Citroen Berlingo / Peugeot Partner since 1996 (updating 2002), repair e-manual (in Russian)

Content

Instruction manual

• Controls and devices
• Ventilation system

Your car is Citroën Berlingo & Peugeot Partner

• Safety first!
• Introduction: Citroën Berlingo & Peugeot Partner
• Troubleshooting an emergency
• If your car's engine does not start
• Starting the engine from an additional power source
• Wheel replacement
• Leak detection
• Towing
• Weekly checks
• Checks under the hood of the car
• Engine oil level
• Coolant level
• Washer fluid level
• Power steering fluid level
• Brake fluid level
• Windshield wipers
• Battery
• Electrical systems
• Tire condition and air pressure
• Working fluids and lubricants
• Tire pressure

Regular maintenance - petrol engines

• General information
• Regular maintenance
• Replacement of engine oil and filter
• Checking hoses and leaks of working fluids
• Checking the drive shaft anther
• Lubrication of awnings and locks
• Road test
• Resetting maintenance indicator
• Replacing the particle filter
• Checking and replacing the auxiliary drive belt
• Checking the front brake pads
• Checking the rear brake pads
• Checking and adjusting the parking brake
• Exhaust system check
• Checking the components of the steering and suspension
• Replacing the timing belt
• Brake fluid replacement
• Replacement of spark plugs
• Replacement of air filter
• Replacing the fuel filter
• Checking the transmission oil level
• Checking the components of the emission control system
• Replacing coolant
• Replacement of airbags and seat belt pretensioners

Regular maintenance - diesel engines

• General information
• Regular maintenance
• Replacement of engine oil and filter
• Draining water from the fuel filter
• Check hoses and system components for leaks
• Checking the drive shaft anther
• Lubrication of awnings and locks
• Road test
• Resetting maintenance indicator
• Replacing the particle filter
• Checking and adjusting the idle speed and minimum speed at which the engine does not stall - models of cars equipped with a 1.8-liter and 1.9-liter engine
• Checking and replacing the auxiliary drive belt - car models equipped with 1.8-liter and 1.9-liter engines
• Checking and replacing the auxiliary drive belt - vehicle models equipped with 2.0-liter engines
• Checking the front brake pads
• Checking the rear brake pads
• Checking and adjusting the parking brake
• Exhaust system check
• Checking the components of the steering and suspension
• Replacing the fuel filter
• Replacement of air filter
• Checking the transmission oil level
• Checking the components of the emission control system
• Replacing the timing belt
• Brake fluid replacement
• Replacing coolant
• Replacement of airbags and seat belt pretensioners

Repair procedures without removing the engine from the engine compartment - gasoline engines

• General information
• Compression check - description and explanation
• Engine assembly / ignition unit openings - general information and use
• Cylinder head cover - removal and installation
• Timing belt cover covers - removal and installation
• Timing belt - general information, removal and installation
• Timing belt tensioner and sprockets - removal, inspection and installation
• Camshaft oil seals - replacement
• Valve clearance - check and adjustment
• Camshafts and rockers / pushers - removal, inspection and installation
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump - removal, inspection and installation
• Crankshaft oil seals - replacement
• Flywheel - removal, inspection and installation
• Engine / gearbox mountings - check and replace

Repair procedures without removing the engine from the engine compartment - diesel engines 1.8 liters and 1.9 liters (series XUD)

• General information
• Compression check and leak test - description and explanation
• Engine assembly / valve timing holes - general information and use
• Cylinder head cover - removal and installation
• Crankshaft pulley - removing and installing
• Timing belt cover covers - removal and installation
• Timing belt - general information, removal and installation
• Asterisks of timing belt - removal and installation
• Right-hand support bracket and timing belt tensioner removing and installing
• Parallel belt pulley timing belt - removing and installing
• Camshaft and pushers - removal, inspection and installation
• Valve clearance - check and adjustment
• Cylinder head - removal and installation
• Pallet - removal and installation
• Oil pump and drive chain - removal, inspection and installation
• Oil seals - replacement
• Engine oil level and pressure sensors - general information
• Flywheel - removal, inspection and installation
• Oil cooler - removal and installation
• Engine / gearbox mountings - check and replace

Repair procedures without removing the engine from the engine compartment - diesel engines 1.9 liters and 2.0 liters (DW series)

