Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Confort
- Connector pinouts
- Current generation
- Dashboard
- Driver information
- Driving assistance
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front springs
- Gearbox assembly
- General points
- General points about the vehicle
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Noises and vibrations
- Other
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear door windows
- Rear doors
- Rear seats
- Rear section
- Rear shock absorbers
- Rear springs
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Towbar
- Transmission
- Washing and wiping
Repair manual
Engine Citroen Berlingo II
Step-by-step instructions on "Engine" for Citroen Berlingo II (2008–2012). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Engine block
Crankshaft
- Identification - data: under engine - EP engine (indirect injection) (EP6C, EP6C B)
- Identification - data: under engine (DV6DTED M, DV6DU, DV6ETED M, DV6C, DV6DTED, DV6EU)
- Data: pistons, piston rings, the piston shaft (DV6B, DV6TED4, 1.6 HDi 90 FAP, DV6BUTED4, DV6ATED4, DV6AUTED4)
- Data: conrods - connecting rod half shells (DV6B, DV6AUTED4, DV6TED4, 1.6 HDi 90 FAP, DV6BUTED4, DV6ATED4)
- Data: crankshaft - crankshaft bearing shells (1.6 HDi 90 FAP, DV6B, DV6ATED4, DV6AUTED4, DV6BUTED4, DV6TED4)
- Data: conrods (TU5JP4B, TU5JP4)
- Data: pistons - piston rings (TU5JP4, TU5JP4B)
- Data: crankshaft - crankshaft half shells (TU5JP4B, TU5JP4)
- Removing - refitting: ancillary drive belt (DV6DTED M, DV6ETED M, 1.6 HDi 90 FAP, DV6C, DV6DTED, DV6EU, DV6DU)
- Removing - refitting: ancillary drive belt (manual steering) (DV6BUTED4, DV6B, DV6ATED4, DV6AUTED4)
- Removing - refitting: ancillary drive belt (TU5JP4B, TU5JP4)
- Removing - refitting: engine ring seals (TU5JP4B, TU5JP4)
- Removing - refitting: engine ring seals (DV6AUTED4, DV6BUTED4, 1.6 HDi 90 FAP)
- Removing-refitting: ancillary drive belt (with and without air conditioning compressor) (EP6C B, EP6C)
- Removing - refitting: engine ring seals (DV6DTED, DV6C, DV6EU, DV6DU)
- Removing - refitting: engine ring seals (EP6C, EP6C B)
- Removing - refitting: engine ring seals (DV6ETED M, DV6DTED M)
- Dismantling - re-assembly: ancillary drive belt (STOP AND START version) (DV6DTED)
- Dismantling - re-assembly: conrods - pistons (TU5JP4B, TU5JP4)
- Dismantling - refitting: connecting rod/piston assemblies (1.6 HDi 90 FAP, DV6TED4, DV6BUTED4, DV6AUTED4, DV6B, DV6ATED4)
- Removing - refitting: actuator / variable timing electrovalve (EP6C, EP6C B)
- Aid to mechanical diagnosis: double damped engine flywheel
Timing gear
- Data: camshafts (DV6TED4, 1.6 HDi 90 FAP, DV6ATED4, DV6B, DV6AUTED4, DV6BUTED4)
- Data: camshafts (TU5JP4, TU5JP4B)
- Data: timing gear (DV6TED4, 1.6 HDi 90 FAP, DV6BUTED4, DV6AUTED4, DV6ATED4, DV6B)
- Removing - refitting: camshaft (1.6 HDi 90 FAP, DV6AUTED4, DV6BUTED4)
- Removing - refitting: camshaft housing (DV6B, DV6BUTED4, DV6ATED4, DV6AUTED4, 1.6 HDi 90 FAP, DV6TED4)
