2002 PEUGEOT PARTNER Service and Repair Manual

Citroen Berlingo & Peugeot Partner Owners Workshop Manual John S. Mead Models covered Crtroen Ber1ingo Multispace & Van and Peugeot Partner Combi & Van, including spec iaVI imited ed iti ons Petrol engines: 1.4 litre (136Occ) & 1.6 litre (1587cc) Diesel engines: 1.Blitre ( 1769cc ), 1.9 litre ( 1868cc & 1905cc) & 2.0 litre ( 1997cc ). I nc. turbo Does NOT cover models with I.Blitre (J 76fcc ) petrol engines C Haynes Publishing 2006 A book in the Haynes Service end Repair Manual Series All righU ...-veci. No part of this book may be ,...,.-odue«S Of' transmitted In any '00'I'I Of by any ~."*, electronic: or mec:hanic.I, inc:luding phot : :;~hlg, ......... diiljjj or by ""'" 1nf0fTJWti0n stonve or rebift81 ~ without ptiii' · slon in writing from1he p. iglll hoIdw. ISBN 1 84425 281 7 British Ubniry Cata60gung In Publication DalII A cataIogIIe record for ttis booIt Is tIY8lIabIe from the British Ubmry. Printed ,"!he USA Hayne, Publl$hi!'lg Spatl<ford, Yeovil. Somerset BA22 7JJ, Englsnd I1aynH NOfttI~, lne 861 Lawnnce DfIo.Ie.~ Park. CaIifomia91320, USA . ...... - 4. Rue de rAbreuYoir 92415 COURBCVOlE CEDEX. Ffance HiJ)'IW' PubIsNng Nofdi.u AB Box 1504, 751 45 UPPSALA. Sverige (4281 - 368 )

Contents LIVING WITH YOUR CITROEN BERLlNGO & PEUGEOT PARTNER Safety firstl Page 0·5 Introduction to the Citroen 8ertingo & Peugeot Partner Page 0·6 Roadside repairs If your car won't start Page 0·7 Jump starting Pag e 0·8 Wheel changing Page 0·9 Identifying leaks Page 0-10 Towing Page 0-10 Weekly checks Introduction Page 0-11 Underbonnet check points Page 0-11 Engine oil level Page 0-13 Coolant level Page 0-14 Screen washer fluid level Page 0-14 Power steering fluid level Page 0-15 Brake fluid level Page 0- 16 Wiper blades Page 0-16 Batte<y Page 0-17 Electrical systems Page 0-17 Tyre conditMln and pressure Page 0-18 Lubricants and fluids Page 0-19 Tyre pressures Page 0·20 MAINTENANCE Routine maintenance and servicing Citroen Berlingo & Peugeot Pa rtner petrol engine models Page 1A-1 Servicing specifications Page 1A-2 Maintenance schedule Page lA-6 Maintenance procedures Page lA-7 Citroen Berlingo & Peugeot Partner diesel engine models Page 18-1 Servicing specifications Page 10-2 Maintenance schedule Page 10- 6 Maintenance procedures Page lS-7 Illegal Copying It Is the policy of Haynes Publishing to actively protect its Copyrights and Trade Mar1<s. Legal action will be taken against anyone who unlawfully copies the cover Of contents of this Manual. This Includes alllorms of unauthorised copying InclUding digital, mechanical, and electronic in any form. Authorisation from Haynes Publishing will only be provided expressly and In writing. Illegal copying wOI also be reported to the appropriate statutOf)' authorities.

REPAIRS AND OVERHAUL Engine and associated systems Petrol engine in.-car repair procedures 1.8 and 1.9 litre diesel engine (XUO series) In-car repair procedures 1.9 and 2.0 litre diesel engine (DW series) in-car repair procedures Petrol engine removal and overhaul procedures Diesel engine removal and overhaul procedures Cooling, heating and air conditioning systems Fuel and exhaust systems - petrol models Fuel and exhaust systems - '.8 and 1.9 litre (XUD series) diesel models Fuel and exhaust systems - 1.9 and 2.0 litre ~W series) diesel models Emission control systems Starting and charging systems Ignition system - petrol models Pre/post·heating system - diesel models Transmission Cl utch Manual transmission Oriveshafts Brakes, Suspension and Steering Braking system Suspension and steenng Body Equipment BodywOf1< and fittings Body electrical systems Wiring diagrams REFERENCE Dimensions and weights Conversion factors Buying spare parts Vehicle identification Jacking and vehicle support General repair procedures Disconnecting the battef'Y Tools and working facilities MOT test checks Fault finding Glossary of technical terms Index Conte nts Page 2A.' Page 28-1 Page .c., Page 20-1 Page 2E-1 Page 3·' Page 4A-1 Page 4S- 1 Page 4C., Page 40-1 Page SA·, Page 5S-1 Page se·, Page 6·' Page 7·' Page e·, Page 9·, Page 10-1 Page 11-1 Page 12-1 Page 12-19 Page REF-, Page REF·2 Page REF-3 Page REF-3 Page REF-3 Page REF-4 Page REF-S Page REF-6 Page REF-e Page REF-12 Page REF-21 Page REF-26

