🏷️ Basic Information Identification Make: Citroën Model: Berlingo Year: 2002 Generation: First Generation (Type M49/M59) Codes Chassis Code Platform: PSA Platform 1 (also used for Peugeot Partner) 👋 Introduction Market Position Vehicle Segment: Compact MPV / Leisure Activity Vehicle Positioning Statement: Practical, versatile, and affordable family vehicle, often used for commercial purposes. Competitive Analysis Key Competitors: Peugeot Partner, Renault Kangoo, Fiat Doblo, Volkswagen Caddy Key Features Unique Selling Points: Spacious and modular interior, sliding rear doors, durable construction, comfortable ride Manual Value Proposition Advantage: Vehicle-specific, technician-grade information, enabling accurate diagnosis and repair, cost savings for owners. 📋 Manual Details Coverage Areas Main Coverage: All models and all repairs A-Z Page Count Estimated Page Count: Likely 800-1200+ pages (typical for comprehensive factory service manuals) Manual Type Type: Service and Repair Manual Language Language: English (presumed, common for international sales) Format Format: Digital (e.g., PDF) or Printed (as per product offering) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning, timing, fuel injection, ignition, cooling, lubrication, emissions Transmission: Manual and Automatic transmission repair, overhaul, clutch, gearbox, driveline, differentials Brakes: Hydraulic systems, ABS, EBD, brake pads, discs, calipers, lines, parking brake Suspension Steering: Front and rear suspension components, shock absorbers, springs, bushings, steering rack, power steering Electrical Electronics: Wiring diagrams, fuses, relays, lighting, ignition system, starter, alternator, battery, comfort systems, ECUs, diagnostics Bodywork Chassis: Body panel removal/installation, structural repairs, doors, windows, interior trim, underbody protection Heating Ventilation Air Conditioning: HVAC system components, refrigerant, diagnostics, cabin filters Procedures Included Maintenance Schedule: Detailed routine maintenance intervals for all major service points Troubleshooting Diagnostics: Systematic fault finding procedures, diagnostic trouble codes (DTCs), live data interpretation Repair Rebuild: Step-by-step instructions for component removal, repair, and reassembly Technical Specifications: Torque values, clearances, fluid capacities, electrical resistance values, alignment specifications Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Depth: Comprehensive, covering basic to advanced repairs, including full engine and transmission rebuilds Target Audience: Professional technicians and experienced DIY mechanics 📊 Manual Specifications File Format Digital Quality: Searchable text, high-resolution diagrams and images (assuming high-quality digital reproduction) Print Quality Print Clarity: Clear, legible text and sharp, detailed illustrations/diagrams (if printed) Binding Type Binding: Stapled or perfect bound for digital copies, typically robust binding for printed manuals Paper Type Paper Quality: Durable, gloss or semi-gloss paper suitable for workshop environments (if printed) ⚙️ Engine Specifications Primary Engine Engine Codes Options: 1.4i (TU3JP - KFX, KDY), 1.6i (TU5JP4 - NFZ), 2.0 HDI (DW10TD - RHY), 1.9 D (DW8 - WJY) Performance 1.4I Horsepower: 75 PS (74 hp; 55 kW) 1.6I Horsepower: 88 PS (87 hp; 65 kW) 2.0 Hdi Horsepower: 90 PS (89 hp; 66 kW) 1.9 D Horsepower: 69 PS (68 hp; 51 kW) Fuel System Injection Type Petrol: Multi-point fuel injection (MPI) Injection Type Diesel: Direct Injection (HDI), Indirect Injection (XUD-based engines in some markets) Fuel Type Petrol Octane Rating: Unleaded 95 RON recommended Fluid Specifications Engine Oil Specification Petrol: API SL/CF or ACEA A3/B4, SAE 5W-40 or 10W-40 (check specific engine variant) Engine Oil Specification Diesel: API CF/CF-4 or ACEA B3/B4, SAE 5W-40 or 10W-40 (check specific engine variant) Coolant Specification: Ethylene glycol-based antifreeze, PSA specification B71 5100 or equivalent, typically pink/red 🔧 Transmission Standard Manual Gearbox: 5-speed manual (e.g., BE4 series) Optional Automatic Gearbox: Optional on some petrol models (e.g., AL4 automatic transmission) Features Clutch Type: Dry single plate clutch (hydraulic actuation) Fluid Specifications Manual Gearbox Oil: API GL-4, SAE 75W-80 or 75W-90 (specific PSA part number or equivalent recommended) Automatic Gearbox Oil: ATF LT 71141 or equivalent (e.g., PSA S71 2401) 📐 Dimensions Exterior Length: Approx. 4213 mm Width: Approx. 1717 mm (without mirrors) Height: Approx. 1801 mm Interior Seating Capacity: 5 seats (2+3), optional 7 seats in some configurations Cargo Luggage Capacity Seats Up: Approx. 500-600 litres (depending on configuration) Weights Curb Weight: Approx. 1200-1400 kg (depending on engine and equipment) Gross Vehicle Weight: Approx. 1800-2000 kg (check model specific) Towing Towing Capacity: Approx. 600 kg (unbraked) to 1200 kg (braked), check specific model/engine 🛡️ Safety Features Ratings Euro Ncap Rating: Likely 3 stars for frontal impact (typical for its era and segment, specific test data required) Active Features ABS: Standard on most models from 2002 onwards, often with EBD (Electronic Brakeforce Distribution) Traction Control: Optional on some higher-spec models Passive Features Airbags: Driver and front passenger airbags standard; side airbags optional Seatbelts: Pre-tensioners and load limiters for front seats 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, often with basic speaker setup. Aftermarket upgrades are common. Navigation: Rarely fitted as standard, likely an aftermarket option or higher-spec dealer fitment. Driver Assistance Cruise Control: Available as an option on higher trim levels. Connectivity Remote Central Locking: Standard on most models, often with key integrated remote. 🔧 Maintenance Service Intervals Oil Change Interval Petrol: Every...
