CITROEN BERLINGO 1.4i Petrol 2004 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Citroën Model: Berlingo Year: 2004 Engine: 1.4i Petrol Codes Engine Code Identifier: KFX (TU3JP) 👋 Introduction Market Position Market Segment: Compact MPV / Leisure Activity Vehicle (LAV). Competitive Analysis Key Competitors: Renault Kangoo, Peugeot Partner, Fiat Doblo, Volkswagen Caddy. Key Features Vehicle Appeal: Practicality, spacious interior, versatile cargo space, comfortable ride. Manual Value Proposition Target Audience: DIY enthusiasts, independent repair shops, fleet maintenance. Benefit To Owner: Cost savings on maintenance and repairs, increased vehicle lifespan, self-sufficiency in troubleshooting. 📋 Manual Details Coverage Areas Vehicle Coverage: Citroën Berlingo (First Generation) 1.4i Petrol models Engine Coverage: 1.4L (1360cc) TU3JP petrol engine Page Count Estimated Page Count: Extensive (often 1000+ pages for comprehensive manuals) Manual Type Manual Type: Full Service and Repair Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, crankshaft, pistons, connecting rods, timing, lubrication, cooling. Fuel System: Fuel injection system (Bosch Motronic), fuel pump, injectors, fuel filter, evaporative emission control (EVAP). Ignition System: Ignition coils, spark plugs, distributorless ignition, timing control. Exhaust System: Exhaust manifold, catalytic converter, mufflers, oxygen sensors. Transmission Manual: Manual gearbox, clutch, gear linkage, gearbox oil. Transmission Automatic: Not applicable for 1.4i Petrol model, but manual likely covers gearbox removal/installation for manual transmission. Brakes: Front disc brakes, rear drum brakes, ABS (if equipped), brake fluid, hydraulic system, parking brake. Steering: Power steering system, steering rack, steering column, tie rods. Suspension: Front MacPherson struts, rear torsion beam suspension, shock absorbers, springs, anti-roll bars. Electrical System: Battery, charging system (alternator), starter motor, lighting, horns, wipers, washers, power windows. Body Electrical: Interior lighting, instrument cluster, central locking, immobiliser, airbags. Climate Control: Heating system, ventilation, air conditioning (if equipped). Bodywork: Body panel removal and installation, door mechanisms, glass, seals, exterior trim. Interior: Seat removal, dashboard removal, trim panels, carpets. Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, spark plug replacement, coolant checks, brake fluid changes. Troubleshooting: Diagnostic procedures for common faults, fault codes, symptom-based troubleshooting. Repair: Component removal, disassembly, inspection, repair, reassembly, and installation. Diagnostics: Engine management system diagnostics, ABS diagnostics, sensor testing. Wiring Diagrams: Detailed electrical wiring diagrams for all major systems. Torques Specifications: Critical torque values for engine components, chassis fasteners, and suspension parts. Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine and transmission overhauls. Suitable for DIY mechanics and professional technicians. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Fully printable, allowing users to print specific sections as needed. Zoom Functionality Zoom Capabilities: Allows zooming in for detailed inspection of diagrams and text. Binding Type Binding Type: Digital (Downloadable PDF), offers convenience over physical binding. Paper Type Paper Type Analogy: Digital format eliminates the need for specific paper types, but print quality is excellent on standard paper. Requirements Software Requirements: Adobe Acrobat Reader, WinZip (for unzipping downloaded files). Compatibility Operating System Compatibility: Compatible with all versions of Windows and macOS. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-cylinder, SOHC (Single Overhead Camshaft), 8-valve Displacement: 1.4 Liters (1360 cc) Bore X Stroke: 75.0 mm x 77.0 mm (approximate) Compression Ratio: 9.7:1 (approximate) Performance Horsepower: 75 PS (74 bhp / 55 kW) at 5300 rpm (approximate) Torque: 118 Nm (87 lb-ft) at 2600 rpm (approximate) Fuel System Fuel Delivery: Multi-point fuel injection (MPI), Bosch Motronic MP7.0 or similar. Fuel Type: Unleaded petrol (Octane rating 95 RON recommended) Engine Management ECU Type: Bosch Motronic (specific model may vary) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transaxle (BE4/5 or similar) Optional Optional Transmission: Not typically offered with the 1.4i petrol in this generation. Features Clutch Type: Hydraulically operated, single dry plate clutch. Fluid Specifications Gearbox Oil Type: API GL-5, SAE 75W-80 (e.g., Mobil Mobilube S75W-80 or equivalent). Fluid Capacity Gearbox Oil Capacity: Approximately 2.1 liters (2.2 US quarts) 📐 Dimensions Exterior Length: 4110 mm (approximate) Width: 1720 mm (approximate, excluding mirrors) Height: 1800 mm (approximate) Wheelbase: 2690 mm (approximate) Weights Kerb Weight: 1150 - 1250 kg (approximate, depending on equipment) Gross Vehicle Weight: 1800 - 1950 kg (approximate) Cargo Luggage Capacity: 620 liters (seats up) to 2430 liters (seats folded), depending on configuration. 🛡️ Safety Features Ratings Euro Ncap Rating: Likely 3 or 4 stars for models of this era, depending on equipment. (Specific data for 2004 model year may vary). Active Features ABS: Optional or standard depending on market and trim level. Esp: Rarely fitted to this engine variant in this generation. Passive Features Airbags: Driver and front passenger airbags standard, side airbags optional. Seat Belts: Pre-tensioning front seatbelts. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player with basic speaker system. Steering wheel controls optional on higher trims. Driver Assistance Cruise Control: Rarely fitted on this engine variant. Connectivity Bluetooth: Not available on this model year. 🔧 Maintenance Service Intervals Oil Change Interval:...
