🏷️ Basic Information Identification Make: Citroen Model: Berlingo Year: 2004 Model Generation Code: First Generation (M49/M59) Codes Chassis Code Series: M49 (early), M59 (late) 👋 Introduction Market Position Vehicle Segment: Compact MPV / Leisure Activity Vehicle (LAV) Target Audience: Families, small businesses, tradespeople requiring versatile cargo and passenger space. Competitive Analysis Key Competitors: Renault Kangoo, Peugeot Partner, Fiat Doblò, Volkswagen Caddy, Ford Connect Key Features Manual Advantage: Provides factory-level technical information, empowering owners and technicians with detailed repair and maintenance procedures. Manual Value: Enables cost savings through DIY repairs and informed maintenance decisions, prolonging vehicle life and reliability. Manual Purpose Intended Users: Professional technicians and Do-It-Yourself (DIY) mechanics with basic electrical and mechanical knowledge. 📋 Manual Details Coverage Areas Market Regions: Global (primarily European focus) Vehicle Variants: Passenger (Multispace) and Commercial (Van) variants Page Count Estimated Page Count: Varies significantly by specific factory manual; digital versions often contain comprehensive content equivalent to hundreds of printed pages. Manual Type Type: Repair Service Manual / Workshop Manual Language Language: English Format File Format: PDF Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip or equivalent unzipping software Operating System Compatibility: All versions of Windows and macOS 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Transmission (manual and automatic), clutch, driveshafts, differentials Chassis: Suspension (front and rear), steering system, braking system Electrical: Complete electrical system, wiring diagrams, lighting, starter, charging system, accessories, body electronics Bodywork: Body panels, doors, windows, interior trim, chassis frame HVAC: Heating, Ventilation, and Air Conditioning system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Repair: Step-by-step repair instructions for all major components and systems Diagnostics: Troubleshooting guides, fault code identification, diagnostic procedures Disassembly Assembly: Detailed instructions for component removal and installation Cleaning Reinstalling: Procedures for cleaning parts during repair and proper reassembly Specifications: Critical torque values, clearances, fluid capacities, electrical specifications Technical Depth Level: Comprehensive; suitable for professional technicians and advanced DIY mechanics. Covers diagnostics, repair, and overhaul procedures. 📊 Manual Specifications File Format Quality: High-resolution, ensuring clarity of text and diagrams. Searchability: Likely text-searchable if created from a digital source, allowing quick information retrieval. Zoom Capability: YES - Allows users to zoom in for detailed examination of diagrams and text. Print Quality Printability: Full Printable - Allows users to print specific sections or the entire manual for offline use. Binding Type Digital Equivalent: N/A (Digital Download) Paper Type Digital Equivalent: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options 2004: 1.4i (TU3JP), 1.6i (KFU/NFU), 2.0 Hdi (RHY/RHX), 1.9 D (WJZ/WJY) Performance 1.6I 16V Power: Approx. 110 PS (108 hp; 81 kW) 2.0 Hdi Power: Approx. 90 PS (89 hp; 66 kW) Fuel System Injection Type Petrol: Multi-point fuel injection (MPI) Injection Type Diesel: Direct Injection (HDI - High Pressure Direct Injection) 🔧 Transmission Standard Transmission Options: 5-speed Manual Transmission Optional Transmission Options: 4-speed Automatic Transmission (likely on some petrol models) Features Clutch Type: Dry single plate, hydraulically actuated 📐 Dimensions Exterior Length Mm: Approx. 4108 - 4203 mm (depending on variant) Width Mm: Approx. 1717 - 1721 mm Height Mm: Approx. 1794 - 1802 mm Cargo Luggage Capacity Litres: Variable, up to approx. 628 liters in passenger variants with rear seats in place, significantly more with seats folded or removed. Weights Kerb Weight Kg: Approx. 1250 - 1400 kg (depending on engine and configuration) 🛡️ Safety Features Ratings Euroncap Score First Gen: 3 stars (initial models tested in 1999, improvements may have been made by 2004, but specific 2004 rating may vary or not be readily available for all configurations). Active Features ABS: Available as an option or standard on higher trims. Passive Features Airbags: Driver and front passenger airbags standard on most models; side airbags may be optional. Seatbelts: Three-point seatbelts with pre-tensioners for front occupants. 💡 Technology Features Infotainment Audio System: Standard radio/CD player with basic speaker setup; higher trims may offer upgraded systems. Driver Assistance Cruise Control: Available as an option on higher specification models. Connectivity Connectivity Options: Limited by 2004 standards; basic Bluetooth or auxiliary input may be present on some later models or aftermarket installations. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 15,000 km or 1 year (whichever comes first), check manual for specific engine type. Timing Belt Interval Petrol: Approx. 120,000 km or 5 years (check specific engine, e.g., TU5JP4). Timing Belt Interval Diesel: Approx. 100,000 km or 5 years (check specific engine, e.g., DW8, DW10). Fluid Specifications Engine Oil Specification: Refer to manual for specific engine: e.g., Total Quartz 7000 10W-40 or Quartz 9000 5W-40 for petrol/diesel, meeting PSA specifications (e.g., B71 2290 for diesel, B71 2300 for petrol). Coolant Specification: OAT (Organic Acid Technology) coolant, typically blue or pink, meeting PSA S71 2102 specifications. Brake Fluid Specification: DOT 4 Transmission Fluid Manual: API...
