CITROEN BERLINGO 1.1i Petrol 2004 Service Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: Berlingo Year: 2004 Engine Type: Petrol Engine Displacement: 1.1i (Liter) Generation Generation: First Generation (M59) Codes Chassis Code: M59 👋 Introduction Market Position...

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Type: Car

Vendor:

Sku: 484443

Tags: 2004 BERLINGO Car Cars Citroen

Product variants

Description

🏷️ Basic Information

Identification

Make:

Citroën

Model:

Berlingo

Year:

Engine Type:

Petrol

Engine Displacement:

1.1i (Liter)

Generation

Generation:

First Generation (M59)

Codes

Chassis Code:

👋 Introduction

Market Position

Vehicle Segment:

Compact MPV (Multi-Purpose Vehicle) / Leisure Activity Vehicle

Target Audience:

Families, small businesses requiring versatile cargo space, and individuals seeking practical, budget-friendly transportation.

Competitive Analysis

Key Competitors Era:

Renault Kangoo, Peugeot Partner, Fiat Doblò, Volkswagen Caddy.

Key Features

Design Philosophy:

Practicality, spaciousness, and modular interior design derived from a commercial van platform.

Manual Value Proposition:

Empowers owners to perform maintenance and repairs themselves, saving money and gaining in-depth knowledge of their vehicle.

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete A-Z repairs for all models and repairs.

Page Count

Page Count:

Not Specified (Comprehensive)

Manual Type

Manual Type:

Official Full Service Repair Manual

Language

Language:

English

Format

File Format:

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul and repair of the 1.1i petrol engine, including cylinder head, block, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system.

Fuel System:

Fuel injection system (Bosch Motronic or similar), fuel pump, injectors, fuel filter replacement, fuel tank maintenance.

Ignition System:

Spark plugs, ignition coils, wiring, ECU control of ignition timing.

Exhaust System:

Catalytic converter, exhaust manifold, muffler, pipe replacement, gasket renewal.

Transmission Manual:

Repair and overhaul of the manual gearbox, clutch replacement, gear linkage adjustments, drivetrain components.

Brakes:

Front and rear brake system diagnostics and repair, including disc and drum brakes, hydraulic lines, master cylinder, ABS (if equipped).

Suspension:

Front and rear suspension components, shock absorbers, springs, control arms, ball joints, wheel alignment procedures.

Steering:

Power steering system maintenance and repair, steering rack, tie rods, steering column.

Electrical System:

Complete wiring diagrams, component location, fuse and relay identification, starter, alternator, battery diagnostics.

Bodywork:

Body panel removal and installation, door mechanisms, locks, hinges, glass replacement, rust prevention.

HVAC:

Heating, ventilation, and air conditioning system service, refrigerant handling, component replacement.

Interior Trim:

Dashboard removal, seat mechanisms, interior paneling.

Procedures Included

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, fluid checks, spark plug replacement, brake pad inspection.

Troubleshooting:

Diagnostic charts and procedures for identifying common problems and their causes.

Repair:

Detailed step-by-step instructions for all mechanical, electrical, and bodywork repairs.

Diagnostics:

Procedures for diagnosing engine performance, electrical faults, and other operational issues, including OBD-II (On-Board Diagnostics II) information where applicable.

Installation:

Instructions for installing optional accessories and replacing major components.

Technical Depth

Depth Of Information:

Complete, factory-level detail, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Format

File Format Details:

PDF (Portable Document Format)

Print Quality

Print Capability:

Fully printable, allowing users to print specific pages or entire sections.

Image Enhancement:

Supports zooming in/out of images and diagrams for detailed viewing and printing of enlarged copies.

Binding Type

Binding Type:

Digital (PDF format) - no physical binding

Paper Type

Paper Type:

N/A (Digital)

Compatibility

Operating Systems:

Compatible with all versions of Windows and Mac.

