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CITROEN BERLINGO 2004 User Manual

CITROEN BERLINGO 2004
523 pages
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PRIVATE CARS
C2-C3-C3 PLURIEL-XSARA
XSARA PICASSO-BERLINGO
PRIVATE CARS
CAR 050014
Volume 1
2004
AC/QCA
V/MTD
Méthodes techniques documentation
f
«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».
2004

Table of Contents

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CITROEN BERLINGO 2004 Specifications

General IconGeneral
BrandCITROEN
ModelBERLINGO 2004
CategoryAutomobile
LanguageEnglish

Summary

GENERAL

PRESENTATION

Outlines the handbook's structure, covering main vehicle functions and models.

XSARA 2, all types Operation to reconnect the battery after a vehicle repair

Details critical steps for battery reconnection post-repair to avoid ECU lock-up.

C2 - C3 OPERATIONS TO BE CARRIED ORT AFTER A REPAIR

Essential post-repair operations for C2/C3 models including tailgate, windows, and sunroof.

C2 IDENTIFICATION OF VEHICLES

Details vehicle identification points on the C2 for VIN and component data.

CAPACITIES (in litres)

Lists fluid capacities for engine oil, cooling, fuel, and gearbox for various models.

LUBRICANTS - TOTAL recommended oils

Provides recommendations for TOTAL engine oils based on vehicle type and climate.

ENGINE

ENGINE SPECIFICATIONS

Presents technical specs for petrol engines: power, torque, bore/stroke, and compression ratio.

SPECIAL FEATURES - TIGHTENING TORQUES (m.daN )

Lists critical torque values for engine component assembly and tightening procedures.

CYLINDER HEAD

Details cylinder head gasket identification, thickness, and tightening sequences.

AUXILIARY EQUIPMENT DRIVE BELT

Instructions for checking, removing, and refitting the auxiliary equipment drive belt.

CHECKING AND SETTING THE VALVE TIMING

Outlines procedures for checking and setting valve timing using specific tools and sequences.

INJECTION

PETROL INJECTION

Details injection system specs for petrol engines: ECU, pump type, and injector values.

DEPOLLUTION TECHNICAL CHECKS (FRANCE)

Specifies depollution check parameters and conditions for petrol/diesel vehicles in France.

SAFETY REQUIREMENTS: HDi DIRECT INJECTION SYSTEM

Critical safety precautions for HDi direct injection systems due to high pressures.

PROHIBITED OPERATIONS: SIEMENS HDI DIRECT INJECTION SYSTEM

Lists prohibited operations and component handling for Siemens HDI injection systems.

CHECKS: LOW PRESSURE FUEL SUPPLY CIRCUIT

Details procedures for checking the low-pressure fuel supply circuit using vacuum gauges.

CHECKS: TURBO PRESSURE

Explains turbocharger pressure check procedures and specifications under various conditions.

CLUTCH GEARBOX TRANSMISSION

CLUTCH SPECIFICATIONS

Lists clutch specs: disc diameter, supplier, and quality for various models.

GEARBOX AND TYRE SPECIFICATIONS

Provides specs for gearboxes and associated tyre sizes and circumferences.

MA/5 GEARBOX

Details features, lubrication, and specifications for the MA/5 gearbox.

AL4 AUTOMATIC GEARBOX

Identifies the AL4 automatic gearbox, with warnings on oil and ECU requirements.

DRAINING / FILLING / TOP-UP: AL4 GEARBOX

Outlines procedures for draining, filling, and checking the oil level of the AL4 gearbox.

AXLES SUSPENSION STEERING

AXLE GEOMETRY C2

Details axle geometry measurement points and conditions for C2 vehicles.

AXLE GEOMETRY

Provides axle geometry specifications and checks at reference height for C3 vehicles.

FRONT AXLE

Lists tightening torques and anti-roll bar specifications for the front axle.

REAR AXLE

Details rear axle tightening torques and anti-roll bar specifications.

STEERING COLUMN SPECIFICATIONS

Provides specifications and identification details for steering columns.

POWER-ASSISTED STEERING SPECIFICATIONS

Lists specifications and tightening torques for power-assisted steering systems.

BRAKES

BRAKE SPECIFICATIONS (WITHOUT ABS)

Lists brake specs for non-ABS systems, including master cylinder and disc/drum details.

BRAKE SPECIFICATIONS (WITH ABS)

Lists brake specs for ABS systems, including caliper and disc details.

HANDBRAKE (Adjustment)

Provides instructions for handbrake adjustment and cable routing checks.

BLEEDING THE BRAKES

Details the procedure for bleeding the braking system, with and without specialized equipment.

ELECTRICAL SYSTEM

STARTER MOTORS

Classifies starter motors by class and climate suitability based on torque and power.

ALTERNATORS

Lists alternator classes and climate allocations by engine/gearbox.

CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR

Explains checks for alternator output and voltage regulator function.

AIRCON

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

Covers features like pollen filter location, compressor types, and R 134.a system specs.

Changing the filtering/drying cartridge

Provides a step-by-step guide for replacing the air conditioning filter/dryer cartridge.

Checking the compressor oil level

Details procedures for checking compressor oil levels based on leak conditions.

AIR CONDITIONING SYSTEM R 134.a

Outlines testing procedures and performance checks for the R 134.a system.

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