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2007 Citroen Berlingo I Service and Repair Manual

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🏷️ Basic Information Identification Make: Citroën Model: Berlingo I Year: 2007 Codes Chassis Codes: M49, M59 Generation Identifier: First Generation (Facelift) 👋 Introduction Market Position Vehicle Segment: Compact MPV / Leisure Activity Vehicle (LAV) Target Audience: Families, small businesses, tradespeople seeking practicality, versatility, and cost-effectiveness Competitive Analysis Key Competitors: Renault Kangoo, Peugeot Partner, Fiat Doblo, Volkswagen Caddy Key Features Practicality: Spacious interior, flexible seating, large sliding doors, cavernous boot space Design Philosophy: Utilitarian yet with distinctive Citroën styling, prioritizing function and comfort Manual Value Proposition Value For Money: Provides technicians and DIYers with the exact information needed to perform accurate and efficient repairs, saving time and money Accuracy And Reliability: Official dealer-level information ensures accuracy, crucial for complex modern vehicle systems 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Estimated Page Count: Extensive (typical for comprehensive workshop manuals, estimated 1500-2500+ pages) Manual Type Type: Service and Repair Manual Language Language: English Format Format: Likely PDF or digital format for technicians 📖 Manual Coverage Systems Covered Powertrain: Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system Transmission: Manual gearbox, Automatic gearbox (if applicable), clutch, drivetrain components (drive shafts, differentials) Chassis: Suspension (front and rear), steering system, braking system (including ABS/ESP if fitted) Electrical: 12V electrical system, battery, charging system, starting system, lighting, instrumentation, body electronics, ECU diagnostics, wiring diagrams Bodywork: Body construction, panels, doors, windows, interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning) Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, lubrication Diagnostics: Troubleshooting common faults, diagnostic trouble codes (DTCs), testing procedures for all major systems Repair: Step-by-step repair instructions for components and systems, including engine overhaul, transmission rebuilds, brake caliper replacement, suspension arm replacement, electrical component repair Adjustment: Component adjustments (e.g., handbrake, clutch linkage), wheel alignment specifications Replacement: Component replacement procedures (e.g., timing belt/chain, water pump, brake pads, shock absorbers) Technical Depth Depth: Technician-level detail, including torque specifications, special tool requirements, detailed diagnostic flowcharts, and overhaul procedures 📊 Manual Specifications File Format File Type: Digital (likely PDF), ensuring searchability and easy navigation Print Quality Quality: High-resolution scans or digital native files, suitable for printing specific sections or the entire manual Binding Type Binding: N/A (for digital format); if printed, typically spiral-bound or perfect-bound for workshop use Paper Type Paper Quality: N/A (for digital format); if printed, professional grade, durable paper ⚙️ Engine Specifications Primary Engine Engine Options 2007: Range typically included petrol and diesel variants. Common petrol: 1.4i (TU3JP), 1.6i (TU5JP4 or ET3J4). Common diesel: 1.4 HDi (DV4), 1.6 HDi (DV6), 2.0 HDi (DW10TD/DW10BTED). Performance Power Output 1.6 Hdi: Typically around 90 PS (66 kW) for the 1.6 HDi engine, but variations exist. Torque Output 1.6 Hdi: Approximately 205 Nm for the 1.6 HDi engine. Fuel System Injection System Hdi: Common Rail Direct Injection (CRDi) Catalytic Converter: Euro 4 compliant for most later models, requiring specific catalyst monitoring and replacement procedures. Maintenance Timing Belt Replacement 1.6 Hdi: Critical interval, typically around 150,000 km or 10 years, including tensioners and idlers. Technical Details Engine Management System: Bosch or Siemens ECU, with diagnostic capabilities via OBD-II (EOBD). 🔧 Transmission Standard Gearbox Options: Primarily a 5-speed manual gearbox. Some models may have offered an automated manual transmission (e.g., SensoDrive). Optional Automatic Transmission: Less common, but certain configurations might have offered a conventional automatic. Features Clutch Type: Single dry plate, hydraulically operated clutch Maintenance Gearbox Oil Capacity Manual: Typically around 1.9 - 2.1 litres. Specific fluid: API GL-4, SAE 75W-80 or 75W-90. Clutch Replacement: Includes flywheel inspection/replacement, release bearing. 📐 Dimensions Exterior Length: Approximately 4137 mm (standard wheelbase) Width: Approximately 1720 mm (excluding mirrors) Height: Approximately 1805 mm Cargo Luggage Capacity Min: Around 500 litres with rear seats in place. Luggage Capacity Max: Over 2800 litres with rear seats removed. Weights Gross Vehicle Weight: Varies by model and payload, typically around 1900-2000 kg Towing Capacity Braked: Often around 1500 kg 🛡️ Safety Features Ratings Euro Ncap Rating: 4 stars for adult occupant protection in earlier tests for the first generation (pre-facelift). Specific tests for the 2007 facelift may vary. Active Features ABS: Standard on many models, optional on base variants. Details on ABS modulator testing and bleeding procedures included. Esp Or Traction Control: Available on higher trims or as an option, detailing its operation and diagnostics. Passive Features Airbags: Front airbags standard, optional side airbags. Procedures for airbag system diagnostics and replacement, including SRS warning light troubleshooting. Seatbelts: Pre-tensioners and load limiters on front seats. Maintenance of seatbelt mechanisms. 💡 Technology Features Infotainment Audio System: Factory fitted radio/CD players, often with steering wheel remote controls. Manual covers head unit removal, speaker replacement, and antenna diagnostics. Driver Assistance Cruise Control: Available on some higher trim levels, detailing activation, setting, and troubleshooting. Connectivity Central Locking: Key fob operation with remote...
