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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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Replacing of the air filter in a 1,9 liter diesel engine (CASA) (for use on the Peugeot Partner, Citroen Berlingo model)

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