check engine Citroen BERLINGO 2005 1.G Workshop Manual

Downloaded from www.Manualslib.com manuals search engine PRESENTATION
THIS HANDBOOKsummarises the specifications, adjustments, checks and special features of CITROËN private vehicles, not including UTILITY vehicles for which there exists a separate
handbook.
The handbook is divided into groups representing the main functions:
GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING.
In each section, the vehicles are dealt with in the following order: C4 - XSARA - XSARA PICASSO - BERLINGO and all models where applicable.
The information given in this handbook is based on vehicles marketed in EUROPE.
Angl-t2-Index-2005 9/01/06 10:05 Page I

Downloaded from www.Manualslib.com manuals search engine GENERAL
C41 - 2
XSARA3 - 4
XSARA PICASSO5 - 6
BERLINGO7 - 8
Operations following a repair: C49
C411 - 12
XSARA13 - 14
XSARA PICASSO15
BERLINGO16
Lubricants17 - 39
ENGINE
Specifications40 - 41
Tightening torques: engines all types42 - 147
Cylinder head tightening: all types148 - 150
Auxiliary drive belt152 - 153
Checking and setting the valve timing181 - 182
C4279
XSARA280
XSARA PICASSO281
Valve clearances282Checking the turbo pressure:
Xsara picasso (DW10ATED)295
Checking the air supply circuit: Xsara (DV4TD)
296
Checking the air supply circuit: C4 (DV6ATED4)297
Checking the air supply circuit: C4 (DV6TED4)298
Checking the air supply circuit: C4 (DW10BTED4)299 - 300
Checking the air supply circuit:
Xsara picasso (DW10TD/ATED)301
Checking the exhaust gas recycling circuit:
Xsara (DV4TD)302
Checking the exhaust gas recycling circuit:
Xsara picasso (DV6TED4)303
Checking the exhaust gas recycling circuit:
Xsara picasso (DW10TD/ATED)304
IGNITION
Sparking plugs305
CLUTCH - GEARBOX - TRANSMISSION
C4307 - 308
Xsara309 - 310
Xsara picasso311
CONTENTS
Vehicle
identification
Capacities
INJECTION
Checking the low pressure fuel supply
circuit: Xsara (DV4TD)283
Checking the low pressure fuel supply
circuit: C4 (DV6TED4/ATED4)284
Checking the low pressure fuel supply
circuit: Xsara Picasso (DV6TED4)285
Checking the low pressure fuel supply
circuit: C4 (DW10BTED4)286
Checking the low pressure fuel supply
circuit: Xsara (DW10TD)287
Checking the low pressure fuel supply
circuit: Xsara Picasso (DW10TD/ATED)288 - 289
Checking the turbo pressure: Xsara (DV4TD)
290
Checking the turbo pressure:
C4 (DV6TED4/ATED4)291
Checking the turbo pressure:
Xsara Picasso (DV6TED4)292
Checking the turbo pressure:
C4 (DW10BTED4)293
Checking the turbo pressure:
Xsara picasso (DW10TD)294
Checking the oil
pressureClutch
specifications
Angl-t2-Index-2005 9/01/06 10:05 Page III

Downloaded from www.Manualslib.com manuals search engine CLUTCH - GEARBOX - TRANSMISSION (continued)
Gearbox specifications312 - 314
Clutch specifications315 - 316
Checking and adjusting the hydraulic
clutch control317 - 318
Tightening torques: manual gearbox
319 - 330
Manual gearbox controls
331 - 343
Recommendations - precautions:
automatic gearbox344 - 346
Tightening torques: manual gearbox
347 - 349
Automatic gearbox controls
350 - 359
Driveshafts360
AXLES - SUSPENSION - STEERING
Axle geometry: C4361 - 364
Tightening torques: front axle365 - 366
Tightening torques: rear axle367
Tightening torques: power steering368 - 369
Setting the steering rack mid-point370
Checking the power steering pressure371 - 374
Axle geometry: Xsara375 - 379Adjusting the handbrake 426
Filling, bleeding the brakes427
AIR CONDITIONING
R134.a: quantities428
Checking the compressor lubricant429 - 430
Pollen filter: all types431 - 433
Filtering and drying cartridge434 - 436
Checking the efficiency of the circuit437 - 446
C4447 - 451
Xsara452
Xsara picasso453 - 456
CONTENTS
Tightening torques: front axle380
Tightening torques: rear axle382
Tightening torques: steering 383 - 384
Tightening torques: power steering385 - 387
Axle geometry: Xsara Picasso388 - 392
Tightening torques: front axle393
Tightening torques: rear axle394
Tightening torques: power steering395 - 397
BRAKES
Brake specifications: C4398 - 399
Tightening torques: Brakes401 - 403
Adjusting the handbrake 405
Filling, bleeding the brakes406 - 410
Brake specifications: Xsara411
Tightening torques 414
Brake specifications415 - 418
Adjusting the handbrake 419
Filling, bleeding the brakes420
Brake specifications: Xsara Picasso421 - 422
Brake specifications423 - 424
Aircon circuit
Angl-t2-Index-2005 9/01/06 10:05 Page IV