- Removing - refitting: camshaft (TU5JP4B, TU5JP4)
- Removing - refitting: camshaft (DV6C, DV6EU, DV6DTED, DV6DU)
- Removing - refitting: camshaft housing (DV6EU, DV6DU, DV6DTED, DV6C)
- Removing - refitting: camshaft (EP6C, EP6C B)
- Removing - refitting: camshafts (EP6C)
- Removing - refitting: Camshaft (DV6ETED M, DV6DTED M)
- Removing - refitting: camshaft housing (DV6ETED M, DV6DTED M)
- Check: setting the valve timing (TU5JP4, TU5JP4B)
- Check: setting the valve timing (1.6 HDi 90 FAP, DV6AUTED4, DV6BUTED4)
- Checking: setting the valve timing - EP engine (indirect injection) (EP6C, EP6C B)
- Check: setting the valve timing (DV6DTED)
- Check: setting the valve timing (DV6ETED M, DV6DTED M)
- Timing: timing gear (without dismantling the engine EP) (indirect injection) (EP6C B, EP6C)
- Removing - refitting: timing belt (TU5JP4B, TU5JP4)
- Removing - refitting: timing belt (DV6BUTED4, DV6ATED4, DV6B, DV6TED4, 1.6 HDi 90 FAP, DV6AUTED4)
- Removing - refitting: timing chain - EP engine (indirect injection) (EP6C B, EP6C)
- Removing - refitting: timing belt (DV6EU, DV6DU, DV6C, DV6DTED)
- Help in diagnosis: noises and vibrations - timing gear (DV6DU, EP6C B, DV6BUTED4, 1.6 HDi 90 FAP, DV6ATED4, DV6C, DV6EU, DV6TED4, EP6C, DV6ETED M, DV6DTED, DV6ETED4, DV6B, DV6AUTED4, DV6DTED M)
- Removing - refitting: timing belt (DV6ETED M, DV6DTED M)
Lubrication
- Check: oil pressure (DV6AUTED4, DV6BUTED4, 1.6 HDi 90 FAP)
- Check: oil pressure (TU5JP4, TU5JP4B)
- Check: oil pressure (DV6DTED M, DV6DTED)
- Check: oil pressure (EP6C, EP6C B)
- Check: oil pressure (DV6DM, DV6EM engines all types) (DV6DTED M, DV6ETED M)
- Removing - refitting: engine oil temperature and level sensor (DV6BUTED4, 1.6 HDi 90 FAP, DV6AUTED4)
- Removing - refitting: oil level sensor (TU5JP4, TU5JP4B)
- Removing - refitting: oil pressure sensor (TU5JP4B, TU5JP4)
- Removing - refitting: oil pressure sensor (1.6 HDi 90 FAP, DV6AUTED4, DV6BUTED4)
- Removing - refitting: oil pressure sensor (DV6DTED)
- Removing - refitting: engine oil temperature and level sensor (EP6C, EP6C B)
- Removing - refitting: oil pressure sensor (EP6C, EP6C B)
- Removing - refitting: engine oil temperature and level sensor (DV6EU, DV6DU, DV6DTED, DV6C)
- Removing - refitting: oil pump (DV6DTED)
- 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)
- Removing - refitting: oil filter (DV6C, DV6DTED, DV6DU, DV6EU)
- Removing - refitting: oil pump electrovalve (EP6C, EP6C B)
- Removing - refitting: oil pump (DV6ATED4, 1.6 HDi 90 FAP, DV6TED4, DV6BUTED4, DV6AUTED4, DV6B)
- Removing - refitting: oil filter (DV6 M type engine) (DV6ETED M, DV6DTED M)
- Removing - refitting: oil filter (DV6TED4 type engine) (1.6 HDi 90 FAP, DV6TED4, DV6BUTED4, DV6ATED4, DV6B, DV6AUTED4)
- Help in diagnosis: oil pressure (DV6DTED, DV6TED4, 1.6 HDi 90 FAP, EP6C, DV6DTED M, DV6AUTED4, DV6B, DV6ATED4, DV6BUTED4)
- Help in diagnosis: fluid level (DV6B, DV6DTED M, DV6DTED, DV6ATED4, 1.6 HDi 90 FAP, EP6C, DV6AUTED4, DV6BUTED4, DV6TED4)
