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CITROEN Berlingo 2003 User Manual

CITROEN Berlingo 2003
482 pages
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PRIVATE CARS
SAXO-C3-XSARA
XSARA PICASSO-BERLINGO
PRIVATE CARS
CAR 050014
Volume 1
2003
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».
2003

Table of Contents

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CITROEN Berlingo 2003 Specifications

General IconGeneral
BrandCITROEN
ModelBerlingo 2003
CategoryAutomobile
LanguageEnglish

Summary

Citroen Service Manual Presentation

Handbook Structure and Vehicle Groups

Outlines the handbook's organization into nine main function groups and lists vehicle models covered.

General Vehicle Identification

Identification of SAXO Vehicles

Details the identification marks for SAXO vehicles, including engine type and chassis stamp.

Vehicle Capacities

General Capacities

Provides general information on fluid capacities in litres for various vehicle types.

SAXO Capacities

Lists fluid capacities in litres for SAXO models, including engine oil and cooling system.

Engine Information

Engine Specifications

Details engine specifications for various models, including power and torque data.

Tightening Torques

Provides essential tightening torque values (m.daN) for engine components.

Belt Tension Correspondence Table

Offers a table for belt tension measurement units (SEEM).

Auxiliary Equipment Drive Belt

Instructions for the removal and refitting of the auxiliary drive belt.

Valve Timing Checks and Settings

Procedures for checking and setting engine valve timing.

Valve Clearance Settings

Specifies valve clearance values and adjustment procedures.

Oil Pressure Checks

Details the procedure for checking engine oil pressure.

Oil Filters

Lists part numbers and specifications for oil filters.

Cooling Circuit Filling and Bleeding

Instructions for filling and bleeding the engine's cooling system.

Fuel Injection System

Idling and Depollution Checks

Technical checks for engine idling and depollution standards.

HDI Direct Injection System Safety

Crucial safety requirements for HDI direct injection systems.

Delphi HDI Injection Prohibited Operations

Lists prohibited operations for Delphi HDI injection systems.

Low Pressure Fuel Supply Checks

Procedures for checking the low-pressure fuel supply circuit.

Air Supply Circuit Specifications

Details the components of the air supply circuit.

Exhaust Gas Recycling Checks

Procedures for checking the exhaust gas recycling (EGR) system.

Turbo Pressure Checks

Diagnostic procedures for checking turbocharger pressure.

Delphi Mechanical Injection Pump Settings

Procedures for checking and setting the Delphi mechanical injection pump.

Engine Mechanical Timing

Valve Timing Checks and Settings

Detailed procedures for checking and setting the engine valve timing.

Clutch System

Clutch Specifications

Provides technical specifications for clutch components.

Clutch Checks and Adjustments

Outlines procedures for clutch system checks and adjustments.

Gearbox and Tyre Specifications

Gearbox and Tyre Specifications

Details gearbox types, tyre sizes, and related specifications.

MA/5 Gearbox Specifications

Specific technical data for the MA/5 gearbox.

BE4/5 Gearbox Specifications

Specific technical data for the BE4/5 gearbox.

BE4/5 Gearbox Checks and Adjustments

Procedures for checking and adjusting the BE4/5 gearbox.

Automatic Gearbox

MB3 Automatic Gearbox Features

Highlights specific features of the MB3 automatic gearbox.

AL4 Automatic Gearbox Precautions

Important precautions and recommendations for AL4 automatic gearbox.

AL4 Automatic Gearbox ECU Downloading

Procedure for downloading and updating the AL4 automatic gearbox ECU.

Driveshafts and Gearbox

Gearbox Specifications

Technical specifications related to the gearbox assembly.

Axle Geometry

SAXO Axle Geometry

Geometric specifications for SAXO vehicle axles.

Front Axle Specifications

Details on front axle components and their specifications.

Front Axle Tightening Torques

Essential tightening torque values for front axle components.

Front Axle Suspension

Information on the components of the front axle suspension system.

Front Axle Geometry and Ball-Joints

Geometric data and ball-joint specifications for the front axle.