• General information
• Checking the compression ratio and checking for leaks - description and explanation
• Engine assembly / valve timing holes - general information and use
• Cylinder head cover - removal and installation
• Crankshaft pulley - removing and installing
• Timing belt cover covers - removal and installation
• Timing belt (models of cars equipped with 1.9-liter engine) - general information, removal and installation
• Timing belt (car models equipped with 2.0 l engine) - general information, removal and installation
• Timing belt timing belts and idler pulley / tensioner pulley - removal, inspection and installation
• Camshaft seal - replacement
• Camshaft and pushers - removal, inspection and installation
• Valve clearance - check and adjustment
• The head of the block of cylinders (models of the cars equipped with the engine of 1.9 l) - removal and installation
• Pallet - removal and installation
• Oil pump- removal, inspection and installation
• Oil cooler - removal and installation
• Crankshaft oil seals - replacement
• Engine oil level and pressure sensors - general information
• Flywheel - removal, inspection and installation
• Engine / gearbox mountings - check and replace

Removing the gasoline engine from the engine compartment and the overhaul procedure

• General information
• Major engine repairs - general information
• Removing engine / gearbox - methods and precautions
• Engine / gearbox - removing and installing
• Engine overhauling - sequence of disassembly
• Cylinder head - disassembly
• Cylinder head and valves - cleaning and checking
• Cylinder head - installation
• Piston / connecting rod assembly - removal
• Crankshaft removal
• Cylinder block / crankcase - cleaning and inspection
• Piston / connecting rod assembly - check
• Crankshaft check
• The main bearing and the lower end of the connecting rod - check
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installation
• Piston / connecting rod assembly - installation
• The engine is the beginning of traffic after major repairs

Removing the diesel engine from the engine compartment and the overhaul procedure

• General information
• Major engine repairs - general information
• Removing engine / gearbox - methods and precautions
• Engine / gearbox - removing and installing
• Cylinder head (vehicle models equipped with 2.0 l engine) - removal and installation
• Engine overhauling - sequence of disassembly
• Cylinder head - disassembly
• Cylinder head and valves - cleaning and checking
• Cylinder head - assembly
• Piston / connecting rod assembly - removal
• Crankshaft removal
• Cylinder block / crankcase - cleaning and inspection
• Piston / connecting rod assembly - check
• Crankshaft check
• The main bearing and the lower end of the connecting rod - check
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installation
• Piston / connecting rod assembly - installation
• The engine is the beginning of traffic after major repairs

Removing the diesel engine from the engine compartment and the overhaul procedure

• General information
• Major engine repairs - general information
• Removing engine / gearbox - methods and precautions
• Engine / gearbox - removing and installing
• Cylinder head (vehicle models equipped with 2.0 l engine) - removal and installation
• Engine overhauling - sequence of disassembly
• Cylinder head - disassembly
• Cylinder head and valves - cleaning and checking
• Cylinder head - assembly
• Piston / connecting rod assembly - removal
• Crankshaft removal
• Cylinder block / crankcase - cleaning and inspection
• Piston / connecting rod assembly - check
• Crankshaft check
• The main bearing and the lower end of the connecting rod - check
• Engine overhaul - assembly sequence
• Piston rings - installation
• Crankshaft - installation
• Piston / connecting rod assembly - installation
• The engine is the beginning of traffic after major repairs

Cooling system, heater and air conditioning

• General information and precautions
• Cooling system slugs - detaching and replacing
• Radiator - removal, inspection and installation
• Thermostat - removal, inspection and installation
• Electric cooling fan - removing and installing
• Electrical switches and sensors of the cooling system - removal and installation
• Cooling pump - removing and installing
• Thermostat / fuel filter housing (car models equipped with 1.8 and 1.9 l diesel engine) - removal and installation
• Heater and ventilation system - general information
• Components of the heater / ventilation system - removal and installation
• Air conditioning system - general information and precautions
• Components of the air conditioning system - removal and installation

The power supply and exhaust system - gasoline engines

• General information and precautions
• Air filter assembly and air ducts - removing and installing
• Accelerator cable - removal and installation
• Accelerator pedal - removal and installation
• Unleaded fuel - general information and use
• Engine management system - general information
• Power system - discharge and pressure build-up
• Fuel pump - removal and installation
• Fuel gauge - removing and installing
• Fuel tank - removal and installation
• The engine management system - check and adjustment
• Throttle body - removing and installing
• Components of the engine management system - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general information, removal and installation

The system of power and exhaust of exhaust gases - diesel engines 1.8 and 1.9 l (series XUD)