Cooling system
- Identification - data: cooling system (DV6 engine type) (DV6ATED4, DV6AUTED4, DV6TED4, 1.6 HDi 90 FAP, DV6B, DV6BUTED4)
- Identification - data: cooling system (TU5JP4 - TU5JP4B engine type) (TU5JP4B, TU5JP4)
- Tightening torques: cooling system (ELECTRIQUE)
- Removing - refitting: coolant outlet housing (TU5JP4, TU5JP4B)
- Removing - refitting: engine cooling radiator (TU5JP4, TU5JP4B)
- Removing - refitting: coolant pump (TU5JP4, TU5JP4B)
- Removing - refitting: engine cooling radiator (DV6TED4, 1.6 HDi 90 FAP, DV6AUTED4, DV6ATED4, DV6B, DV6BUTED4)
- Removing - refitting: coolant pump (DV6BUTED4, 1.6 HDi 90 FAP, DV6AUTED4)
- Removing - refitting: coolant temperature sensor (TU5JP4, TU5JP4B)
- Removing - refitting: coolant temperature sensor (1.6 HDi 90 FAP, DV6AUTED4, DV6BUTED4)
- Removing - refitting: coolant outlet housing (DV6TED4, DV6BUTED4, DV6AUTED4, DV6ATED4, DV6B)
- Removing - refitting: coolant pump (DV6DTED)
- Removing - refitting: coolant temperature sensor (DV6DU, DV6EU, DV6C)
- Removing - refitting: engine cooling radiator (DV6DTED M, DV6C, DV6ETED M, DV6DTED)
- Removing - refitting: coolant outlet housing (DV6DTED, DV6EU, DV6DU, DV6C)
- Removing - refitting: piloted thermostat (EP6C)
- Removing - refitting: coolant temperature sensor (EP6C B, EP6C)
- Removing - refitting: coolant outlet housing (EP6C, EP6C B)
- Removing - refitting: engine cooling radiator (EP6C B, EP6C)
- Removing - refitting: coolant pump (EP6C B, EP6C)
- Removing - refitting: coolant inlet manifold (DV6DU, DV6EU, DV6C)
- Removing - refitting: coolant inlet manifold (DV6ETED4, DV6C)
- Removing - refitting: cooling fan
- Removing - refitting: Coolant pump (DV6ETED M, DV6DTED M)
- Removing - refitting: coolant inlet manifold (DV6DTED M, DV6ETED M)
- Removing - refitting: coolant outlet housing (DV6DTED M, DV6ETED M)
- Dismantling - re-assembly: electric coolant pump (ELECTRIQUE)
- Drain and refill - refilling - bleeding: cooling system
- Operating methods: exhaust thermal recuperator (Summary)
- Dismantling - re-assembly: cooling radiator (ELECTRIQUE)
- Draining - filling - bleeding: cooling system (ELECTRIQUE)
- Operating methods: engine cooling (Summary)
Cylinder head
- Identification - data: engine top (variable valve lift) (EP6C B, EP6C)
- Identification - data: engine top (DV6ETED M, DV6C, DV6EU, DV6DTED, DV6DU, DV6DTED M)
- Data: cylinder head bolts - cylinder head tightening (DV6BUTED4, DV6AUTED4, 1.6 HDi 90 FAP, DV6B, DV6ATED4, DV6TED4)
- Data: cylinder head (DV6ATED4, DV6B, DV6BUTED4, DV6TED4, 1.6 HDi 90 FAP, DV6AUTED4)
- Data: valves and valve springs (DV6AUTED4, DV6TED4, DV6B, 1.6 HDi 90 FAP, DV6ATED4, DV6BUTED4)
- Data: valve seats and guides (DV6BUTED4, DV6ATED4, DV6B, DV6TED4, 1.6 HDi 90 FAP, DV6AUTED4)
- Data: valves and valve springs (TU5JP4B, TU5JP4)
- Data: valve seats and guides (TU5JP4, TU5JP4B)
- Data: Cylinder head seal (DV6AUTED4, 1.6 HDi 90 FAP, DV6TED4, DV6B, DV6ATED4, DV6BUTED4)
