🏷️ Basic Information

Make:

Citroën

Model:

Berlingo

Year:

2005

Engine Type:

1.9D (Diesel)

Generation:

First Generation (M49/M59)

Chassis Code:

M59 (Facelift model)

👋 Introduction

Market Position:

The Citroën Berlingo 1.9D (2005) is a versatile compact MPV/leisure activity vehicle known for its practicality, spacious interior, and robust diesel engine. This manual targets owners and independent workshops seeking detailed repair and maintenance guidance.

Competitive Analysis:

Competitors in its segment included the Peugeot Partner, Renault Kangoo, and Fiat Doblo. The 1.9D engine offered a balance of economy and durability, making it a popular choice.

Key Features:

The manual emphasizes step-by-step instructions and exploded views for ease of use, covering all aspects of the vehicle's maintenance and repair, including electrical systems.

📋 Manual Details

Coverage Areas:

All Models / Engines / Trim / Transmissions Types

Page Count:

Not specified, but described as comprehensive.

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF (delivered electronically)

📖 Manual Coverage

Systems Covered:

General Information, Chassis, Powertrain, Electrical, Bodywork, Loads

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the 1.9D diesel engine. Includes cylinder head, pistons, connecting rods, crankshaft, camshaft, timing system, lubrication system, and cooling system.

Engine Fuel System:

Detailed coverage of the diesel fuel injection system, including fuel pump, injectors, fuel lines, filters, and glow plug system.

Transmission Manual:

Removal, disassembly, repair, and reassembly of the 5-speed manual gearbox. Includes clutch operation and hydraulic system.

Chassis Suspension:

Front and rear suspension systems, including shock absorbers, springs, control arms, ball joints, bushings, and wheel bearings.

Chassis Steering:

Steering rack, power steering pump, fluid, and linkage. Wheel alignment procedures and specifications.

Chassis Brakes:

Front and rear brake systems, including disc and drum brakes, brake calipers, master cylinder, brake lines, parking brake, and ABS system components.

Electrical Lighting:

Headlights, taillights, interior lighting, fog lights, and related wiring harnesses and switches.

Electrical Instruments:

Instrument cluster, gauges, warning lights, and associated sensors.

Electrical Comfort:

Heating, ventilation, and air conditioning (HVAC) system, power windows, door locks, central locking, and mirrors.

Bodywork:

Body panel repair, doors, tailgate, bumpers, interior trim, and seating systems.

Procedures Included:

Maintenance, Repair, Troubleshooting, Step-by-step instructions, Exploded views, Electrical information

Engine Tune Up:

Spark plug replacement (if applicable to specific variants, though less common on early diesels), ignition timing, fuel injection timing, idle speed adjustment.

Lubrication Service:

Engine oil and filter change, gearbox oil change, differential oil change, lubrication points.

Cooling System Service:

Coolant flush and refill, thermostat replacement, water pump inspection/replacement, radiator and hose checks.

Electrical Diagnostics:

Troubleshooting of common electrical faults, wiring diagrams for all major systems, fuse and relay locations and identification.

Troubleshooting Guides:

Systematic approach to diagnosing common problems based on symptoms, with specific troubleshooting trees.

Technical Depth:

Comprehensive coverage for routine maintenance to major repairs, including electrical diagnostics.

Torque Specifications:

Detailed torque specifications for all critical fasteners, engine components, chassis parts, and wheel nuts.

Clearances And Tolerances:

Specifications for engine component clearances (e.g., piston ring gap, bearing clearances) and other critical measurements.

Wiring Diagrams:

Comprehensive and clear wiring diagrams for all electrical systems, including engine management, lighting, and accessories.

📊 Manual Specifications

File Format:

HTML (though delivered as PDF)

Print Quality:

Printable pages

Binding Type:

N/A (Electronic Delivery)

Paper Type:

N/A (Electronic Delivery)

⚙️ Engine Specifications

Primary Engine:

1.9L DW8 Turbocharged Diesel (or naturally aspirated depending on specific market variant)

Horsepower:

Approximately 70-75 HP (depending on specific DW8 variant)

Torque:

Approximately 125-135 Nm (depending on specific DW8 variant)

Fuel System:

Indirect Injection Diesel, likely with Bosch or Lucas fuel injection pump.

Engine Code:

DW8 (common engine code for this variant)

Cylinder Configuration:

Inline 4-cylinder

Bore X Stroke:

Specifics to be detailed in the manual (e.g., 83mm x 90mm for DW8)

Compression Ratio:

Specifics to be detailed in the manual (e.g., ~22:1 for DW8)

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

Likely a 5-speed Automated Manual Transmission (e.g., Sensodrive) was available on some variants, but manual is primary.

Transmission Features:

Manual transmission offers reliable operation; automated manual may have specific service procedures.

📐 Dimensions

Length:

Approx. 4135 mm (for the M59 generation)

Width:

Approx. 1720 mm

Height:

Approx. 1804 mm

Cargo Volume:

Highly variable depending on seating configuration, typically exceeding 600 liters with rear seats folded.

Curb Weight:

Approx. 1300-1400 kg (varies with specification)

Gross Vehicle Weight:

Specifics to be detailed in the manual, typically around 2000-2100 kg.

🛡️ Safety Features

Euro Ncap Rating:

4 Stars (for the first generation Berlingo, tested in 2001, relevant for the M59 facelift)

Active Features:

ABS, Power Steering (likely standard or optional).

Passive Features:

Front airbags, Seatbelt pre-tensioners.

💡 Technology Features

Infotainment Features:

Basic radio/CD player, likely with steering wheel mounted controls on higher trims. The manual will cover basic electrical system diagnostics for these components.

Driver Assistance Features:

Limited by 2005 standards; primarily ABS. Cruise control might be an option on higher trims.

Connectivity Features:

May include provisions for aftermarket AUX input or early Bluetooth systems on later M59 variants.

🔧 Maintenance

Service Intervals:

Routine service intervals typically 10,000-15,000 miles or 12 months, whichever comes first. Specific intervals for oil changes, filter replacements, and timing belt inspection/replacement are crucial and detailed in the manual.

Engine Oil:

Refer to manual for specific grade (e.g., 5W-40 or 10W-40, meeting specific PSA specifications like B71 2296).

Coolant:

Antifreeze/coolant (e.g., G30 or similar, silicate-free, purple/blue color).

Brake Fluid:

DOT 4

Transmission Fluid:

Specific manual gearbox oil grade (e.g., 75W-80 GL-4) and automatic transmission fluid if applicable.

Common Issues:

Wear on suspension components (ball joints, wishbone bushes), rear axle pivot bushes, clutch wear, potential for DMF (Dual Mass Flywheel) issues on some models, turbocharger wear (if applicable), injector sealing issues on diesel engines, electrical gremlins in older models.

Timing Belt Replacement Interval:

Critical: Typically 60,000-80,000 miles or 5-6 years. The manual will specify the exact interval and procedure, including replacement of the tensioner and idler pulleys.

📚 Vehicle History

Brand Heritage:

Citroën has a long history of producing practical and innovative vehicles, with the Berlingo building on the success of previous van-based people carriers.

Model Evolution:

The 2005 model is part of the facelifted M59 version of the first-generation Berlingo, which introduced updated styling, interior improvements, and revised engine options.

Production Years:

First generation: 1996–2011 (with M59 facelift from 2002)

Manufacturing Locations:

Primarily manufactured in Europe, with major plants in Spain and France.

🏆 Awards & Recognition

Recognitions:

While specific awards for the 2005 1.9D model are not prominently advertised, the Berlingo family has consistently been praised for its practicality and value in the compact MPV segment.