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2007 Citroen Berlingo I Service and Repair Manual
🏷️ Basic Information
Identification
Make:
Citroën
Model:
Berlingo I
Year:
2007
Codes
Chassis Codes:
M49, M59
Generation Identifier:
First Generation (Facelift)
👋 Introduction
Market Position
Vehicle Segment:
Compact MPV / Leisure Activity Vehicle (LAV)
Target Audience:
Families, small businesses, tradespeople seeking practicality, versatility, and cost-effectiveness
Competitive Analysis
Key Competitors:
Renault Kangoo, Peugeot Partner, Fiat Doblo, Volkswagen Caddy
Key Features
Practicality:
Spacious interior, flexible seating, large sliding doors, cavernous boot space
Design Philosophy:
Utilitarian yet with distinctive Citroën styling, prioritizing function and comfort
Manual Value Proposition
Value For Money:
Provides technicians and DIYers with the exact information needed to perform accurate and efficient repairs, saving time and money
Accuracy And Reliability:
Official dealer-level information ensures accuracy, crucial for complex modern vehicle systems
📋 Manual Details
Coverage Areas
Coverage Scope:
All models and all repairs A-Z
Page Count
Estimated Page Count:
Extensive (typical for comprehensive workshop manuals, estimated 1500-2500+ pages)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Likely PDF or digital format for technicians
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system
Transmission:
Manual gearbox, Automatic gearbox (if applicable), clutch, drivetrain components (drive shafts, differentials)
Chassis:
Suspension (front and rear), steering system, braking system (including ABS/ESP if fitted)
Electrical:
12V electrical system, battery, charging system, starting system, lighting, instrumentation, body electronics, ECU diagnostics, wiring diagrams
Bodywork:
Body construction, panels, doors, windows, interior trim, seats, HVAC (Heating, Ventilation, and Air Conditioning)
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, lubrication
Diagnostics:
Troubleshooting common faults, diagnostic trouble codes (DTCs), testing procedures for all major systems
Repair:
Step-by-step repair instructions for components and systems, including engine overhaul, transmission rebuilds, brake caliper replacement, suspension arm replacement, electrical component repair
Adjustment:
Component adjustments (e.g., handbrake, clutch linkage), wheel alignment specifications
Replacement:
Component replacement procedures (e.g., timing belt/chain, water pump, brake pads, shock absorbers)
Technical Depth
Depth:
Technician-level detail, including torque specifications, special tool requirements, detailed diagnostic flowcharts, and overhaul procedures
📊 Manual Specifications
File Format
File Type:
Digital (likely PDF), ensuring searchability and easy navigation
Print Quality
Quality:
High-resolution scans or digital native files, suitable for printing specific sections or the entire manual
Binding Type
Binding:
N/A (for digital format); if printed, typically spiral-bound or perfect-bound for workshop use
Paper Type
Paper Quality:
N/A (for digital format); if printed, professional grade, durable paper
⚙️ Engine Specifications
Primary Engine
Engine Options 2007:
Range typically included petrol and diesel variants. Common petrol: 1.4i (TU3JP), 1.6i (TU5JP4 or ET3J4). Common diesel: 1.4 HDi (DV4), 1.6 HDi (DV6), 2.0 HDi (DW10TD/DW10BTED).
Performance
Power Output 1.6 Hdi:
Typically around 90 PS (66 kW) for the 1.6 HDi engine, but variations exist.
Torque Output 1.6 Hdi:
Approximately 205 Nm for the 1.6 HDi engine.
Fuel System
Injection System Hdi:
Common Rail Direct Injection (CRDi)
Catalytic Converter:
Euro 4 compliant for most later models, requiring specific catalyst monitoring and replacement procedures.
Maintenance
Timing Belt Replacement 1.6 Hdi:
Critical interval, typically around 150,000 km or 10 years, including tensioners and idlers.
Technical Details
Engine Management System:
Bosch or Siemens ECU, with diagnostic capabilities via OBD-II (EOBD).