0-4 Introduction Advanced driving Many people see the words 'advanced driving' and believe that it won't Interest them or that it Is 8 style of drivIng beyood their own abilities. Nothing could be further from the truth . Advanced driving Is straightfOfWard safe. sensible driving - the sort of driving we should all do every time we get behind the Wheel. AA average or 10 people are killed evety day 00 UK roads and 870 more are ~jured. some seriously. Uves are ru ined dally. usually because somebody did something stupid. Something Uke 95% of aD accidents are due to human error, mostly driver failure. Sometimes we make genuine mistakes - everyone does. Sometimes WiI have lapses of concentl1lltion. Sometimes we deliberately take risks. For many people, the process of 'Ieamlng to drive' doesn't go much further than learning how to pass the drivIng test because of a common belief that good drivers are made by 'experience' . le arning to drive by 'experience' teaches three driving skills: o Quick reactions. (Whoops, that was close!) o Good handling skills. (Horn, swerve, brake. horn). o Reliance on vehicle technology. (Great stuff this ASS, stop in no distance even in the wet ••. ) Orivers whose skills are 'experience based ' generally have a lot of near misses and the odd accldent. Tl)e results can be seen every day in our courts and our hospital casualty Advanced drivers haVil leamt to control the risks by controling the position and speed of their vehicle. They avoid accidents and near misses. even if the driveB around them make -. The key skills of adVanced driving are concentration, effective all-round observation, anticipation and plann i ng. When good vehicle handling is added to these skills, all driving situations can be approached and negotiated in a safe, methodical way, leaving nothing to chance. Concentration means applying your mind to safe driving , completely excluding anything that's not relevant. Ofiving Is usually the most dangerous activity that most of us undertake In our daily routines. It deserves our full attention. Observation means not just looking, but seeing and seeking out the Information found In the driving environment. Anticipation means asking yourself what Is happening, whal you can reasonably expect 10 happen and what could happen unexpectedly. (One of the commonest words used in compiling accident reports Is ' suddenly' .) Planning is the link between seeing something and taking the appropriate action. For- many drivers, planning is the missing link.. If ~ want 10 become a safer and more skiful driver and you want to er10y you" diving more, contact the Institute of Advanced Motorists at www.iam.org.uk, phone 0208 996 9600, or write to lAM House, 510 Chiswick High Road, London W4 SAG for an Information pack.

