Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Confort
- Current generation
- Dashboard
- Driver information
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Front springs
- Gearbox assembly
- General points
- General points about the vehicle
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Other
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear door trim
- Rear door windows
- Rear doors
- Rear seats
- Rear section
- Rear shock absorbers
- Rear springs
- Roof bow
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Citroen Berlingo I facelift
Step-by-step instructions on "Engine" for Citroen Berlingo I facelift (2002–2012). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Identification - data: under engine (DV6DTED M, DV6ETED M)
- Data: conrods
- Data: crankshaft (DW8B)
- Data: pistons - piston rings - the piston shaft
- Data: conrods — variant 2
- Data: pistons-gudgeon pins-rings (DW10TD)
- Data: crankshaft - crankshaft bearing shells (DW10TD)
- Data: conrods — variant 3
- Data: pistons - piston rings - the piston shaft — variant 2
- Data: half shells
- Data: pistons, piston rings, the piston shaft (DV6B, DV6ATED4)
- Data: conrods - connecting rod half shells (DV6B, DV6ATED4)
- Data: crankshaft - crankshaft bearing shells (DV6ATED4, DV6B)
- Data: conrods — variant 4
- Data: pistons - piston rings (TU1JP, TU3JP, TU3A)
- Data: crankshaft - crankshaft half shells (TU1JP, TU3JP, TU3A)
- Data: conrods — variant 5
- Data: half shells — variant 2
- Data: pistons - piston rings - the piston shaft — variant 3
- Data: crankshaft (TU5JP4)
- Check: liner protrusion (aluminium block) (TU3JP, TU3A, 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)
- Removing - refitting: engine ring seals (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: ancillary drive belt (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: engine ring seals (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: ancillary drive belt (DV6ETED M, DV6DTED M)
- Removing - refitting: ancillary drive belt (WMI 935, 936, 8BC, 8BD) (TU3A)
- Dismantling - re-assembly: conrods - pistons (TU3A, TU5JP4, TU3JP, TU1JP)
- Matching: crankshaft bearing shells (TU3A, TU3JP, TU1JP)
- Dismantling - re-assembly: dynamic seals - tu engine - 8 valves (TU1JP, TU3A, TU3JP)
- Dismantling - re-assembly: dynamic seals (tu 16 -valve engine) (TU5JP4)
- Dismantling - refitting: connecting rod/piston assemblies (DV6B, DV6ATED4)
- Modification: engine flywheel (engine DW8B) (DW8B)
Lubrication
- Summary: engine oil filter cartridges (year 2003)
- Engine oil capacities: 2003 model year
- Engine oil capacities: 2004 model year
- Engine oil capacities: CITROËN BERLINGO 2
- Check: engine oil pressure DV6DM (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Check: oil pressure (DV6DM, DV6EM engines all types) (DV6DTED M, DV6ETED M)
- Check: oil pressure (DW8B)
- Check: oil pressure (TU3A)
- Check: oil pressure (TU1JP, TU3JP, TU5JP4)
- Check: oil pressure (DW10TD)
- Check: oil pressure (DV6B, DV6ATED4)
- Removing - refitting: oil pressure sensor (DV6DTED M, DV6ETED M)
- Removing - refitting: oil pump (DV6ETED M, DV6DTED M)
- Removing - refitting: oil level/temperature sensor (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: oil pump (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: oil pressure sensor (WMI 935, 936, 8BC 8AD) (DV6DTED M)
- Dismantling - re-assembly: engine oil temperature and level sensor (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: oil pump (DV6B, DV6ATED4)
- Removing - refitting: oil filter (DV6 M type engine) (DV6ETED M, DV6DTED M)
- Removing - refitting: oil filter (DV6TED4 type engine) (DV6ATED4, DV6B)
- Modification: dipstick - dipstick guide tube (TU3JP)
- Modification: oil filter (TU3JP)
- Maintenance: recommended ingredients, year 2006
Exhaust
- Tightening torques: exhaust line (WMI 935; 936; 8BC; 8AD) (DV6DTED M)
- Data: exhaust system (DW8B)
