and adjustments: (BOSCH) injection pump (XUD9, 1.8 D)
- Check - timing: injection pump (XUD9, 1.8 D) — variant 2
- Checking -- adjusting: injector (XUD9, 1.8 D)
- Checks and adjustments: injection pump controls (BOSCH) (DW8)
- Checks and adjustments: injection pump controls (LUCAS DIESEL) (DW8)
- Check - timing: BOSCH injection pump (DW8)
- Check - timing: LUCAS DIESEL injection pump (DW8)
- Check - adjustment: diesel injectors (DW8B, DW8)
- Checking-adjusting: LPG evaporator-control valve (1.1 i (TU1M+))
- Checking-adjusting: lpg feed pressure (TU3JP)
- Diagnostic: initialisation of an engine management ECU
- Diagnostic: initialisation of an engine management ECU — variant 2
- Removing - refitting: injection pump (lucas diesel) (XUD9, 1.8 D)
- Removing - refitting: (BOSCH) injection pump (XUD9, 1.8 D)
- Removing - refitting: injectors (XUD9, 1.8 D)
- Removing - refitting: injectors (XU7JB)
- Removing - refitting: LUCAS DIESEL injection pump (DW8)
- Removing - refitting: diesel injectors (DW8B, DW8)
- Removing - refitting: diffuser (1.1 i (TU1M+))
- Removing - refitting: LPG evaporator-control valve (1.1 i (TU1M+))
- Removing - refitting: electrical components (1.1 i (TU1M+))
- Removing - refitting: electrical components (TU3JP)
- Removing - refitting: LPG evaporator-control valve (TU3JP)
- Removing - refitting: high pressure fuel sensor (DW10TD)
- Removing - refitting: fuel high pressure common injection rail (DW10TD)
- Removing - refitting: diesel injectors (DW10TD)
- Removing - refitting: LPG distributor and LPG distributor filter (TU3JP)
- Removing - refitting: LPG evaporator-control valve (TU3JP, 10.1999–07.2001)
- Removing - refitting: electrical components (TU3JP, 10.1999–07.2001)
- Removing - refitting: high pressure fuel pump (DW10TD)
- Removing - refitting: high pressure fuel sensor (DW10TD) — variant 2
- Removing - refitting: fuel high pressure common injection rail (DW10TD) — variant 2
- Removing - refitting: diesel injectors (DW10TD) — variant 2
- Removing - refitting: electrical components (TU3JP, 01.2004+)
- Depressurizing the system: CNG supply circuit (TU3JP)
- Depressurizing the system: LPG supply circuit (TU3JP)
- Removing - refitting: mechanical units (TU3JP)
- Re-pressurising: CNG supply circuit
- Replacement: coded antitheft device module - plastic cowling (BOSCH equipment)
- Replacement: coded antitheft device module - metal screening (BOSCH equipment) (XUD9, 05.1996+)
- Replacement: coded antitheft device module (LUCAS DIESEL equipment) (XUD9, 1.8 D)
- Replacement: coded antitheft device module - plastic cowling (BOSCH equipment) — variant 2
- Replacement: coded antitheft device module - metal screening (BOSCH equipment) (XUD9)
- Replacement: transponder module - metal screening (BOSCH equipment) (XUD9)
- Replacement: coded antitheft device module (LUCAS DIESEL equipment) (XUD9)
- Replacement: transponder module solenoid valve (LUCAS DIESEL equipment) (XUD9)
- Drain and refill: LPG supply circuit (1.1 i (TU1M+))
- Drain and refill: LPG supply circuit (TU3JP)
- Drain and refill: LPG supply circuit (TU3JP, 10.1999–07.2001)
- Drain - refill: fuel tank
- Unlocking: coded antitheft device module (XUD9)
- Cleaning: fuel high pressure common injection rail unions
- Cleaning: fuel high pressure common injection rail unions — variant 2
- Cleaning: fuel high pressure common injection rail unions — variant 3
- Safety recommendations: Dual fuel petrol/LPG vehicles (TU3JP)
- Safety recommendations: petrol/natural gas (CNG) dual fuel system
- Safety recommendations: petrol/natural gas (CNG) dual fuel system — variant 2
- Repair: injection MAGNETI MARELLI 1.AP (XU7JB, TU3JP)
- Repair: injection BOSCH MA 3.1 (1.1 i (TU1M+))
- Diagnostic: downloading an injection ECU using the "ELIT" diagnostic equipment (on vehicle)