• General information and precautions
• Power system - refueling and air removal
• Air filter assembly and air ducts - removing and installing
• Thermostatic sensor for increased idling speed - removal, installation and adjustment
• High pressure fuel pump - removing and installing
• Setting the timing of the injection - verification and adjustment methods
• Setting the injection timing (Lucas fuel pump) - checking and adjusting
• Setting the injection timing (Bosch high-pressure fuel pump) - checking and adjusting
• High pressure fuel pump - adjustment
• Fuel injectors - check, removal and installation
• Throttle cable - removal, installation and adjustment
• Accelerator pedal - removal and installation
• Fuel level sensor module and fuel - booster pump - removing and installing
• Fuel tank - removal and installation
• The engine management system - check and adjustment
• Throttle body - Removing and installing
• Components of the engine management system - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Exhaust system - general information, removal and installation

The system of power and exhaust of exhaust gases - diesel engines 1.8 and 1.9 l (series XUD)

• General information and precautions
• Power system - refueling and air removal
• Air filter assembly and air ducts - Removing and installing
• Thermostatic sensor for increased idling speed - removal, installation and adjustment
• High pressure fuel pump - Removing and installing
• Setting the timing of the injection - verification and adjustment methods
• Setting the injection timing (Lucas fuel pump) - checking and adjusting
• Setting the injection timing (Bosch high-pressure fuel pump) - checking and adjusting
• High pressure fuel pump - adjustment
• Fuel injectors - check, removal and installation
• Throttle cable - removal, installation and adjustment
• Accelerator pedal - removal and installation
• Fuel level sensor module and fuel - booster pump - removing and installing
• Fuel tank - removal and installation
• Collectors - removal and installation
• Exhaust system - general information and component replacement

The system of power and exhaust of exhaust gases - diesel engines 1.9 and 2.0 l (series DW)

• General information
• High-pressure diesel injection system (HDi system) - special information
• Air filter assembly and air ducts - removing and installing
• Throttle cable - removal, installation and adjustment
• Accelerator pedal - removal and installation
• Power system - refueling and air removal
• Fuel pump (models with 2.0 l engine) - removal and installation
• Fuel level sensor module - removing and installing
• Fuel tank - removal and installation
• Thermostatic sensor for increased idle speed (models of cars equipped with a 1.9-liter engine) - removal, installation and adjustment
• High-pressure fuel pump (models of cars equipped with 1.9-liter engine) - adjustment
• Electrical components of injection system - removal and installation
• High pressure fuel pump - removing and installing
• Setting the injection timing - checking and adjusting
• Fuel injectors - removal and installation
• The fuel directing-distributor (models of cars equipped with a 2.0-liter engine) - removal and installation
• Intake manifold - removal and installation
• Exhaust manifold - removal and installation
• Turbocharger (car models equipped with 2.0 l engine) - description and precautions
• Turbocharger (models of cars equipped with 2.0 l engine) - removal, testing and installation
• Exhaust system - general information, removal and installation

Emission control systems

• General information
• Emission control systems (petrol engines) - checking and replacing components
• Emission control systems (diesel engines) - checking and replacing components
• Catalytic converter - general information and precautions

Starting and recharging systems

• General information and precautions
• Detecting faults in the electrical system - general information
• Battery - check and charge
• Battery - removal and installation
• Shelf and battery mounting plate
• Recharging system - check
• Belt of the generator drive - removal, installation and tension adjustment
• Generator - removal and installation
• Generator - check and overhaul
• Start-up system - check
• Starter motor - removal and installation
• Starter motor - check and overhaul
• Ignition switch - removal and installation
• Engine oil warning light sensor - removing and installing
• Engine oil level sensor

Ignition system - petrol engines

• Ignition system - general information
• Ignition system - check
• Ignition coil - removal, check and installation
• Ignition advance - check and adjustment
• Detonation sensor - removal and installation

Diesel engine preheating system

• Engine preheating system - description and verification
• Glow plugs - removal, inspection and installation
• Pre-heating control unit - removal and installation

Clutch

• General information
• Clutch cable - removing and installing
• Clutch pedal - removal and installation
• Clutch assembly - removal, inspection and installation
• Clutch release mechanism - removal, inspection and installation

Manual transmission

• General information
• Manual transmission - filling and draining transmission oil
• Shift mechanism - removal and installation
• Oil seals - replacement
• Switch for reversing lights - check, remove and install
• Speedometer drive - removal and installation
• Manual gearbox - removing and installing
• Major overhaul of a manual transmission - general information

Power shafts

• General information
• Drive shafts - removal and installation
• Anthers of drive shafts (drive shaft type GKN) - replacement
• Anthers of drive shafts (drive shaft type PSA) - replacement
• Drive shaft overhaul - general information
• Intermediate bearings of the right drive shaft - replacement