Direct Injection (HDI), Indirect Injection (XUD-based engines in some markets)
Fuel Type
Petrol Octane Rating:
Unleaded 95 RON recommended
Fluid Specifications
Engine Oil Specification Petrol:
API SL/CF or ACEA A3/B4, SAE 5W-40 or 10W-40 (check specific engine variant)
Engine Oil Specification Diesel:
API CF/CF-4 or ACEA B3/B4, SAE 5W-40 or 10W-40 (check specific engine variant)
Coolant Specification:
Ethylene glycol-based antifreeze, PSA specification B71 5100 or equivalent, typically pink/red
🔧 Transmission
Standard
Manual Gearbox:
5-speed manual (e.g., BE4 series)
Optional
Automatic Gearbox:
Optional on some petrol models (e.g., AL4 automatic transmission)
Features
Clutch Type:
Dry single plate clutch (hydraulic actuation)
Fluid Specifications
Manual Gearbox Oil:
API GL-4, SAE 75W-80 or 75W-90 (specific PSA part number or equivalent recommended)
Automatic Gearbox Oil:
ATF LT 71141 or equivalent (e.g., PSA S71 2401)
📐 Dimensions
Exterior
Length:
Approx. 4213 mm
Width:
Approx. 1717 mm (without mirrors)
Height:
Approx. 1801 mm
Interior
Seating Capacity:
5 seats (2+3), optional 7 seats in some configurations
Cargo
Luggage Capacity Seats Up:
Approx. 500-600 litres (depending on configuration)
Weights
Curb Weight:
Approx. 1200-1400 kg (depending on engine and equipment)
Gross Vehicle Weight:
Approx. 1800-2000 kg (check model specific)
Towing
Towing Capacity:
Approx. 600 kg (unbraked) to 1200 kg (braked), check specific model/engine
🛡️ Safety Features
Ratings
Euro Ncap Rating:
Likely 3 stars for frontal impact (typical for its era and segment, specific test data required)
Active Features
ABS:
Standard on most models from 2002 onwards, often with EBD (Electronic Brakeforce Distribution)
Traction Control:
Optional on some higher-spec models
Passive Features
Airbags:
Driver and front passenger airbags standard; side airbags optional
Seatbelts:
Pre-tensioners and load limiters for front seats
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, often with basic speaker setup. Aftermarket upgrades are common.
Navigation:
Rarely fitted as standard, likely an aftermarket option or higher-spec dealer fitment.
Driver Assistance
Cruise Control:
Available as an option on higher trim levels.
Connectivity
Remote Central Locking:
Standard on most models, often with key integrated remote.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Every 15,000 km or 12 months, whichever comes first (typical for the era).
Oil Change Interval Diesel:
Every 10,000-15,000 km or 12 months, whichever comes first (diesel engines might have shorter intervals).
Timing Belt Interval:
For TU engines: 90,000 km or 5 years. For DW engines (HDI/D): 120,000 km or 5 years (Crucial interval, check manual for specifics).
Air Filter Replacement:
Every 30,000 km or 24 months.
Fuel Filter Replacement Diesel:
Every 60,000 km or 4 years.
Cabin Filter Replacement:
Every 20,000 km or 12 months.
Fluid Specifications
Brake Fluid Specification:
DOT 4 (PSA S71 2113)
Power Steering Fluid:
ATF Dexron II or III, or PSA Fluide Hydraulique 20 (check specific recommendation)
Known Issues
Common Wear Items:
Front suspension bushes, drop links, rear wheel bearings, clutch wear, catalytic converter failure (petrol), glow plugs (diesel)
Electrical Gremlins:
Occasional issues with window regulators, central locking, and dashboard warning lights due to aging wiring or components.
Diesel Engine Specifics:
HDI engines can be prone to injector issues or turbocharger problems if not maintained diligently. 1.9D (DW8) is generally robust but less refined.
HVAC Issues:
Heater matrix leaks or blower motor failure can occur.
📚 Vehicle History
Brand Heritage
Citroen Heritage:
Citroën is a French manufacturer known for innovation, comfort, and often avant-garde design, dating back to 1919.
Model Evolution
Berlingo I Introduction:
Launched in 1996 as a versatile compact MPV, developed alongside the Peugeot Partner.
Berlingo I Facelift:
Received a facelift in 2002 (M59 generation), featuring updated styling, interior refinements, and improved safety features.
Production
Manufacturing Locations:
Primarily manufactured in Spain (Vigo) and France.
Production Period:
First generation produced from 1996 to 2010 (with facelifts).
🏆 Awards & Recognition
Recognitions
Segment Awards:
The Berlingo/Partner platform consistently received positive reviews for practicality and value, often appearing on 'best MPV' or 'best van' lists in its time.
Ratings
Consumer Ratings:
Generally good for reliability and practicality, though specific reliability can vary by engine and individual maintenance history.