Comprehensive; suitable for professional technicians and advanced DIY mechanics. Covers diagnostics, repair, and overhaul procedures.
📊 Manual Specifications
File Format
Quality:
High-resolution, ensuring clarity of text and diagrams.
Searchability:
Likely text-searchable if created from a digital source, allowing quick information retrieval.
Zoom Capability:
YES - Allows users to zoom in for detailed examination of diagrams and text.
Print Quality
Printability:
Full Printable - Allows users to print specific sections or the entire manual for offline use.
Binding Type
Digital Equivalent:
N/A (Digital Download)
Paper Type
Digital Equivalent:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options 2004:
1.4i (TU3JP), 1.6i (KFU/NFU), 2.0 Hdi (RHY/RHX), 1.9 D (WJZ/WJY)
Performance
1.6I 16V Power:
Approx. 110 PS (108 hp; 81 kW)
2.0 Hdi Power:
Approx. 90 PS (89 hp; 66 kW)
Fuel System
Injection Type Petrol:
Multi-point fuel injection (MPI)
Injection Type Diesel:
Direct Injection (HDI - High Pressure Direct Injection)
🔧 Transmission
Standard
Transmission Options:
5-speed Manual Transmission
Optional
Transmission Options:
4-speed Automatic Transmission (likely on some petrol models)
Features
Clutch Type:
Dry single plate, hydraulically actuated
📐 Dimensions
Exterior
Length Mm:
Approx. 4108 - 4203 mm (depending on variant)
Width Mm:
Approx. 1717 - 1721 mm
Height Mm:
Approx. 1794 - 1802 mm
Cargo
Luggage Capacity Litres:
Variable, up to approx. 628 liters in passenger variants with rear seats in place, significantly more with seats folded or removed.
Weights
Kerb Weight Kg:
Approx. 1250 - 1400 kg (depending on engine and configuration)
🛡️ Safety Features
Ratings
Euroncap Score First Gen:
3 stars (initial models tested in 1999, improvements may have been made by 2004, but specific 2004 rating may vary or not be readily available for all configurations).
Active Features
ABS:
Available as an option or standard on higher trims.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models; side airbags may be optional.
Seatbelts:
Three-point seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Standard radio/CD player with basic speaker setup; higher trims may offer upgraded systems.
Driver Assistance
Cruise Control:
Available as an option on higher specification models.
Connectivity
Connectivity Options:
Limited by 2004 standards; basic Bluetooth or auxiliary input may be present on some later models or aftermarket installations.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 15,000 km or 1 year (whichever comes first), check manual for specific engine type.
Timing Belt Interval Petrol:
Approx. 120,000 km or 5 years (check specific engine, e.g., TU5JP4).
Timing Belt Interval Diesel:
Approx. 100,000 km or 5 years (check specific engine, e.g., DW8, DW10).
Fluid Specifications
Engine Oil Specification:
Refer to manual for specific engine: e.g., Total Quartz 7000 10W-40 or Quartz 9000 5W-40 for petrol/diesel, meeting PSA specifications (e.g., B71 2290 for diesel, B71 2300 for petrol).
Coolant Specification:
OAT (Organic Acid Technology) coolant, typically blue or pink, meeting PSA S71 2102 specifications.
Brake Fluid Specification:
DOT 4
Transmission Fluid Manual:
API GL-4, SAE 75W-80 or 75W-90 synthetic gear oil (check specific gearbox code).
Known Issues
Common Problems:
Rear suspension torsion bar issues, clutch slave cylinder failure, electrical gremlins, exhaust system corrosion, starter motor issues, HDI injector seals.
Routine Checks:
Regularly check for fluid leaks, especially from the gearbox and engine oil seals. Inspect exhaust mounts and bodywork for corrosion.
📚 Vehicle History
Brand Heritage
Citroen Philosophy:
Known for innovative design, comfort-oriented suspension, and practical solutions, particularly in utility vehicles.
Model Evolution
Berlingo Introduction:
Launched in 1996 as a pioneering leisure activity vehicle, combining van practicality with car-like comfort.
2004 Model Year:
Part of the first generation (typified by M49/M59 codes), which received facelifts and updates throughout its production run.
Production
Manufacturing Locations:
Primarily France (PSA Group plants)
🏆 Awards & Recognition
Recognitions
Vehicle Type Recognition:
Often cited as a pioneer in the Leisure Activity Vehicle segment, praised for its practicality and versatile interior.