Brake system

• General information
• Hydraulic system - air removal
• Hydraulic connections and hoses
• Front brake pads - change
• Rear brake pads - replacement
• Front disc brake - checking, removing and installing
• Rear drum brake - removal, inspection and installation
• Front brake caliper - removal, overhaul and installation
• Rear working cylinder - removal and installation
• Master brake cylinder - removal, overhaul and installation
• Vacuum brake booster - checking, removing and installing
• Check valve of the vacuum brake amplifier
• Parking brake - adjustment
• Parking brake lever - adjustment
• Parking brake cables - removal and installation
• The valve of adjustment of pressure of back brakes - removal and installation
• Brake light switch - removal, installation and adjustment
• Brake warning system switch - removing and installing
• Anti-lock braking system (ABS) - general information
• Anti-lock components (ABS) - removal and installation
• Vacuum pump (models of cars equipped with diesel engine) - removal and installation
• Vacuum pump (models of cars equipped with diesel engine) - check and overhaul

Suspension and steering

• General information
• Folding knuckle assembly - removing and installing
• Front hub bearings
• Front suspension bracket - removing and installing
• Front suspension - overhaul
• Lower front suspension lever - removal, overhaul and installation
• Ball joint of lower front wishbone - removal and installation
• Front axle anti-roll bar - removal and installation
• Front stabilizer bar for front suspension - removing and installing
• Front axle subframe - removing and installing
• Rear hub assembly - removal and installation
• Rear hub bearings - replacement
• Rear suspension components - general information
• Rear shock absorber - removal, inspection and installation
• Rear axle assembly - removal and installation
• Adjustable ground clearance - check
• Steering wheel - removal and installation
• Steering column - removal, inspection and installation
• The locking mechanism of the ignition / steering column - removal and installation
• Gearbox assembly - removal, overhaul and installation
• Power steering system - air removal
• Power steering pump - removal and installation
• Ball joint of the tie rod - removal and installation
• Adjusting the installation angles and steering angle - general information, checking and adjustment

Body structure and components

• General information
• Maintenance - body and frame
• Maintenance - upholstery and rugs
• Elimination of minor body damage - repairs
• Removing serious body damage - repairs
• Front bumper - removal and installation
• Rear bumper - removal and installation
• Hood - removal, installation and adjustment
• A cable of blocking and opening of a cowl - removal and installation
• Door - removal and installation
• Internal door trim panel - removing and installing
• Handle and components of the front door lock - removal and installation
• Handle and components of the side sliding door lock - removal and installation
• Handle and components of the rear swinging door lock - removal and installation
• Front window glass and window lifter - removal and installation
• Rear lift door and support posts - removal and installation
• Components of the tailgate lock - removal and installation
• Components of the central lock - removal and installation
• External mirrors and removal of the mirror from the case - removal and installation
• The windscreen, the windows of the swinging and lifting luggage compartment door - general information
• Opening side and rear door windows - removal and installation
• Luke - general information
• External components of the body - removal and installation
• Air intake panel - removal and installation
• Radiator grille - removal and installation
• Seats - removal and installation
• Safety belt components - removal and installation
• Internal lining - removal and installation
• Central console - removal and installation
• Panel trim components (car models, manufactured before September 2002) - removal and installation
• Panel paneling components (car models released after September 2002) - removal and installation

Electrical equipment and electrical systems

• General information
• Detection of malfunctions in the electrical system - general information
• Fuses and relays - general information
• Switches - removal and installation
• Lamps (external lighting) - replacement
• Lamps (internal lighting) - replacement
• External headlamps - removal and installation
• Adjusting the height of the headlights - general information
• Dashboard - removal and installation
• Multi-function display unit - removal and installation
• Cigarette lighter / outlet - removal and installation
• Acoustic signal - removal and installation
• Wiper arm - removal and installation
• Windscreen wiper motor and winding - removing and installing
• Rear window wiper motor
• Washer components - removal and installation
• Audio system - removal and installation
• Speakers - removal and installation
• Immobilizer system and anti-theft system - general information
• Airbag system - general information, precautions and system shutdown
• Components of the airbag system - removal and installation
• The BSI (built-in systems interface) block / fuse box - general information, removal and installation
• Electrical diagrams

Applications

• Overall dimensions and weight
• Vehicle identification numbers
• Lifting the car with a jack and the point of the pillars
• General repair procedures
• Disconnecting the negative battery terminal
• Tools and devices
• Checking the technical condition of the car
• Troubleshooting
• Glossary

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