- Stripping - re-assembling: cylinder head (DV6BUTED4, DV6B, DV6AUTED4, 1.6 HDi 90 FAP, DV6ATED4, DV6TED4)
- Removing - refitting: cylinder head (on the vehicle) (TU5JP4, TU5JP4B)
- Removing - refitting: cylinder head (on the vehicle) (DV6BUTED4, DV6B, DV6AUTED4, 1.6 HDi 90 FAP, DV6TED4, DV6ATED4)
- Removal - refitting: cylinder head on the vehicle (DV6C, DV6EU, DV6DTED, DV6DU)
- Removing - refitting: Cylinder head (on the vehicle) (EP6C, EP6C B)
- Removing - refitting: cylinder head cover (DV6DU, DV6C, DV6EU, DV6DTED)
- Removing - refitting: cylinder head cover (DV6DTED M, DV6ETED M)
- Removal - refitting: cylinder head (on vehicle) (DV6DTED M, DV6ETED M)
- Modification: work on diesel injector (DV6TED4 type engine) (DV6ATED4, DV6AUTED4, DV6B, DV6BUTED4, DV6TED4, 1.6 HDi 90 FAP)
- Removing - refitting: inlet air metering unit (DV6DTED, DV6EU, DV6DU, DV6C)
- Removing - refitting: air inlet pipe (DV6DTED)
- Removing - refitting: turbo air cooler by-pass unit (DV6DU, DV6DTED, DV6EU, DV6C)
- Removing - refitting: air filter unit (DV6ETED M, DV6DTED M)
- Removing - refitting: turbo air cooler by-pass unit (DV6ETED M, DV6DTED M)
- Removing - refitting: air inlet pipe (DV6DTED M, DV6ETED M)
Air and fuel supply
- Check: air supply circuit (DV6BUTED4, DV6AUTED4, 1.6 HDi 90 FAP)
- Check: Vacuum circuit (DV6DU, DV6ETED M, DV6DTED, DV6ETED4, DV6EU, DV6C, DV6DTED M)
- Removing - refitting: double inlet air doser unit (1.6 HDi 90 FAP)
- Removing - refitting: inlet air metering unit (DV6ATED4, DV6B, DV6AUTED4, DV6BUTED4)
- Removing - refitting: inlet air pressure sensor (DV6AUTED4, DV6TED4, DV6ATED4, 1.6 HDi 90 FAP, DV6BUTED4, DV6B)
- Removing - refitting: motorised throttle housing (TU5JP4, TU5JP4B)
- Removing - refitting: inlet air pressure sensor (TU5JP4, TU5JP4B)
- Removing - refitting: integrated air intake system (DV6BUTED4, DV6AUTED4, 1.6 HDi 90 FAP)
- Removing - refitting: fuel tank (DV6C, 1.6 HDi 90 FAP, DV6AUTED4, DV6BUTED4, DV6TED4, TU5JP4B, EP6C, DV6ATED4, DV6B, DV6DTED, TU5JP4, EP6C B, DV6ETED M, DV6DTED M)
- Removing - refitting: fuel pump-gauge assembly (TU5JP4, TU5JP4B, DV6TED4, DV6BUTED4, DV6AUTED4, 1.6 HDi 90 FAP, DV6ATED4, DV6B)
- Removing - refitting: air cleaner (EP6C)
- Removing - refitting: fuel filter (DV6DTED M, DV6DTED)
- Removing - refitting: inlet air pressure sensor (EP6C B, EP6C)
- Removing - refitting: Motorised throttle unit (EP6C, EP6C B)
- Removing - refitting: fuel pump-gauge assembly (EP6C, EP6C B)
- Removing - refitting: air filter unit (DV6EU, DV6DTED, DV6C, DV6DU)
- Removing - refitting: fuel pump-gauge assembly (DV6C, DV6ETED M, DV6DTED M, DV6DTED)
- Removing - refitting: fuel filter (1.6 HDi 90 FAP, DV6BUTED4, DV6AUTED4)
- Check: fuel additive circuit
- Removing - refitting: fuel filter (DV6ETED M, DV6DTED M)
- Check: additive level (DV6DU, DV6DTED M, DV6EU, DV6ETED4, DV6ETED M, DV6C, DV6DTED)
- Removing - refitting: fuel additive unit (1.6 HDi 90 FAP, DV6TED4)