- Learning: CPH or transponder and engine management ECU (TU3JP)
- Learning: CPH or transponder and engine management ECU (TU3JP) — variant 2
- Learning: CPH or transponder and engine management ECU (1.1 i (TU1M+))
- Modification: fuel supply system (TU3JP)
- Modification: diesel injector holder (DW10TD)
- Modification: checking the setting of the diesel injection pump LUCAS (DW8)
- Diagnostic: the engine will not start, no smoke
- Diagnostic: the engine will not start, black smoke
- Diagnostic: the engine will not start, light smoke
- Diagnostic: the engine is difficult to start when cold, smoke
- Diagnostic: the engine starts and then stops
- Diagnostic: unstable idling ("hunting")
- Diagnostic: the engine vibrates at idle
- Diagnostic: at idle, the engine accelerates itself
- Diagnostic: the engine stalls when decelerated (no idling speed), deceleration too slow
- Diagnostic: the engine misfires, and runs unevenly
- Diagnostic: the engine lacks power, black smoke
- Diagnostic: excessive fuel consumption
- Diagnostic: the engine lacks power, no smoke
- Diagnostic: engine slap
- Diagnostic: the engine races
- Diagnostic: the engine hesitates at constant speed
- Diagnostic: the engine hesitates on acceleration
- Diagnostic: blue smoke, when hot, at idle, on deceleration or under light load
- Diagnostic: black smoke, on load
- Diagnostic: injection MAGNETI MARELLI 1.AP20 (LFX / XU7JB 1761 cc engine) (XU7JB)
- Diagnostic: injection BOSCH MP 7.3 (TU3JP KFX IFL4 1360 cc engine) (TU3JP)
- Diagnostic: SAGEM SL 96 petrol injection (engine KFX / TU3JP+ /L3) (TU3JP)
- Diagnostic: BRC LPG monopoint injection (HDZ/HDY TU1M+ 1124 cc engine) (1.1 i (TU1M+))
- Diagnostic: injection system DIESEL BOSCH EDC15 (DW10 TD/L3/L4 RHY 1997 cm3 turbocharged engine without air/air heat exchanger) (DW10TD)
- Symptoms: fault analysis (no fault memorised) (DW10TD)
- Diagnostic: BRC multipoint LPG "Flying Injection" system (KFX TU3JP+ 1360 cc engine) (TU3JP)
- Diagnostic: Necam-Koltec GSI LPG/CNG sequential injection system (KFX TU3JP/L4 + 1360 cc engine) (TU3JP)
- Data: ignition system (1.4)
- 1998 Model Year range: sparking plugs (60 000 km)
- 1999 Model Year range: sparking plugs
- 2000 Model Year range: sparking plugs
- 2002 model year range: sparking plugs
- Modification: Accelerator pedal sensor: not defined (DW10TD, TU3JP, TU5JP4)
- General: diagnosis of depollution systems (EOBD)
- General: EURO 3 (L4) emission control standards
- Fault codes EOBD: TU1JP (HFX) engine (TU1JP)
- Fault codes EOBD: TU3JP (KFW) engine (TU3JP)
- Fault codes EOBD: TU5JP4 (NFU) engine (TU5JP4)
- Modification: clutch (DW8)
- Data: motor (SA18)
- Diagnostic (using the ELIT test unit): diesel pump ADC module
- Diagnostic (using the PROXIA station): diesel pump ADC module
- Diagnostic (using the 26A station): diesel pump ADC module
- Principles of operation: coded anti-start
- Principles of operation: immobiliser
- Presentation: immobiliser
- After-sales operations: immobiliser
- Presentation: coded anti-start - diesel engines XUD - mechanical injection pump
- Principles of operation: coded anti-start - XUD diesel engines - mechanical injection pump
- Location and role of parts: coded anti-start - diesel engines XUD - mechanical injection pump
- Maintenance: coded anti-start - XUD diesel engines - mechanical injection pump
- Removing - refitting: accelerator sensor (SA18)
- Configuration: engine ECU BOSCH MP7.2 - BOSCH MP7.3
- Configuration: engine ECU SIEMENS SID 801 - SID 802 - SID 804 - SID 805
- Configuration: engine ECU DELPHI DCN2 - DELPHI C6
- Configuration: engine ECU SAGEM S2000 - S2000 PM1 - S2000 PM2
- Configuration: engine ECU BOSCH ME7.4.4 - ME7.4.6
- Configuration: engine ECU BOSCH EDC15C2
- Diagnostic: LPG/CNG ECUs
- Information: protection and safety (SA18)