Segment:
Compact MPV (Multi-Purpose Vehicle) / Leisure Activity Vehicle
Key Competitors Era:
Renault Kangoo, Volkswagen Caddy, Fiat Doblò, Peugeot Partner (sister vehicle).
Design Philosophy:
Practical, spacious interior, based on the Citroën ZX platform, offering a versatile load-carrying and passenger-carrying capability.
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Estimated Page Count:
Varies by specific engine and configuration, typically 1000+ pages for a comprehensive factory manual
Type:
Workshop Service Repair Manual (Factory Service Manual equivalent)
Engine Mechanical:
Detailed overhaul procedures, component testing, specifications for petrol and diesel engines.
Engine Management:
Ignition system, fuel injection systems (multi-point, direct injection), emissions control, diagnostic trouble codes (DTCs).
Transmission Manual:
Clutch system, gearbox overhaul, gear shift mechanisms, lubrication.
Transmission Automatic:
If applicable, detailed diagnosis, overhaul, and fluid specifications.
Suspension:
Front suspension (MacPherson struts), rear suspension (torsion beam with trailing arms), steering system (power steering), wheel alignment.
Brakes:
Front disc brakes, rear drum brakes (or discs on some variants), ABS system (if equipped), parking brake, brake fluid specifications.
Electrical System:
Battery, charging system (alternator), starting system, lighting, wipers, horn, power accessories.
Body And Chassis:
Body panel removal and installation, door mechanisms, glass replacement, interior trim, chassis component inspection and repair.
HVAC:
Heating, ventilation, and air conditioning system diagnosis and repair, refrigerant handling (R134a).
Safety Systems:
Airbag system diagnosis and component replacement, seat belt mechanisms.
Routine Maintenance:
Oil changes, filter replacements, spark plug replacement, fluid checks and top-ups, belt inspection.
Diagnostic Troubleshooting:
Step-by-step procedures for identifying and resolving common and complex faults.
Component Overhaul:
Detailed instructions for disassembling, inspecting, repairing, and reassembling major vehicle components.
Wiring Schematics:
Comprehensive electrical diagrams for all vehicle systems, facilitating fault finding.
Torque Specifications:
Accurate torque values for critical fasteners to ensure correct assembly and prevent damage.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Depth:
Comprehensive, covering all aspects from routine maintenance to complete engine and transmission rebuilds. Suitable for both DIY enthusiasts and professional technicians.
Printability:
Fully Printable. Allows users to print specific sections or the entire manual as needed for workshop use.
Binding:
N/A (Digital PDF)
Paper Quality:
N/A (Digital PDF)
Zoom Capability:
YES - Allows for detailed examination of diagrams and schematics.
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip (for extraction)
Operating Systems:
All Versions of Windows & Mac
Petrol Engine 1.4I:
TU3JP (1.4L SOHC 8-valve), approx. 75 PS (74 hp; 55 kW), Bosch Motronic MP3.2 or similar EFI.
Petrol Engine 1.6I:
NFZ (1.6L SOHC 8-valve, developed from TU5), approx. 88 PS (87 hp; 65 kW), Bosch Motronic MP3.2 or similar EFI.
Diesel Engine 1.9D:
DW8 (1.9L SOHC 8-valve Naturally Aspirated Diesel), approx. 68 PS (67 hp; 50 kW), Bosch mechanical injection.
Diesel Engine 2.0Hdi:
RHY (2.0L SOHC 8-valve Turbocharged Direct Injection Diesel), approx. 90 PS (89 hp; 66 kW), Bosch EDC 15C2 common rail.
Typical Acceleration 0 60Mph:
Varies significantly by engine; approx. 12-16 seconds for common variants.
Injection Type:
Electronic Fuel Injection (EFI) for petrol, Mechanical Diesel Injection or Common Rail Direct Injection (CDi) for diesel.
Length:
Approx. 4033 - 4175 mm (depending on model year and specific variant)
Width:
Approx. 1660 - 1710 mm
Height:
Approx. 1710 - 1810 mm
Passenger Capacity:
2-5 seats depending on configuration (panel van vs. passenger variants).
Load Volume:
Significant cargo space, particularly in panel van versions, often exceeding 3000 liters with rear seats folded/removed.
Curb Weight:
Varies by engine and equipment, typically between 1150 kg and 1450 kg.
Euro Ncap Results:
The first generation Berlingo underwent Euro NCAP testing, with varying results depending on the specific test year and equipment. Early tests often showed limitations in frontal and side impact protection compared to modern standards.
ABS:
Optional Anti-lock Braking System (ABS) available on higher trims and later models.
Airbags:
Driver's airbag standard on passenger variants, optional on some commercial versions. Passenger airbag availability varied by market and trim.
Seat Belts:
Three-point seatbelts with pre-tensioners for front occupants; lap belts or three-point belts for rear occupants depending on configuration.
Audio System:
Basic radio/cassette or CD player systems were common. Higher trims might have had upgraded speakers.
Cruise Control:
Rarely fitted on early models, potentially available as an option on later, higher-spec passenger variants.
Central Locking:
Standard on most passenger versions, often with remote keyless entry on higher trims.
Oil Change Interval:
Typically 7,500 - 10,000 miles (12,000 - 15,000 km) or 1 year, whichever comes first, depending on engine oil type and driving conditions. Check manual for exact specification.
Timing Belt Replacement:
Critical for petrol engines (e.g., TU3, TU5) and non-HDI diesel engines. Intervals typically around 60,000 - 75,000 miles (100,000 - 120,000 km) or 5 years. HDI engines use a timing chain on some variants, while others use a belt. Consult manual for specific engine.
Engine Oil Type:
API SJ/SL or ACEA A3/B3/B4, viscosity typically 5W-30, 5W-40, or 10W-40 depending on engine and climate. Consult manual for specific engine and ambient temperature requirements.
Coolant:
Ethylene glycol-based coolant with anti-corrosion inhibitors. Typically a pink or blue OAT (Organic Acid Technology) or HOAT (Hybrid OAT) formulation. Capacity approximately 6-7 liters.
Brake Fluid:
DOT 4 brake fluid. Should be replaced every 2 years to maintain performance and prevent moisture absorption.
Transmission Fluid Manual:
API GL-4, viscosity typically 75W-80 or 75W-90. Capacity approx. 2 liters.
Suspension Wear:
Common wear on front suspension components (bushings, ball joints) and rear axle bearings due to load carrying and typical usage.
Electrical Gremlins:
Intermittent electrical faults can occur, often related to aging wiring harnesses, earth points, or module failures. This manual is crucial for diagnosing these.
Diesel Glow Plugs:
Glow plugs can degrade over time, affecting cold start performance. The manual details testing and replacement procedures.
Hdi Injectors:
On 2.0 HDI engines, injector seals can sometimes leak, causing rough running or starting issues. The manual covers injector removal and overhaul.
Rear Axle Torsion Bars:
Wear in the rear axle's torsion bar suspension can lead to sagging or uneven ride height. The manual will detail inspection and potential repair.
Citroen Philosophy:
Citroën's history of innovative and practical vehicle design, often focusing on comfort and functionality for everyday use.
Development:
Developed as a successor to the Citroën C15 van, it pioneered the 'leisure activity vehicle' segment, blending commercial practicality with passenger comfort.
Manufacturing Locations:
Primarily manufactured in Spain (Vigo) and also in other PSA plants globally.
Production Timeline:
Launched in 1996 and continued through the facelifted M59 version until the introduction of the second generation Berlingo in 2008. This manual covers the majority of the original production run.