- Data: exhaust system (TU1JP, TU3JP, TU5JP4)
- Data: exhaust system (DW10TD)
- Tightening torques: exhaust system (engine DV6ATED4) (DV6B, DV6ATED4, DV6ETED M, DV6DTED M)
- Removing - refitting: catalytic converter (DV6B, DV6ATED4)
- Removing - refitting: exhaust manifold (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: exhaust manifold (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: exhaust system (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: exhaust manifold (TU3JPH)
- Removing - refitting: exhaust manifold (TU3A)
- Forced regeneration: particle filter (technical note)
- Modification: exhaust silencer (DV6B, DW8B, DV6ATED4, DW10TD)
Engine block
- Data: cylinder block
- Data: cylinder block — variant 2
- Data: cylinder block — variant 3
- Data: cylinder block — variant 4
- Data: dynamic seals (TU3A, TU3JP, TU5JP4, TU1JP)
- Data: aluminium cylinder block (TU3A, TU3JP, TU1JP)
- Data: cast cylinder block (TU3A, TU1JP, TU3JP)
- Data: cylinder block — variant 5
Cylinder head
- Identification - data: engine top (DV6ETED M, DV6DTED M)
- Data: cylinder head
- Data: swirl chambers (DW8B)
- Data: valves and valve springs
- Data: valve seats and guides
- Data: cylinder head gasket (DW8B)
- Data: cylinder head bolts - cylinder head tightening (DW8B)
- 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: cylinder head bolts - cylinder head tightening (DV6B, DV6ATED4)
- Data: cylinder head — variant 4
- Data: valves and valve springs — variant 4
- Data: valve seats and guides — variant 4
- Data: valves and valve springs — variant 5
- Data: valve seats and guides — variant 5
- Data: cylinder head — variant 5
- Data: cylinder head — variant 6
- Data: valve seats and guides — variant 6
- Data: valves and valve springs — variant 6
- Data: Cylinder head seal (DV6B, DV6ATED4)
- Stripping-assembling: cylinder head (DW8B)
- Stripping-assembling: cylinder head (DW10TD)
- Stripping - re-assembling: cylinder head (TU5JP4)
- Stripping - re-assembling: cylinder head (DV6B, DV6ATED4)
- Stripping-assembling: cylinder head (TU3JP, TU1JP, TU3A)
- Stripping - re-assembling: engine (TU3JP, TU1JP, TU3A)
- Stripping-assembling: cylinder head (TU5JP4)
- Removing - refitting: cylinder head cover (DV6DTED M, DV6ETED M)
- Removal - refitting: cylinder head (on vehicle) (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: cylinder head (on the vehicle) DV6DM engine (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: cylinder head cover (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Removing - refitting: cylinder head (WMI 935, 936, 8AD, 8BC) (TU5JP4)
- Removing - refitting: cylinder head on the vehicle (DW8B)
- Removing - refitting: cylinder head (DW10TD)
- Removing - refitting: cylinder head on the vehicle (TU1JP, TU3JP, TU5JP4)
- Removing - refitting: cylinder head (on vehicle) (DV6B, DV6ATED4)
- Removing - refitting: cylinder head on the vehicle (TU3A)
- Modification: work on diesel injector (DV6TED4 type engine) (DV6ATED4, DV6B)
- Modification: engines TU petrol all types (TU3JP)
- Modification: cylinder head cover (TU3JP)
- Removing - refitting: air filter unit (DV6DTED M, DV6ETED M)
- Removing - refitting: turbo air cooler by-pass unit (DV6DTED M, DV6ETED M)
- Removing - refitting: air inlet pipe (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: air filter unit (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: turbo air cooler air bypass unit (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: air inlet pipe (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Dismantling - re-assembly: inlet air metering unit (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Presentation: tool 4533-T
Timing gear
- Data: camshaft
- Data: timing gear (DW8B)
- Data: camshaft — variant 2
- Data: camshaft — variant 3
- Data: camshafts (DV6B, DV6ATED4)
- Data: camshafts (TU1JP, TU3A, TU3JP)
- Data: valve rockers (TU3A, TU1JP, TU3JP)