Rear Axle Components and Torques

Details on rear axle components and associated tightening torques.

Rear Axle Hub Nut Evolution

Information on the evolution of rear axle hub nut fittings.

Rear Axle Silentblock Alignment

Alignment specifications for rear axle silentblocks.

Rear Damper Adjustment

Procedure for adjusting the rear axle dampers.

Steering System

Electric Power Steering Features

Details and features of the electric power steering system.

Steering System Features

General features and specifications of the steering system.

Steering Column Specifications

Technical specifications for the steering column assembly.

Manual Steering Specifications

Technical data and specifications for manual steering systems.

Power-Assisted Steering Specifications

Technical specifications for power-assisted steering systems.

Brakes

Saxo Brake Specifications

Brake specifications for SAXO models without ABS.

Handbrake Adjustment

Procedure for adjusting the handbrake system.

Saxo Brake Specifications Continued

Continued brake specifications for SAXO models.

Handbrake Adjustment

Procedure for adjusting the handbrake system.

Brake Specifications Without ABS

Technical data for brake systems without ABS.

Brake Specifications With ABS

Technical data for brake systems with ABS.

Braking System Specifications (ABS with ESP)

Specifications for braking systems with ABS and ESP.

Braking System Specifications (ABS REF)

Specifications for ABS REF braking systems.

Braking Circuit with ESP (BOSCH 5.7)

Details of the braking circuit with ESP (Bosch 5.7).

Brake System Bleeding and Filling

Procedures for bleeding and filling the brake system.

Saxo Brake Specifications

Brake specifications for SAXO models.

Brake Specifications

General brake specifications.

Brake Compensator Checks and Adjustments

Procedures for checking and adjusting the brake compensator.

Brake Compensator Checks and Adjustments Continued

Further procedures for checking and adjusting the brake compensator.

Compensator Adjustment

Specific steps for adjusting the brake compensator.

Handbrake Adjustment

Procedure for adjusting the handbrake.

Brake Bleeding Procedure

Instructions for bleeding the brake system.

Load-Sensitive Brake Compensator Checks and Adjustments

Checks and adjustments for the load-sensitive brake compensator.

Load-Sensitive Brake Compensator Graph N° 1 & 2

Graphs for load-sensitive brake compensator settings.

Load-Sensitive Brake Compensator Graph N° 3 & 4

Graphs for load-sensitive brake compensator settings.

Load-Sensitive Brake Compensator Graph N° 5 & 6

Graphs for load-sensitive brake compensator settings.

Load-Sensitive Brake Compensator Checks

Checks to be performed on the load-sensitive brake compensator.

Electrical System Components

Starter Motors

Information and specifications for starter motors.

Starter Motor Specifications

Detailed specifications for starter motors across different models.

Alternator Specifications (SAXO)

Alternator specifications specific to SAXO models.

Alternator Specifications (C3)

Alternator specifications specific to C3 models.

Charging Circuit - Alternator with Mono-Function Regulator

Details on the charging circuit with a mono-function regulator.

Air Conditioning System

Air Conditioning System Features (SAXO)

Features of the air conditioning system for SAXO.

Air Conditioning System Features (SAXO, C3, XSARA, PICASSO, BERLINGO)

General features of the air conditioning system across multiple models.

Pollen Filter Replacement

Procedure for removing and refitting the pollen filter.

Filtering/Drying Cartridge Replacement

Instructions for replacing the filter/dryer cartridge.

Air Conditioning System Features

Features of the air conditioning system.

Pollen Filter Replacement

Procedure for removing and refitting the pollen filter.

Filtering/Drying Cartridge Replacement

Instructions for replacing the filter/dryer cartridge.

Condenser and Filter/Dryer Cartridge

Details on the condenser and filter/dryer cartridge.

Compressor Oil Level Check

Procedure for checking the compressor oil level.

Air Conditioning Efficiency Checks

Procedures for checking the air conditioning system efficiency.

AC System Components and Tightening Torques

Information on AC system components and tightening torques.

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