⚙️ Engine Specifications

Primary Engine

Engine Code:

TU1JP (or similar variant)

Engine Layout:

Inline 4-cylinder, SOHC (Single Overhead Camshaft)

Bore X Stroke:

72.0 mm x 77.0 mm (approximate)

Compression Ratio:

9.7:1 (approximate)

Performance

Horsepower:

Approx. 60 PS (59 bhp; 44 kW) at 5300 rpm

Torque:

Approx. 94 Nm (69 lb-ft) at 3400 rpm

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Petrol (RON 95 recommended)

Cooling System

Coolant Capacity:

Approx. 5.5 liters

Lubrication System

Oil Capacity:

Approx. 3.4 liters (with filter)

Recommended Oil Viscosity:

10W-40 (API SG/SH/SJ or ACEA A3/B3)

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission

Optional

Transmission Type Optional:

Not typically offered with automatic transmission for the 1.1i variant in this year.

Features

Gear Ratios:

Specific gear ratios for each gear and final drive are detailed within the manual.

Transmission Fluid Type:

Manual Transmission Fluid (MTF), specifications provided in the manual.

Clutch Type:

Dry single plate, hydraulically operated

📐 Dimensions

Exterior

Length:

Approx. 4113 mm (4.11 m)

Width:

Approx. 1715 mm (1.72 m)

Height:

Approx. 1802 mm (1.80 m)

Weights

Curb Weight:

Approx. 1150 - 1200 kg (depending on configuration)

Gross Vehicle Weight:

Approx. 1700 - 1800 kg (depending on configuration)

Cargo

Luggage Capacity Seats Up:

Approx. 505 liters

Luggage Capacity Seats Down:

Approx. 2500 liters (with rear seats removed)

🛡️ Safety Features

Ratings

Euro Ncap Rating:

3 Stars (for 2002 model, generally applicable to early M59 generation)

Active Features

Available as an option on many models, detailed diagnostics and repair procedures included.

Rarely equipped on the 1.1i model of this era.

Passive Features

Airbags:

Driver and front passenger airbags standard or optional depending on trim level. Side airbags available.

Seatbelts:

Pre-tensioned seatbelts with force limiters, ISOFIX child seat anchor points.

💡 Technology Features

Infotainment

Radio Cd Player:

Factory fitted or optional radio with CD player, often with steering wheel mounted controls.

Driver Assistance

Cruise Control:

Optional on higher trim levels.

Connectivity

Bluetooth:

Rarely factory-fitted on this specific engine/year variant; often an aftermarket addition.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 15,000 km or 12 months, whichever comes first.

Air Filter Replacement:

Every 30,000 km or 24 months.

Spark Plug Replacement:

Every 60,000 km (for standard platinum or iridium plugs).

Brake Fluid Change:

Every 2 years.

Coolant Replacement:

Every 4 years or 60,000 km.

Fluid Specifications

Brake Fluid:

DOT 4

Power Steering Fluid:

LHM (Citroën's hydraulic fluid) or equivalent specified by manufacturer.

Known Issues

Common Wear Items:

Suspension components (ball joints, bushings), clutch wear, exhaust system corrosion, rear axle beam wear (a known issue on many PSA vehicles of this era).

Electrical Gremlins:

Occasional issues with central locking, window regulators, and instrument cluster faults are reported in general forums.

📚 Vehicle History

Brand Heritage

Citroen Legacy:

Citroën's history of innovative design and practical vehicle solutions.

Model Evolution

Berlingo Origins:

Launched in 1996 as a Leisure Activity Vehicle (LAV) based on the Peugeot 106/Citroën Saxo platform.

M59 Facelift:

The 2004 model falls within the first generation (M59), which received a significant facelift in 2002, introducing updated styling and features.

Production

Production Period:

First generation: 1996-2008 (with facelift in 2002).

Manufacturing Locations:

Primarily manufactured in Vigo, Spain.

🏆 Awards & Recognition

Recognitions

Utilitarian Awards:

The Berlingo (and its Peugeot Partner sibling) consistently ranked highly in European compact van/MPV sales and was often praised for its practicality and load-carrying ability.