- Removing - refitting: fuel additive pump (DV6TED4, 1.6 HDi 90 FAP)
- Removing - refitting: additive tank (DV6DTED, DV6C)
- Replacement: flexible additive reservoir (DV6TED4, 1.6 HDi 90 FAP)
- Refilling: additive tank (DV6DTED, DV6C)
- Refilling: additive tank (DV6DTED, DV6EU, DV6DU, DV6ETED M, DV6C, DV6DTED M, DV6ETED4)
- Modification: particle filter additive
- Checking: traction battery support (following collision) (electrical vehicle)
- Removing - refitting: fuel filler flap
- Removing - refitting: sliding side door retaining system
- Removing - refitting: normal charge flap and fast charge flap (ELECTRIQUE)
- Checking: insulation of high power components (ELECTRIQUE)
- Removing - refitting: central voltage retention device (DV6DTED)
- Dismantling - re-assembly: traction battery ECU (ELECTRIQUE)
- Dismantling - re-assembly: traction battery fuses (ELECTRIQUE)
- Dismantling - re-assembly: traction battery (ELECTRIQUE)
- Dismantling - re-assembly: onboard charger (ELECTRIQUE)
- Dismantling - re-assembly: cooling system temperature sensor (ELECTRIQUE)
- Dismantling - re-assembly: cooling hose (ELECTRIQUE)
- Operation prior to removal: traction battery flooded (ELECTRIQUE)
- Table: fault codes - Fuel additive ECU
- Table: fault codes - traction battery ECU (ELECTRIQUE)
- Table: fault codes - Onboard charger of the traction battery (ELECTRIQUE)
- Table: fault codes - drive train interface ECU - passenger compartment heater element (ELECTRIQUE)
- Table: fault codes - Drive train interface ECU - electric air conditioning compressor (ELECTRIQUE)
- Table: fault codes - Drive train interface ECU (ELECTRIQUE)
- Additional information: reservoir cap - tank unit module - reservoir
- Help in diagnosis: fuel gauging system
- Help in diagnosis: noises and vibrations - Pedal control
Exhaust
- Identification - data: exhaust system (TU5JP4, TU5JP4B)
- Tightening torques: exhaust system (TU5JP4B, TU5JP4)
- Tightening torques: exhaust system (DV6BUTED4, 1.6 HDi 90 FAP, DV6AUTED4)
- Identification - data: exhaust system (1.6 HDi 90 FAP, DV6AUTED4, DV6BUTED4)
- Tightening torques: exhaust system (EP6C, EP6C B)
- Tightening torques: exhaust system (DV6ETED4, DV6EU)
- Tightening torques: exhaust system (DV6DTED, DV6ETED M, DV6DTED M, DV6C)
- Tightening torques: exhaust system (DV6ETED M)
- Removing - refitting: exhaust system (TU5JP4, TU5JP4B)
- Removing - refitting: exhaust system (DV6BUTED4, DV6TED4, DV6B, 1.6 HDi 90 FAP, DV6ATED4, DV6AUTED4)
- Removing - refitting: exhaust manifold (TU5JP4B, TU5JP4)
- Removing - refitting: catalytic converter (DV6ATED4, DV6BUTED4, DV6AUTED4, DV6B)
- Removing - refitting: catalytic converter - particle filter (DV6TED4)
- Removing - refitting: exhaust manifold (DV6C, DV6EU, DV6DU, DV6DTED)
- Removing - refitting: catalytic converter/particle filter assembly (DV6DTED, DV6C)
- Removing - refitting: exhaust manifold/catalytic converter assembly (EP6C B, EP6C)
- Removing - refitting: exhaust system (EP6C, EP6C B)