- Data: camshaft — variant 4
- Data: timing gear (DV6ATED4, DV6B)
- Removing - refitting: Camshaft (DV6DTED M, DV6ETED M)
- Removing - refitting: camshaft housing (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: Camshaft (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: camshaft housing (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Removing - refitting: camshaft seal (DW8B)
- Removing - refitting: camshaft (DW8B)
- Removing - refitting: camshaft seal (DW10TD)
- Removing - refitting: camshaft (DW10TD)
- Removing - refitting: camshaft (TU1JP, TU3JP, TU5JP4)
- Removing - refitting: camshaft seal (DV6B)
- Removing - refitting: camshafts (DV6B, DV6ATED4)
- Removing - refitting: camshaft (TU3A)
- Removing - refitting: camshaft seal (TU3A)
- Check: setting the valve timing (DV6DTED M, DV6ETED M)
- Check: setting the valve timing (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Check: setting the valve timing (DW8B)
- Check: setting the valve timing (DW10TD)
- Check: setting the valve timing (TU1JP, TU3JP, TU5JP4)
- Check: setting the valve timing (DV6ATED4)
- Check: setting the valve timing (TU3A)
- Dismantling - re-assembly: timing belt (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Removing - refitting: timing belt (DV6DTED M, DV6ETED M)
- Removing - refitting: (WMI 935, 936, 8BC, 8AD) timing belt (TU3A)
- Removing - refitting: timing belt (DW8B)
- Removing - refitting: timing belt (from RPO No. 9128) (DW10TD)
- Removing - refitting: timing belt (TU1JP, TU3JP, TU5JP4)
- Removing - refitting: timing belt (from RPO No. 10064) (DW8B)
- Removing - refitting: timing belt (DV6B, DV6ATED4)
- Removing - refitting: timing belt (TU3A)
- Modification: removal of the crankshaft pulley bolt (DW10TD)
- Modification: new timing system (DW8B)
Air and fuel supply
- Check: Vacuum circuit (DV6ETED M, DV6DTED M)
- Check: Vacuum circuit (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Check: air supply circuit (DV6ATED4, DV6B)
- Removing - refitting: load lever potentiometer on DELPHI DIESEL SYSTEM injection pump (DW8B)
- Removing - refitting: inlet air metering unit (DV6B, DV6ATED4)
- Dismantling - re-assembly: Fuel filter (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Dismantling - re-assembly: Fuel tank. (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: fuel pump and gauge assembly (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Dismantling - re-assembly: additional fuel tank (flex fuel) (TU5JP4)
- Removing - refitting: fuel tank (TU5JP4, TU3JP, TU1JP)
- Removing - refitting: fuel pump and gauge assembly (TU3A, DW8B)
- Removing - refitting: fuel tank (DW10TD, DW8B)
- Removing - refitting: fuel pump and gauge assembly (DW10TD)
- Removing - refitting: fuel filter (DW10TD)
- Tightening procedure: LPG supply unions (TU3JP)
- Removing - refitting: LPG tank (TU3JP)
- Repair operations: units on LPG tank (TU3JP)
- Removing - refitting: integrated air intake system (DV6ATED4, DV6B)
- Removing - refitting: fuel filter (DV6B, DV6ATED4)
- Removing - refitting: solenoid valve piston kit GNV (TU3JP)
- Removing - refitting: CNG reservoir (TU3JP)
- Drain - refill: Fuel tank (engine DV6DM) (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Draining - rinsing: LPG tank (TU3JP)
- Modification: particle filter additive
- Data: charging cord and socket (SA18)
- Checking: traction battery charge status (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: battery charger (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: traction battery (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: charge converter (dcdc230v) (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: traction battery cooling fan (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: emergency stop switch (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: charging socket (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: (DCAC 12V) converter (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: adaptor housing (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: charging socket harness (SA18)
