🏷️ Basic Information

Make:

Citroën

Model:

Berlingo

Year:

2004

Generation:

First Generation (Mk1)

Body Style:

MPV / Panel Van

Platform:

PSA Platform 2

👋 Introduction

Market Segment:

Light Commercial Vehicle (LCV) / Compact MPV

Key Competitors:

Peugeot Partner, Renault Kangoo, Fiat Doblo, Volkswagen Caddy

Unique Selling Points:

Practicality, robust construction for commercial use, spacious interior, versatile cargo/passenger configurations, cost-effective operation.

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance personnel.

📋 Manual Details

Applicable Models:

Citroën Berlingo 1.9 D (All Trims, Engine Variants, Transmission Types)

Coverage Areas:

General Information, Periodic Maintenance, Engine, Fuel System and Throttle Body, Cooling and Lubrication System, Chassis, Electrical System, Servicing Information, Emission Control Information, Wiring Diagrams, and more.

Manual Type:

Factory Service Repair Workshop Manual

Language:

English

File Format:

PDF

Digital Delivery:

Instant Download

Software Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered:

Engine mechanicals, fuel injection system, cooling system, lubrication system, intake and exhaust systems, manual and automatic transmission, clutch, braking system (front discs, rear drums), suspension (front independent McPherson struts, rear torsion beam), steering system (power assisted rack and pinion), electrical system (lighting, ignition, charging, starting, instrumentation), climate control, bodywork, interior components.

Procedures Included:

Routine maintenance, component inspection, diagnosis and troubleshooting, repair and replacement of all major mechanical and electrical components, engine overhaul, transmission service, brake servicing, suspension and steering alignment, body panel repair, wiring harness diagnostics.

Technical Depth:

Comprehensive, covering complete disassembly and reassembly, detailed diagnostic procedures, torque specifications, repair times, special tool requirements, and wiring diagrams.

📊 Manual Specifications

Print Quality:

Printable without restrictions

Searchable Text:

Assumed to be searchable PDF text

Manual Completeness:

Complete and intact, no missing or corrupt parts/pages.

⚙️ Engine Specifications

Engine Code:

DW8B (typically)

Engine Type:

Naturally Aspirated Diesel

Displacement:

1.9 Liters (1868 cc)

Bore X Stroke:

82.2 mm x 88.0 mm

Compression Ratio:

19.0:1 (approx.)

Horsepower Output:

69 bhp (51 kW) @ 4600 rpm

Torque Output:

120 Nm (89 lb-ft) @ 2000 rpm

Fuel Delivery:

Indirect Injection (IDI) with Bosch VE rotary injection pump

Oil Capacity:

5.0 Liters (with filter change)

Coolant Capacity:

6.5 Liters

Emission Standard:

Euro 3 (likely)

🔧 Transmission

Transmission Type:

5-speed Manual Transmission

Optional Transmission:

None specified for this engine variant in 2004

Clutch Type:

Hydraulically operated single dry plate clutch

Transmission Fluid Type:

API GL-4, SAE 75W-80 (Hypoid gear oil)

Transmission Fluid Capacity:

1.9 Liters

📐 Dimensions

Length:

4107 mm

Width:

1720 mm

Height:

1812 mm

Curb Weight:

1280 kg (approx.)

Gross Vehicle Weight Rating:

1900 kg (approx.)

Cargo Volume Seats Up:

395 Liters (MPV configuration)

Cargo Volume Seats Down:

2600 Liters (approx. panel van configuration)

🛡️ Safety Features

Euro Ncap Rating:

3 Stars (for early models, variations may exist)

Airbags:

Driver airbag standard, Passenger airbag optional on some trims.

Seatbelts:

Pre-tensioned front seatbelts, three-point rear seatbelts.

ABS:

Optional on many variants.

Braking System Front:

Ventilated Discs

Braking System Rear:

Drums

💡 Technology Features

Audio System:

Basic radio with CD player (optional), cassette player standard on early models.

Instrumentation:

Analog gauges for speedometer, tachometer, fuel level, coolant temperature. Warning lights for various systems.

Cruise Control:

Not commonly available on this 1.9D variant.

Bluetooth:

Not available on this model year.

🔧 Maintenance

Oil Change Interval:

Every 10,000 miles or 12 months, whichever comes first (typical for this era diesel).

Air Filter Replacement:

Every 20,000 miles or 24 months.

Fuel Filter Replacement:

Every 40,000 miles or 48 months.

Timing Belt Replacement:

Every 70,000 miles or 5 years, whichever comes first (critical for engine longevity).

Engine Oil Specification:

ACEA B4, API CF, SAE 10W-40 or 5W-40 (check manual for exact spec)

Coolant Specification:

Antifreeze/coolant meeting PSA S71-2376 specification (Ethylene Glycol based, blue/green color).

Common Problems:

Glow plug failure, injector seal leaks, diesel particulate filter clogging (if fitted), exhaust gas recirculation (EGR) valve issues, suspension wear (especially rear bushings), clutch slave cylinder leaks, rust on sills and wheel arches.

Typical Repairs:

Replacement of timing belt and water pump, glow plug replacement, clutch replacement, brake caliper and disc replacement, suspension component replacement.

📚 Vehicle History

Citroen Heritage:

Citroën, a French automotive manufacturer, has a long history of innovative and practical vehicles, known for pioneering front-wheel drive and hydro-pneumatic suspension.

Berlingo Mk1 Introduction:

Launched in 1996 as a compact MPV/leisure activity vehicle and light commercial van.

Facelifts:

Received a significant facelift in 2002, which updated styling and features, with the 2004 model representing this updated version.

Manufacturing Location:

Vigo, Spain (primary)

🏆 Awards & Recognition

Lcav Awards:

The Berlingo has consistently been a strong contender in the compact MPV and LCV segments, often praised for its practicality and value for money, though specific awards for the 2004 1.9D model are not widely documented.