Multi-point fuel injection (MPI), Bosch Motronic MP7.0 or similar.
Fuel Type:
Unleaded petrol (Octane rating 95 RON recommended)
Engine Management
ECU Type:
Bosch Motronic (specific model may vary)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transaxle (BE4/5 or similar)
Optional
Optional Transmission:
Not typically offered with the 1.4i petrol in this generation.
Features
Clutch Type:
Hydraulically operated, single dry plate clutch.
Fluid Specifications
Gearbox Oil Type:
API GL-5, SAE 75W-80 (e.g., Mobil Mobilube S75W-80 or equivalent).
Fluid Capacity
Gearbox Oil Capacity:
Approximately 2.1 liters (2.2 US quarts)
📐 Dimensions
Exterior
Length:
4110 mm (approximate)
Width:
1720 mm (approximate, excluding mirrors)
Height:
1800 mm (approximate)
Wheelbase:
2690 mm (approximate)
Weights
Kerb Weight:
1150 - 1250 kg (approximate, depending on equipment)
Gross Vehicle Weight:
1800 - 1950 kg (approximate)
Cargo
Luggage Capacity:
620 liters (seats up) to 2430 liters (seats folded), depending on configuration.
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Likely 3 or 4 stars for models of this era, depending on equipment. (Specific data for 2004 model year may vary).
Active Features
ABS:
Optional or standard depending on market and trim level.
Esp:
Rarely fitted to this engine variant in this generation.
Passive Features
Airbags:
Driver and front passenger airbags standard, side airbags optional.
Seat Belts:
Pre-tensioning front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player with basic speaker system. Steering wheel controls optional on higher trims.
Driver Assistance
Cruise Control:
Rarely fitted on this engine variant.
Connectivity
Bluetooth:
Not available on this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 20,000 km (12,500 miles) or 12 months, whichever comes first.
Air Filter Replacement:
Every 40,000 km (25,000 miles) or 24 months.
Spark Plug Replacement:
Every 60,000 km (37,500 miles) or 48 months (using NGK BKR6EKC or equivalent).
Timing Belt Replacement:
Crucial: Every 90,000 km (56,000 miles) or 5 years. This is an interference engine, so belt failure will cause severe damage.
Fluid Specifications
Engine Oil Type:
Synthetic or semi-synthetic SAE 5W-40 or 10W-40, meeting PSA B71 2295 or API SL/CF, ACEA A3/B4 specifications.
Engine Oil Capacity:
Approximately 3.25 liters (3.4 US quarts) with filter change.
Coolant Type:
Antifreeze/coolant, ethylene glycol based, blue or pink colour, meeting PSA S71 2710 specification (e.g., Castrol Radicool SF).
Coolant Capacity:
Approximately 5.0 liters (5.3 US quarts).
Brake Fluid Type:
DOT 4 (e.g., Bosch DOT 4).
Known Issues
Common Failures Engine:
Timing belt tensioner and idler pulley wear, oil leaks from rocker cover gasket, occasional ignition coil failure.
Common Failures Transmission:
Clutch wear, potential synchromesh wear in higher mileage vehicles.
Common Failures Suspension:
Front suspension top mounts, rear torsion bar bearings, worn anti-roll bar links.
Common Failures Electrical:
Central locking actuator failures, interior light failures, immobiliser issues on some early models.
Common Failures Exhaust:
Corrosion of exhaust system components, premature failure of rear silencer.
📚 Vehicle History
Brand Heritage
Citroen Legacy:
Citroën has a long history of innovation in comfort and design, dating back to the Traction Avant and 2CV.
Model Evolution
Berlingo First Gen:
The first generation Berlingo (often referred to as 'Berlingo First' after the introduction of the second generation) was launched in 1996, based on the PSA platform shared with the Peugeot Partner.
Production
Production Period:
First generation produced from 1996 to 2010 (with facelift in 2002).
Manufacturing Locations:
Primarily manufactured in Spain (Vigo) and France.
🏆 Awards & Recognition
Recognitions
Market Recognition:
The Berlingo has consistently been praised for its practicality and value for money within the compact MPV segment.