- Removing - refitting: charging flap locking device (SA18)
- 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)
- 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)
- 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)
Cooling system
- Repair operation: temperature sensor (SA18)
- Data: battery cooling system (SA18)
- Data: cooling system (TU1JP, TU3JP, TU5JP4)
- Data: cooling circuits (DW10TD)
- Data: cooling system (DW8B)
- Data: cooling system (engine DV6TED4) (DV6B)
- General specifications: cooling system (TU1 and TU3 engines) (TU3A)
- Data: cooling system (engine DV6BTED4) (DV6B)
- Removing - refitting: coolant outlet housing (TU5JP4)
- Removing - refitting: cooling fan (MOTEUR ELECTRIQUE VENTURI)
- Removing - refitting: Coolant pump (DV6DTED M, DV6ETED M)
- Dismantling - re-assembly: Coolant pump (dv6dm engine) (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: coolant outlet housing (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: coolant inlet manifold (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Removing - refitting: engine cooling radiator (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: cooling fan (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: coolant outlet housing (DV6ETED M, DV6DTED M)
- Removing - refitting: water pumps (SA18)
- Removing - refitting: battery cooling radiator (SA18)
- Removing - refitting: engine cooling air blower (SA18)
- Removing - refitting: coolant outlet housing (DV6B, DV6ATED4)
- Removing - refitting: coolant outlet housing temperature sensor (DV6B, DV6ATED4)
- Drain and refill - refilling - bleeding: cooling system
- Filling and bleeding: battery cooling system (SA18)
- Removing - refitting: Cooling cassette
- Data - identification: heating unit (SA18)
- 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)
- Removing - refitting: drivetrain cooling radiator (MOTEUR ELECTRIQUE VENTURI)
- Drain - refill - bleeding: cooling system (drive train) (MOTEUR ELECTRIQUE VENTURI)
- Diagnostic: cooling circuit check - during performance limitation by temperature (SA18)
- Presentation: passenger compartment heating (SA18)
Emission control
- Check: exhaust gas recirculation circuit (DW10TD)
- Dismantling - re-assembly: discharge (by-pass) circuit control electrovalve of the exhaust gas recirculation heat exchanger (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: exhaust gas recycling valve (EGR) (DW10TD)
- Check: exhaust gas recirculation circuit (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: electrically-controlled exhaust gas recycling valve (DV6DTED M, DV6ETED M)
- Removing - refitting: EGR module assembly (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: electrically-controlled exhaust gas recycling valve (WMI 936, 935, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: exhaust gas recycling valve (DW8B)
- Removing - refitting: exhaust gas recycling valve (EGR) (DV6B, DV6ATED4)
- Modification: oxygen sensor
- Diagnostic: oxygen sensor
- Help in diagnosis: electric EGR valve DV6 engine type (BOSCH) (Summary) (DV6ATED4, DV6B)
Turbocharging
- Checking: turbocharger pressure (DV6DM engine) (wmi 935; 936; 8BC; 8AD) (DV6DTED M)
- Check: turbocharge pressure (DW10TD)
- Removing - refitting: Turbocharger (MHI) (DV6ETED M, DV6DTED M)
- Removing - refitting: turbocharger pressure regulation electrovalve (DV6ETED M, DV6DTED M)
- Removing - refitting: Turbocharger (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Dismantling - re-assembly: turbocharger pressure regulation electrovalve (wmi 935, 936, 8bc, 8ad) (DV6DTED M)
- Removing - refitting: turbocharging air cooler (WMI 935, 936, 8BC, 8AD) (DV6DTED M)
- Removing - refitting: turbocharger (DW10TD)
- Removing - refitting: turbocharger (MHI) (DV6ATED4, DV6B)