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CITROEN 2001 BERLINGO User Manual

CITROEN 2001 BERLINGO
395 pages
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PRIVATE CARS
SAXO-XSARA-BERLINGO
PRIVATE CARS
CAR 050008
Book 1
2001
AC.QCAV/MTD
Méthodes Techniques Documentation

’’The intellectual property rights relating to the technical information contained in this document belong
exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without
prior written authorisation from the manufacturer is forbidden.‘‘
«The technical information contained in this document is intended for the exclusive use of the trained personnel of the
motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The
information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full
responsibility to the exclusion of that of the manufacturer».
’’The technical information appearing in this brochure is subject to updating as the characteristics of each
model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically
for further information and to obtain any possible updates».
2001

Table of Contents

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CITROEN 2001 BERLINGO Specifications

General IconGeneral
BrandCITROEN
Model2001 BERLINGO
CategoryAutomobile
LanguageEnglish

Summary

PRESENTATION

INDEX

GENERAL

Covers vehicle identification and capacities.

ENGINE

Details lubricants, specifications, and injection systems.

CLUTCH, GEARBOX, TRANSMISSION

Covers clutch, gearbox, and transmission systems.

AXLES, SUSPENSION, STEERING

Details axle, suspension, and steering components.

BRAKES

Covers brake system specifications and adjustments.

ELECTRICAL

Details electrical system components like starters and alternators.

AIR CONDITIONING

Covers air conditioning system specifications and checks.

ENGINE

IDENTIFICATION OF VEHICLES

Details vehicle identification marks and labels for SAXO.

CAPACITIES

Lists oil capacities in litres and defines draining methods.

LUBRICANTS

Recommends TOTAL engine oils based on SAE norm and factory evolutions.

GEARBOX OILS

Details recommended oils for manual and automatic gearboxes.

OILS FOR POWER-ASSISTED STEERING

Lists recommended oils for power-assisted steering systems.

ENGINE SPECIFICATIONS

Provides specifications for various petrol engines (1.0i to 1.4i).

SPECIAL FEATURES - TIGHTENING TORQUES

Lists tightening torques for cylinder head components for various engines.

CYLINDER HEAD

Details cylinder head gasket identification for TU/TUD engines.

CYLINDER HEAD GASKET IDENTIFICATION

Identifies cylinder head gasket thickness and number of holes for WJZ engine.

AUXILIARY EQUIPMENT DRIVE BELT

Provides tools and essential checks for drive belt replacement.

CHECKING AND SETTING THE VALVE TIMING

Details valve timing checks for various SAXO, XSARA, and PICASSO engines.

SPECIAL FEATURES OF THE TIMING

Details camshaft hub marking identification for XSARA LFY engines.

VALVE CLEARANCE SETTINGS

Specifies valve clearance values and adjustment procedures for various engines.

CHECKING THE OIL PRESSURE

Provides engine oil pressure checks for various engine types and conditions.

ENGINE OIL PRESSURE SWITCH

Details engine oil pressure switch location, tightening torque, and warning lamp pressure.

OIL FILTERS

Lists PURFLUX oil filter specifications for various SAXO, XSARA, BERLINGO, TUD, EW, XU engines.

FILLING AND BLEEDING THE COOLING CIRCUIT

Provides a procedure for filling and bleeding the cooling circuit.

INJECTION

IDLING - ANTI-POLLUTION

Specifies idling speeds and anti-pollution values for SAXO engines.

PETROL INJECTION

Details injection specifications for SAXO petrol engines.

EMISSION STANDARDS

Details EEC and US emission standards for various vehicles.

ANTI-POLLUTION TECHNICAL CHECKS (FRANCE)

Outlines anti-pollution checks, conditions, and features for French vehicles.

SAFETY REQUIREMENTS : PETROL/LPG DUAL FUEL SYSTEM

Details safety precautions for working on petrol/LPG dual fuel vehicles.

SPECIFICATIONS : PETROL/LPG DUAL FUEL SYSTEM

Lists specifications for fuel tanks, gauges, injectors, and filters.

PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM

Lists prohibited operations for HDI direct injection systems.

SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM

Details safety requirements for interventions on the injection system.

CLEANLINESS REQUIREMENTS

Outlines preliminary operations and work area cleanliness for injection system work.

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT

Details checks for the low pressure fuel supply circuit, including static and dynamic pressure.

CHECKS : AIR SUPPLY CIRCUIT

Details checks for the vacuum pump and pressure regulator valve.

