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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