- Removing - refitting: exhaust system (DV6DTED M, DV6DTED, DV6ETED M)
- Removing - refitting: exhaust manifold (DV6ETED M, DV6DTED M)
- Removing - refitting: exhaust gas pressure sensor pressure take-off (1.6 HDi 90 FAP)
- Removing - refitting: particle filter (DV6TED4, 1.6 HDi 90 FAP)
- Removing - refitting: particle filter (DV6DTED, DV6C)
- Removal - refitting: exhaust gas pressure sensor pressure take-off (DV6DTED, DV6C)
- Forced regeneration: particle filter
- Forced regeneration: particle filter (technical note)
Emission control
- Removing - refitting: oxygen sensor (TU5JP4B, TU5JP4)
- Removing - refitting: oxygen sensor (EP6C, EP6C B)
- Removing - refitting: oxygen sensor (DV6ETED M, DV6DTED, DV6DTED M)
- Removing - refitting: discharge (by-pass) circuit control electrovalve of the exhaust gas recirculation heat exchanger (DV6DU, DV6EU, DV6DTED, DV6C)
- Removing - refitting: oxygen sensor (EP6C)
- Check: exhaust gas recirculation circuit (DV6BUTED4, DV6AUTED4, 1.6 HDi 90 FAP)
- Removing - refitting: oxygen sensor (DV6EU, DV6ETED4)
- Removing - refitting: exhaust gas pressure sensor (1.6 HDi 90 FAP)
- Removing - refitting: canister discharge electrovalve (TU5JP4, TU5JP4B)
- Removing - refitting: exhaust gas temperature sensor (1.6 HDi 90 FAP)
- Removing - refitting: electric EGR valve / exhaust gas recirculation exchanger (DV6AUTED4, 1.6 HDi 90 FAP, DV6BUTED4)
- Removing - refitting: purge canister solenoid valve (EP6C, EP6C B)
- Removing - refitting: exhaust gas temperature sensor (DV6DTED, DV6C)
- Removing - refitting: electrically-controlled exhaust gas recycling valve (DV6DU, DV6EU, DV6DTED, DV6C)
- Removing - refitting: EGR module assembly (DV6EU, DV6DU, DV6C, DV6DTED)
- Removing - refitting: electrically-controlled exhaust gas recycling valve (DV6ETED M, DV6DTED M)
- Removing - refitting: EGR module assembly (DV6ETED M, DV6DTED M)
- Modification: oxygen sensor
Turbocharging
- Check: turbocharge pressure (DV6AUTED4, DV6BUTED4, 1.6 HDi 90 FAP)
- Check: turbocharger pressure (DV6DTED)
- Removing - refitting: turbocharger air cooler (DV6C, DV6ETED M, DV6DTED, 1.6 HDi 90 FAP, DV6AUTED4, DV6DTED M, DV6BUTED4)
- Checking: turbocharge pressure (DV6ETED M, DV6DTED M)
- Removing - refitting: turbocharger pressure regulation electrovalve (DV6ATED4, DV6B, DV6AUTED4, 1.6 HDi 90 FAP, DV6BUTED4, DV6TED4)
- Removing - refitting: turbocharger (1.6 HDi 90 FAP, DV6BUTED4, DV6AUTED4)
- Removing - refitting: turbocharger pressure regulation electrovalve (DV6EU, DV6DTED, DV6DU, DV6C)
- Removing - refitting: turbocharger (DV6EU, DV6DU, DV6DTED)
- Removing - refitting: turbocharger pressure regulation electrovalve (DV6DTED M, DV6ETED M)
- Removing - refitting: turbocharger (DV6C)
- Help in diagnosis: noises and vibrations - turbocharging (DV6ETED4, DV6B, DV6BUTED4, DV6ETED M, DV6DTED M, DV6TED4, DV6ATED4, DV6DU, 1.6 HDi 90 FAP, DV6EU, DV6C, DV6AUTED4, DV6DTED)
- Removing - refitting: Turbocharger (MHI) (DV6ETED M, DV6DTED M)