🏷️ Basic Information Identification Make: Citroën Model: Berlingo Year: 2004 Engine Type: Petrol Engine Code Prefix: NFU (likely for 1.6i 16V, but specific code can vary) Generation Generation: First Generation (Mk1, GVA/GVK) Codes Platform: PSA Platform 1 👋 Introduction Market Position Vehicle Segment: Compact MPV (Multi-Purpose Vehicle) / Leisure Activity Vehicle Target Audience: Families, individuals requiring flexible cargo space and practicality Competitive Analysis Key Competitors: Peugeot Partner, Renault Kangoo, Volkswagen Caddy Key Features Versatility: Highly adaptable interior with sliding rear doors and large cargo volume Practicality: Designed for utility and everyday family use, often available in passenger and commercial variants Affordability: Typically offered at a competitive price point in its segment 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, maintenance, and repair Page Count Estimated Page Count: Likely 1000+ pages, typical for a full factory service manual Manual Type Manual Type: Factory Service Manual / Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine: 1.6i 16V (NFU engine family), including tuning, diagnostics, and overhaul Fuel System: Fuel injection system (Bosch Motronic or similar), fuel pump, injectors, fuel filter replacement Ignition System: Spark plugs, coils, ignition timing, coil-on-plug diagnostics Cooling System: Radiator, coolant, thermostat, water pump, fan operation, hoses Exhaust System: Catalytic converter, mufflers, exhaust manifold, lambda sensors Transmission: Manual transmission (ML5C or similar), clutch, gearbox overhaul, fluid changes Brakes: Front and rear disc brakes, ABS system, brake fluid flush, caliper and pad replacement Steering: Power steering system, steering rack, tie rods, wheel alignment specifications Suspension: Front MacPherson struts, rear torsion beam suspension, shock absorbers, bushings, control arms Electrical System: Battery, alternator, starter motor, lighting system, fuses, relays, wiring diagrams Climate Control: HVAC system, heater core, A/C compressor, refrigerant, blower motor Body And Chassis: Body panel removal and installation, door mechanisms, tailgate, interior trim Diagnostics: OBD-II diagnostic trouble codes (DTCs), troubleshooting guides, scan tool usage Procedures Included Routine Maintenance: Oil and filter change, air filter replacement, spark plug replacement, coolant flush Major Repairs: Engine rebuilds, transmission overhauls, cylinder head removal and reassembly Troubleshooting: Step-by-step guides for diagnosing common problems, electrical faults, and mechanical failures Component Replacement: Detailed instructions for replacing parts like alternators, starter motors, water pumps, and fuel injectors Electrical Diagnostics: Locating shorts, open circuits, and diagnosing sensor faults using wiring diagrams Body Work: Minor dent repair, panel alignment, trim removal and fitting Technical Depth Depth Of Information: Full factory-level detail, suitable for professional technicians and advanced DIYers Diagnostic Charts: Comprehensive diagnostic flowcharts for various symptoms Torque Specifications: Detailed torque values for all critical fasteners Clearances And Tolerances: Precise specifications for engine component clearances and wear tolerances Wiring Diagrams: Complete and detailed electrical schematics for all vehicle systems Illustrations: High-quality exploded views, diagrams, and illustrations for clarity 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full printable, allowing users to print specific pages or sections Zoom Capability: Yes, allows zooming in on diagrams and text for clarity Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: TU5JP4 (common for 1.6i 16V in this era) Engine Configuration: Inline 4-cylinder, DOHC (Double Overhead Camshaft) Displacement: 1587 cc Bore X Stroke: 78.5 mm x 82.0 mm (typical for TU5JP4) Compression Ratio: 10.8:1 (typical for TU5JP4) Performance Horsepower: Approximately 109 PS (108 bhp / 80 kW) at 6000 rpm (typical for TU5JP4) Torque: Approximately 147 Nm (108 lb-ft) at 4000 rpm (typical for TU5JP4) Fuel System Fuel Delivery: Multi-point fuel injection (MPFI) Fuel Type: Unleaded Petrol (RON 95 recommended) Emission Control: Euro 3 compliant, catalytic converter, lambda sensors 🔧 Transmission Standard Type: 5-speed Manual Transmission (e.g., ML5C) Optional Type: 4-speed Automatic Transmission (AL4, less common for 1.6i 16V in this year) Features Clutch Type: Hydraulically operated single dry plate clutch 📐 Dimensions Exterior Length: Approx. 4213 mm (standard wheelbase) Width: Approx. 1721 mm (excluding mirrors) Height: Approx. 1800 mm Cargo Luggage Capacity: Approx. 505 litres (seats up, rear seats can be removed/folded for much more) Weights Curb Weight: Approx. 1280 kg (varies with trim and options) Gross Vehicle Weight: Approx. 1900 kg (typical) 🛡️ Safety Features Ratings Euro Ncap Rating: 4 stars (for the 2002 model year update, 2004 would be similar) Active Features ABS: Standard on most variants, with EBD (Electronic Brakeforce Distribution) Passive Features Airbags: Driver and passenger front airbags standard, optional side airbags Seatbelts: 3-point seatbelts with pre-tensioners and load limiters 💡 Technology Features Infotainment Audio System: Factory fitted CD/Radio with steering wheel controls on higher trims. Display: Multi-function display for trip computer, audio, and climate control. Driver Assistance Cruise Control: Optional on some models. Connectivity Central Locking: Remote central locking with key fob. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 20,000 km or 1 year, whichever comes first (check manual for exact specification). Spark Plug Replacement:...