🏷️ Basic Information

Make:

Citroën

Model:

Berlingo

Year:

2005

Engine:

1.6 16V HDi

Engine Code Variant:

DV6ATED4 (common for 1.6 HDi in this era)

👋 Introduction

Segment:

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

Target Audience:

Families, small businesses, tradespeople seeking practical, versatile, and economical transport.

Key Competitors Era:

Renault Kangoo, Peugeot Partner, Volkswagen Caddy, Fiat Doblò

Versatility:

Spacious interior, practical seating configurations, large cargo area, sliding rear doors.

Engine Efficiency:

The 1.6 HDi engine offered a good balance of power and fuel economy, particularly suited for its segment.

Comfort Ride:

Citroën's signature comfortable ride quality, often attributed to its suspension tuning.

📋 Manual Details

Primary Focus:

Service, Repair, Maintenance, Diagnostics

Secondary Focus:

Troubleshooting, Wiring Diagrams, Technical Specifications

Estimated Pages:

Extensive (typically 1000+ pages for full factory manuals)

Type:

Factory Service and Repair Manual (FSM)

Language:

English

Format:

PDF (Digital Download)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, timing belt, cylinder head, pistons, crankshaft, lubrication system, cooling system, fuel injection system (HDi specifics)

Engine Electrical:

ECU, sensors, actuators, ignition system (glow plugs), starting and charging system

Transmission:

Manual transmission (likely BE4 or similar), clutch system, gearbox overhaul, fluid specifications

Drivetrain:

Front-wheel drive, CV joints, drive shafts

Brakes:

Front and rear disc brakes, ABS system, hydraulic circuits, bleeding procedures

Suspension:

Front MacPherson struts, rear torsion beam or leaf springs (depending on specific model variant), shock absorbers, springs, bushings

Steering:

Hydraulic power steering system, steering rack, column

Body And Chassis:

Body structure, panels, doors, hinges, locks, glass, bumpers, underbody protection

Electrical System:

Lighting, interior and exterior, instrumentation, warning lights, fuses, relays, battery, charging system

HVAC:

Air conditioning system, heating, ventilation, blower motor, controls, refrigerant circuits

Fuel System:

Diesel injection (common rail HDi), fuel tank, pump, injectors, filters

Exhaust System:

Catalytic converter (if applicable), DPF (Diesel Particulate Filter) if fitted, mufflers, pipes

Emissions Control:

EGR valve, DPF regeneration, relevant sensor data

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-ups, brake inspections, tire rotations

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper replacement

Diagnostics:

Troubleshooting guides for common faults, diagnostic trouble codes (DTCs), sensor data interpretation

Electrical Troubleshooting:

Wiring diagrams, component testing, fault tracing

Specific Hdi Procedures:

Diesel particulate filter (DPF) regeneration and replacement, fuel injector testing and replacement, glow plug system diagnostics

Bodywork Repairs:

Panel replacement, door alignment, glass fitting

Depth:

Comprehensive: from basic scheduled maintenance to complete engine and component rebuilds, including advanced diagnostics and electrical schematics.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely text-searchable within the PDF

Printability:

Full Printable (high resolution for clear diagrams and text)

Zoom Capabilities:

Yes (allows for detailed examination of diagrams and text)

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format, printable on various paper types)

⚙️ Engine Specifications

Engine Type:

Turbocharged Direct Injection Diesel (HDi)

Displacement:

1560 cc

Bore X Stroke:

75.3 mm x 88.3 mm (typical for DV6 series)

Compression Ratio:

17.6:1 (typical for DV6ATED4)

Valve Train:

DOHC (Double Overhead Camshaft), 4 valves per cylinder

Horsepower Ps:

Approximately 90 PS (this is a common output for the DV6ATED4, exact figure may vary slightly by market/specific tune)

Torque Nm:

Approximately 180-200 Nm (this is a common torque range for the DV6ATED4, exact figure may vary slightly by market/specific tune)

Injection Type:

Common Rail Direct Injection (Bosch or Delphi system common)

Fuel Type:

Diesel (Euro 3 / Euro 4 emissions depending on specific market and build date)

Emissions Standard:

Likely Euro 3 or Euro 4 compliant for a 2005 model year.