Downloaded from www.Manualslib.com manuals search engine 10
GENERAL
Draining methods
Oil capacities are defined according to the following methods
CAPACITIES (in litres)
Draining of the engine lubrication system by GRAVITY
Place the vehicle on horizontal ground
(in the high position if
hydropneumatic suspension)
.
The engine should be hot
(oil temperature 80°C).
Drain the sump by gravity.
Remove the oil filter cartridge
(time for draining and drip-drip = 15
minutes approx.)
.
Refit the cap with a new seal.
Refit a new oil filter cartridge.
Refill the engine with oil
(see table for oil capacity).
Start the engine to fill the oil filter cartridge.
Stop the engine
(allow to stabilise for 5 minutes).Draining of the engine lubrication system by SUCTION
Place the vehicle on horizontal ground
(in the high position if
hydropneumatic suspension).
The engine should be hot (oil temperature 80°C).
Remove the oil by suction through the dipstick tube.
Remove the oil filter cartridge.
Maintain the suction of oil in the sump
(15 minutes approx.).
Refit a new oil filter cartridge.
Refill the engine with oil
(see table for oil capacity).
Start the engine to fill the oil filter cartridge.
Stop the engine
(allow to stabilise for 5 minutes).
WARNING: Remove the suction container before starting the engine.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 10

Downloaded from www.Manualslib.com manuals search engine 11
GENERAL
C4 CAPACITIES (in litres)
1.4i 16V 1.6i 16V 2.0i 16V 2.0i 2.0i 16V
KFU NFU RFN RFJ RFK
3,75 3,25 4,25 5 5,5
1,2 1,5 1,7 1,7 1,5
2 ± 0,15 2 2
(1) (1)
With ESP = 0,85 Without ESP = 0,75
5,8 6,2 6,2 (2) - 6,6 (3) 6,2 (2) - 6,6 (3) 6,6
6,7 6,8 (2) - 6,9 (3)
0,85
60
Petrol
IMPERATIVE: Systematically check the oil level using the oil dipstick.(1) = The gearbox is lubricated for life (as a guide, the TOTAL capacity is5.85 litres after draining3 litres).
(2) = Temperature37°C. (3) = Temperature 45°C. Engine type
Oil capacity with change
of cartridge
Between Min. and Max.
Manual gearbox
Automatic gearbox
After draining
Braking circuit
Cooling circuit
Manual gearbox
Automatic gearbox
Steering electro-pump
reservoir
Fuel tank
AUTO.AUTO.
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 11

Downloaded from www.Manualslib.com manuals search engine 12
GENERAL
Engine type
Oil capacity with change
of cartridge
Between Min. and Max.
Manual gearbox
Braking circuit
Cooling circuit
Additive reservoir
Steering electro-pump
reservoir
Fuel tank9HX 9HY 9HZ RHR
3,75 5,25
1,55 1,9
2 2,7
With ESP = 0,85 Without ESP = 0,75
6,5 8,1
2,5 2,5
0,85
60
CAPACITIES (in litres)
Diesel
1.6 HDi 16V 2.0 HDi 16V
NOTE: (*) = Version with additional heating.
IMPERATIVE: Systematically check the oil level using the oil dipstick.
C4
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 12

Downloaded from www.Manualslib.com manuals search engine 13
GENERAL
Engine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tankKFW NFU RFN
3 3,25 4,25
1,5 1,5 1,7
21,9
66
33
With ABS = 0,50 Without ABS = 0,55
7
6,5
6,5 (1)
54
XSARA
CAPACITIES (in litres)
Petrol
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4i 1.6i 16V 2.0i 16V
AUTO.AUTO.
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 13

Downloaded from www.Manualslib.com manuals search engine 14
GENERAL
Engine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tank8HX 8HZ 8HX 8HZ 8HY WJY WJY RHY RHZ
3,75 4,5 3,75 4,5
1,8 1,5 1,8 1,5 1,2 1,8 1,4
2 1,8
8,3
5,3
With ABS = 0,50 Without ABS = 0,55
5,7 9 8,5
54
XSARA
CAPACITIES (in litres)
Diesel
(1) =➔RPO 9337 (manual dipstick with two twists).
(2) = RPO 9338 ➔(manual dipstick without twists but with a sphere).
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4 HDi 1.4 16V HDi 1.9D
AUTO.
2.0 HDi
➔ RPO RPO➔ RPO RPO
9884 9885 ➔9884 9885 ➔(1) (2)
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 14

Downloaded from www.Manualslib.com manuals search engine 15
GENERAL
Engine type
Engine with filter element filtrante
Between Min. and Max.
5-speed gearbox
Automatic gearbox
After draining
Hydraulic or brake circuit
Cooling circuit
Fuel tank capacity
NFV 6FZ RFN 9HZ 9HY RHY
3 4,25 3,75 4,5
1,5 1,7 1,55 (3) 1,4
1,81,8
6
3
0,58 litres
5,8 (1) and (2) 6,5 (1) and (2) 11 11 (1) and (2)
55 60
XSARA PICASSO CAPACITIES (in litres)
Diesel Petrol
1.6i1.8i 16 V 2.0i 16V 1.6 16V HDi
(1) = With air conditioning.
(2) = Without air conditioning.
(3) = RPO 9884 ➔ = Restyled XSARA PICASSO.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
AUTO.
2.0 HDi
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 15

Downloaded from www.Manualslib.com manuals search engine 16
GENERALEngine type
Engine with filter element
Between Min. and Max.
5-speed gearbox
Hydraulic or brake circuit
Cooling circuit
Fuel tank capacity
HFX KFW NFU 9HX WJY RHY
3 3,25 3,75 4,5
1,5 1,55 1,2 1,4
2 1,8
With ABS = 0,45 - Without ABS = 0,36
89
55 60
BERLINGO CAPACITIES (in litres)
Diesel Petrol
1.1i 1.4i1.6i 16V
2.0 HDi
1.9 D
(1)
(1) = Manual dipstick without twists but with a sphere.
ESSENTIAL: Systematically check the oil level using the oil dipstick.
1.4i 16V HDi
Angl.-t2-page001-39-2005 9/01/06 10:07 Page 16