CHECKS : TURBO PRESSURE

Outlines turbo pressure checking requirements and procedure.

CHECKS : EXHAUST GASES RECYCLING CIRCUIT

Details checks for the EGR valve and electrovalve.

SPECIFICATIONS OF THE DELPHI DIESEL INJECTION PUMP

Lists Delphi diesel injection pump types and references for SAXO and XSARA.

CHECKING AND SETTING THE DELPHI MECHANICAL INJECTION PUMP

Details checking and setting procedures for the Delphi mechanical injection pump.

ADJUSTING THE DELPHI MECHANICAL INJECTION PUMP CONTROLS

Details adjustments for fast idle, accelerator control, and idle speed.

IGNITION

SPARKING PLUGS

Lists BOSCH, CHAMPION, EYQUEM spark plugs for SAXO, XSARA, BERLINGO.

CLUTCH, GEARBOX, DRIVESHAFTS

SPEEDOMETER

Explains EEC decree on speed display accuracy and influencing factors.

CLUTCH SPECIFICATIONS

Lists clutch specifications for SAXO models with different engines.

CLUTCH : CHECKS AND ADJUSTMENTS

Details checks and adjustments for the SAXO clutch control.

MA/5 GEARBOX

Details tightening torques and controls for the MA/5 gearbox.

BE3/5 GEARBOX

Details tightening torques and controls for the BE3/5 gearbox.

BE4/5 GEARBOX CONTROLS

Details the gear control levers and mechanisms for the BE4/5 gearbox.

BE4/5 GEARBOX SPECIFICATIONS

Provides detailed specifications and tightening torques for the BE4/5 gearbox.

BE4/5 GEARBOX - CHECKS AND ADJUSTMENTS

Details principles and procedures for adjusting BE4/5 gearbox controls.

AXLES, SUSPENSION, STEERING

AXLE GEOMETRY

Details geometry measurements for SAXO front and rear axles.

SPECIAL FEATURES : SUSPENSION - STEERING

Covers evolutions in front suspension springs, driveshafts, hubs, and steering.

FRONT AXLE

Details special features and evolutions for the front axle.

MANUAL STEERING SPECIFICATIONS

Lists tightening torques for manual steering components.

POWER-ASSISTED STEERING SPECIFICATIONS

Details tightening torques for power-assisted steering components.

REAR AXLE

Details torsion and anti-roll bars for XSARA rear axle.

REAR DAMPER

Details adjusting lengths of rear dummy dampers for XSARA PICASSO.

STEERING SPECIFICATIONS

Details steering specifications for XSARA PICASSO, including rack travel and ratio.

MANUAL STEERING SPECIFICATIONS

Lists tightening torques for manual steering components.

STEERING COLUMN SPECIFICATIONS

Lists tightening torques and specifications for the steering column.

BRAKES

BRAKE SPECIFICATIONS

Details brake specifications for SAXO models.

HANDBRAKE (Adjustment)

Provides steps for checking and adjusting the handbrake.

PURGE DES BRAKES

Details the imperative order for bleeding the brake system.

CHECKS AND ADJUSTMENTS : BRAKE COMPENSATOR

Explains how to calculate rear vehicle weight for brake compensator adjustment.

CHECKING AND ADJUSTING THE LOAD-SENSITIVE BRAKE COMPENSATOR

Explains how to determine vehicle weight and use graphs for brake compensator adjustment.

BLEEDING THE BRAKES

Details the bleeding procedure and imperative order for XSARA PICASSO brakes.

BRAKING SYSTEM SPECIFICATIONS

Describes braking system specifications for XSARA PICASSO.

ELECTRICAL SYSTEM

STARTER MOTORS

Lists starter motor specifications, manufacturers, and climate ratings for SAXO.

ALTERNATORS

Lists alternator specifications for SAXO without power-steering.

ALTERNATORS

Lists alternator specifications for XSARA PICASSO.

ALTERNATORS

Lists alternator specifications for BERLINGO without power-steering.

CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR

Details checks for alternator output and voltage regulator.

AIR CONDITIONING

AIR CONDITIONING R 134 a (HFC)

Details refrigerant refill, variable capacity, oil quantity, and reference for SAXO.

CHECKING TEMPERATURES

Provides preliminary conditions and checks for air conditioning efficiency.

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)

Details connector/union tightening torques and tools for AC system.

CHECKING PRESSURES

Details high and low pressure checks for the air conditioning system.

Checking the air conditioning system

Provides a key for understanding the AC system performance graph.

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