🔧 Transmission

Type:

5-speed Manual Transmission

Type:

Likely no automatic transmission offered for this specific engine/model year combination.

Clutch Type:

Hydraulically operated dry single plate clutch

📐 Dimensions

Length:

Approx. 4137 mm

Width:

Approx. 1721 mm (excluding mirrors)

Height:

Approx. 1801 mm (depending on roof rails)

Seating Capacity:

5 Seats (standard configuration, some versions might have optional 7 seats)

Luggage Capacity Liters:

Approx. 500-600 liters (with rear seats in place, depending on configuration)

Kerb Weight Kg:

Approx. 1400-1500 kg (depending on specific trim and equipment)

🛡️ Safety Features

Euro Ncap Rating:

Likely 3 or 4 stars for the generation/year range. Specific results for 2005 models are readily available through Euro NCAP archives.

ABS:

Anti-lock Braking System (standard on most models)

Ebs:

Electronic Brake-force Distribution (often paired with ABS)

Esp:

Electronic Stability Program (may be optional or standard depending on trim and market)

Airbags:

Front airbags for driver and passenger (standard), side airbags (optional on some trims)

Seatbelts:

Three-point seatbelts with pretensioners

Child Safety:

ISOFIX mounting points for child seats

💡 Technology Features

Radio Cd:

Standard radio with CD player, often with steering wheel mounted controls.

Display:

Basic monochrome display for radio and trip computer information.

Cruise Control:

Optional on higher trim levels.

Bluetooth:

Likely not standard, but could be an optional accessory or integrated into higher-spec head units.

🔧 Maintenance

Oil Change:

Typically every 12,500 miles (20,000 km) or 12 months, whichever comes first. Specific conditions may alter this.

Timing Belt:

Critical item. Usually replaced every 75,000 - 100,000 miles (120,000 - 160,000 km) or 5-6 years, whichever comes first. Refer to manual for exact interval and associated components (tensioners, pulleys, water pump).

Air Filter:

Typically replaced every 2 years or 30,000 miles (48,000 km).

Fuel Filter:

Diesel fuel filter replacement is crucial for HDi engines, often recommended every 30,000 - 40,000 miles (48,000 - 64,000 km).

Engine Oil:

Refer to the manual for precise API and ACEA specifications (e.g., ACEA B3/B4, API CF). Viscosity typically 5W-40 or 0W-30 low-SAPS oil is recommended for HDi engines.

Coolant:

Long-life coolant (e.g., PSA specification - 'Paraflu' type) mixed with distilled water. Capacity around 5-6 liters.

Brake Fluid:

DOT 4 brake fluid.

Transmission Fluid:

Manual transmission fluid, typically GL-4 specification. Capacity around 2 liters.

Dpf Clogging:

Common issue on HDi engines if not driven on longer journeys regularly, leading to regeneration failures and potential DPF blockage.

Egr Valve Fouling:

EGR (Exhaust Gas Recirculation) valve can get coked up with carbon deposits, leading to performance issues or engine warning lights.

Injector Issues:

Diesel injectors can become faulty over time, affecting performance, fuel economy, and emissions.

Turbocharger Wear:

Like many turbocharged engines, wear on the turbocharger can occur, leading to loss of power or oil consumption.

Suspension Components:

Bushes and ball joints in suspension can wear, especially on vehicles used for commercial purposes or on rough roads.

📚 Vehicle History

Citroen Legacy:

Citroën has a long history of innovation in vehicle design and comfort, dating back to André Citroën.

Berlingo First Gen Intro:

The first generation Berlingo was introduced in 1996, revolutionizing the small MPV/leisure vehicle segment.

Second Gen Intro:

The second generation, which includes the 2005 model, debuted in 2002, offering a more refined design and updated technology.

Manufacturing Location:

Primarily manufactured in Spain (Vigo plant) and other PSA facilities.

🏆 Awards & Recognition

Segment Popularity:

The Berlingo (and its Peugeot Partner sibling) has historically been a segment leader in terms of sales and practicality.

Engine Awards:

The 1.6 HDi engine (PSA's DV6 series) was well-regarded for its efficiency and became a common powertrain across many PSA and Ford models, winning 'Engine of the Year' awards in its class.

Consumer Reviews:

Generally praised for practicality, comfort, and economy, though some early HDi versions had specific known issues which this manual would address.