Working on your C3I" can be dangerous. This page shows just some of the potential risks and hazards. with the aim of aeating a safety-conscious attitude.. General hazards Scal ding • Don't remove the radiator Of expansion tank cap while the engine is hot. • Engine 011, automatic transmission fluid Of power steering fluid may also be dangerously hot if the engine has recentty been running. Burn i ng • Beware of bums from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot Immediately after use. Crushing • When working under or near a raised vehicle, always supplement the Jack with ax1e stands, Of use dm..-oo """PS. N_ lIent unJ under., car which Is only supported by a jack. • Take CBf"9 if loosening Of tightening high- torque nuts when the vehicle Is on stands. Initial loosening and final tightening should be done with the wheels on the groLnd . Fire • Fuel Is highly flammable; fuel vapour Is explosive. • Don't let fuel spill onto a hot engine. • Do not smoke or allow naked lights (Including pilot li ghts) anywhere near a vehicle being wor1ted on. Also beware of creating spar1<.s (electrically or by use of tools). • Fuel vapour is heavier than air, so don't wOl1t on the fuel system with the vehicle over an nspectioo pit. • Another cause of fire is an electrical ovef1oad or short-cin::uit Take care 'Nhen repairing or modifying the vehide wiring. • Keep a fire extinguisher handy. of a type suitable fOf use on fuel and electrical fires. Elecbic shock 1, • ""';on HT F::;:;;i~~ vottage can be "l. dangerous. - especially to people with heaIt problems Of a ..r pacemakE!f". Don't ./ w~ on or near the ) ..... Ignition system with J J • , \" ... the engine running or , , the ignition switched on . • Mains voltage Is also dangerous. Make sure that any mains-operated equipment Is correctly earthed. Mains power points should be protected by a residual current deYk:e (ReD) circuit breaket". Fume or gas i ntoxicati on • Exhaust fumes are poisonous; they often oootain cart>on monoxide, which Is rapidly fatal if inhaled. Never run the engineina confined space such as a garage wit h the doors shut. • Fuel vapour Is also poisonous, as are the vapours from some cleaning solvents and paint thlnners. Poisonous or irri tant substances • Avoid skin contact with battery acid and with any fuel, fluid or lubricant, aspeciaIly antifme.ze. brake hydraulic ftuid and Diesel fuel. Don't syphon them by mouth. If such a substance is swallowed or getS Into the eyes, seek medical advice. • PI aloe !Qed contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream If necessary. Change out of oil- soaked dothes and do not keep oily rags in "'" pock"'- • Air conditioring refrigerant forms a poisonous gas if exposed to a naked flame (1fICluding a cigarette). It can also cause skin burns on contact. Asbestos • Asbestos dust can cause cancef If inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it Is safest to assume that they contain asbestos. Remember ••• DO • 00 use eye protection when using power tools, and when worIong lrIder the veNcIe. • 00 wear g60ves Of" use barrier cream to protect your hands when 1« my. • 00 get someone 10 check JAM iodicaIly that an is well when wor1dng aione on the vehicle. • 00 keep loose cIothiog and long hair well out of the way of tnOI/lng mechanical parts. • 00 remove rings, wristwatch etc, before working on the vehicle - especially the electrical system. • Do ensure that any lifting Of jaclOOg equipment has a safe wor1ting load rating adequate fOf the job. Safety first! 0. 5 Special hazards Hy drofluoric ac id • This extremety corrosive acid Is formed when certain types of synthetic n.Dber, found In some Q..rings. oil seals, fuel hoses etc, are exposed to temperatures above 400"C. The rubber changes into a charred or sticky substance containing the acid. Once fotmed, the acid remains dangerous for years. tf it gets onto the skin, it may be necessat)' to amputate the limb COiIC6'iiI6d. • When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use. The batte ry • Batteries cont ain sulphuric acid, which attacks clOthing, eyes and skin. Take care when topping-up or carrying the battery. • The hydrogen gas given off by the battery Is highly explosive. Never cause a spartt ()( alJow a naked light nearby. Be careful when connecting and disconoecting battery chargers Of" )limp leads. Ak bag s • IW bags can cause injury if they 90 off aoddentaIty. Take care when removing the steering wheel 300101 facia Special storage Iosttuctions may apply. Diesel injec ti on equ i pment • Diesel injection pumps supply fuel 81 very high prf!SSlK8. Take care when worlUng on the fuel injectOfS and fuel pipes. A Waming: Never expose the hands, , face or any other part of the body • to injector spray; the fuel can pene trate the skin wi th potentially fatal results. DON'T • Don't attempt to lift a heavy component which may be beyond your capability - get ~ • Don't rush to finish a job, Of" take .......... , ""'" cuIs. • Don't use lA-fitting tools which may sip and cause injury. • Don't leave tools Of" parts lying ~ whefe someone can trip 0'Vf!# them. Mop up 011 and fuel spills at once. • Don't slow children or pets 10 play In or ..,. a velicle being worked on.