🔧 Transmission
Standard
Gearbox Options:
Primarily a 5-speed manual gearbox. Some models may have offered an automated manual transmission (e.g., SensoDrive).
Optional
Automatic Transmission:
Less common, but certain configurations might have offered a conventional automatic.
Features
Clutch Type:
Single dry plate, hydraulically operated clutch
Maintenance
Gearbox Oil Capacity Manual:
Typically around 1.9 - 2.1 litres. Specific fluid: API GL-4, SAE 75W-80 or 75W-90.
Clutch Replacement:
Includes flywheel inspection/replacement, release bearing.
📐 Dimensions
Exterior
Length:
Approximately 4137 mm (standard wheelbase)
Width:
Approximately 1720 mm (excluding mirrors)
Height:
Approximately 1805 mm
Cargo
Luggage Capacity Min:
Around 500 litres with rear seats in place.
Luggage Capacity Max:
Over 2800 litres with rear seats removed.
Weights
Gross Vehicle Weight:
Varies by model and payload, typically around 1900-2000 kg
Towing Capacity Braked:
Often around 1500 kg
🛡️ Safety Features
Ratings
Euro Ncap Rating:
4 stars for adult occupant protection in earlier tests for the first generation (pre-facelift). Specific tests for the 2007 facelift may vary.
Active Features
ABS:
Standard on many models, optional on base variants. Details on ABS modulator testing and bleeding procedures included.
Esp Or Traction Control:
Available on higher trims or as an option, detailing its operation and diagnostics.
Passive Features
Airbags:
Front airbags standard, optional side airbags. Procedures for airbag system diagnostics and replacement, including SRS warning light troubleshooting.
Seatbelts:
Pre-tensioners and load limiters on front seats. Maintenance of seatbelt mechanisms.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/CD players, often with steering wheel remote controls. Manual covers head unit removal, speaker replacement, and antenna diagnostics.
Driver Assistance
Cruise Control:
Available on some higher trim levels, detailing activation, setting, and troubleshooting.
Connectivity
Central Locking:
Key fob operation with remote central locking. Manual covers receiver module diagnostics and key programming procedures.
Comfort Features
HVAC System:
Manual or automatic climate control. Manual covers refrigerant handling, component testing (compressor, evaporator, heater matrix), and diagnosis of airflow issues.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically every 15,000 km or 12 months, whichever comes first.
Oil Change Interval Diesel Hdi:
Typically every 20,000 km or 12 months, whichever comes first (often with DPF considerations). Always consult the manual for specific intervals based on driving conditions.
Air Filter Replacement:
Every 30,000-60,000 km or as required by conditions.
Cabin Filter Replacement:
Annually or every 15,000-20,000 km.
Fluid Specifications
Engine Oil Specification:
For petrol engines, typically ACEA A3/B4 or A5/B5, SAE 5W-40 or 10W-40 depending on climate. For HDi diesel engines, typically ACEA C2/C3 or B4, SAE 5W-30 (low SAPS for DPF models).
Coolant Specification:
Antifreeze/coolant, typically a long-life type, OAT (Organic Acid Technology) based, conforming to PSA S71 2103 specification. Colour: Blue/Green.
Brake Fluid Specification:
DOT 4
Known Issues
Suspension Wear:
Common wear on suspension components like ball joints, drop links, and bushes, particularly with high mileage or heavy use. Manual details inspection and replacement.
Diesel Particulate Filter Dpf:
1.6 HDi engines with DPFs can experience clogging if not driven in conditions allowing regeneration. Manual covers DPF regeneration procedures and troubleshooting.
Electrical Gremlins:
Intermittent issues with dashboard lights, central locking, or windows can occur. Manual provides comprehensive wiring diagrams and diagnostic procedures.
Hdi Injectors:
Diesel common rail injectors can require cleaning or replacement. Manual details testing and replacement procedures for injector systems.
📚 Vehicle History
Brand Heritage
Citroen Philosophy:
Known for innovative design, comfort-focused suspension (e.g., Hydractive), and practical vehicle concepts.
Model Evolution
Berlingo I Development:
Launched in 1996 as a revolutionary leisure activity vehicle based on the PSA platform. The 2007 model represents the facelifted version with updated styling and technology.
Facelift 2002:
The 2007 model is part of the first generation, which received a significant facelift around 2002/2003, featuring revised front end styling (headlights, grille, bumper), dashboard updates, and improved engines.
Production
Production Locations:
Primarily manufactured by PSA Peugeot Citroën plants, including Vigo, Spain.
🏆 Awards & Recognition
Recognitions
Earlier Awards:
The Berlingo range, in its various iterations, has consistently been praised for its practicality and value in the European market. While specific awards for the 2007 model year might not be readily available, the model's success in its segment speaks to its market acceptance.
Ratings
Reliability Perception:
Generally considered reliable for its class, especially the diesel variants. Manuals help maintain this reliability.
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