0-6 Introduction to the Citroen 8erlingo & Peugeot Partner Designed as a joint venture between Citroen and Peogeot. the Bet1lngo and Partner were Introduced Into the UK In 1996 as purpose-built Vans available in 600kg or- 800kg payIoads. To increase the appeal of the range, the 8ertingo Multispace MPV was intrOdI.J(;ed in mkl-1998. The Muttlspace is mechanically identicaJ to the Van V9fSlon but with the addition of rear seats. side windows and additional interior trim. Initially. all models were available only in three-door format, but in mid-l999, the option of a sliding side door on the right-hand side was added. The Peugeot MPV version, known as the Partner Comb!, joined the model line-up for the 2001 model year. which also saw the introduction, on all models, of a second sliding side door for the left-hand side. In the autumn of 2002, the enUre range underwent a major faeell«. wi th significant styling changes to the Iront bumpers, headlights, bonnet and front wings, together with numerous mechanical and electrical - O\.ring the production run a variety of petrol and diesels engi nes have been offered according to model and year of production . These include 1.4 litre (136Occ), and 1.6 litre (1 587cc) petrol engines, and 1.8 litre (1769cc), 1.9 litre (1868cc &1905cc) and 2.0 litre ( 1997cc) diesel and turbo-diesel engines. A 1.8 litre 11761cc) petrol engine was also available for a limited period on early models, but is not covered in thi$ manual. The engi nes are all of four-cylinder si ngle- or double- overtlead camshaft design and are vernions of the well-proven units which have appeared in many Gitroiin and Peugoot vehicles over the years. All engines are fitted with a manual tr ansmission as standard and are mount ed transversely at the front of vehicle, with the transmission mounted on the left-hand end. The front suspension is of the fully- Independent MacPhersoo strut type, incorporating shock absorbers, coil springs and an anti-roll bar. The rear suspension is derived from the Peugeot 405 range and is of the semHndependent type with torsion bars and trailing anns_ Rack-and-pinion steering gear Is used with power assistance available on most models. A wi de range of standard and optional equipment is available within the range to suit most tastes, including power steering. central locking. engine immobiliser. electric windows, electric sunroof and alrbags. An anti-lock braking system and air conditioning system are also available as options, or standard equipment on certain model s. Provided that regular servicing Is carried out In accordance with the manufacturer's recommendations, the vehicle should prove reliable and very economical. The engine compartment is well-designed. and most of the items requiring frequent anention are easily accessible. Your Owner's Manual The aim of this manual is to help you get the best value from your vehicle. It can do so In several ways. It can help you decide what WOf1I; must be done (even shou6d you choose to get It done by a garage), provide information on routine maintenance and set'lricing, and give a logical course of action and diagnosis when random faults OCCtJr. However, It Is hoped that you will use the manual by tackling the work yourself. On simpler Jobs it may even be quicker than booking the vehicle into a garage and going there twice. to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the funct ion of the various components so that their layout can be understood. Tasks are described and photographed in a clear step-by-step sequence. References to the 'Ieft-hand' and 'rlght- hand' sides of the vehicle are always In the sense 01 when viewed by a person sat in the driver's seat, facing forwards. Acknowledgements Thanks are due to Draper Tools Umlted, who provided some of the worll.shop tools. and to all those people at Sparkford who heiped in the production of this Manual. We take great pride in the accuracy of information gi ven in thi s manual, but vehicle manufacturers m ake atterations and design changes during the producdon run of a particular vehicle of whkh they do not inform us . No liability can be accepted by the auth ors or publi s hers for toss, damage or injury ca used by errors In, or omissions from, the information given.

• The following pages are i ntended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair Information in the main chapters. If your car won't start and the starter motor doesn't turn o Open the bonnet and make sure that the battery terminals are clean and tight. o Swnch on the headlights and try to start the engine. tf the headlights go very dim when you're trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend's car. Roadside repairs 0-7 If your car won't start even though the starter motor turns as normal o Is there fuel in the tank? o Is there moisture on electrical components under the bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent 8erosc:M product (WD-40 or equivalent) on ignition and fuel system electrical connectOfS like those shown in the photos. A Check the secunty and condition of the battery connections. B On petrol engIneS check that the ignition HT coli wiring connector is securely COJV18Cted (1.4 litnt petrol model shown). C Also check the security of the wiring connectors at the various engine management sensors such as the coolant temperature sensor. Check that all eIectricaJ connec:tIons are secure (with the ignition swi1ched off) and spray them E Check that all fuses are stin in good with a water-dispersa1t spray like WD-4O if you suspect a problem due to damp. condition and none have blown.

o-s Roadside repairs Jump starting When jump-starting a car using a booster battery. observe the following precautions: '" Before connecting the booster battery. make sure that the ignition is switched off. '" Ensure that all electrical equi pment Qights, heater, wipers. ete) is switched off. '" Take note of any special precautions printed on the battery case. --------., I I '" Make sure that the booster battery is the same voltage as the discharged one in the vehicle. '" If the battery is being jump-started from the battery in another vehicle. the two vehicles MUST NOT TOUCH each other. .,. Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission). ~;;;;~ ... ;;;Ootl;;;;18i end of the red lead to the positive (+) terminal of the booster battery. -----, I I I ,.- ~-----------------------------~ • of trouble, but)'OCl must comtCt ~ Jump starting will get you out HIN what_ nYdIt the ~tt8tY go flat i'J the first ~ TIHtre are thme possibilities: 1 The battM)' has been drained by repeated attempts to start, Of' by leaving the lights on. 2 The charging system Is not worldng p!OIJa 1) (altematordrivebelt slack or bnHten, alternstor wiring fsult or alternator Itself faulty ). 3 The bBttfH)' Itseff is at faun (electrolyte low, or battery worn out). Connect the other end of the black Jump lead to a bolt or bnIcket on the engine bkx:k, well away from the battery, on the 'J9tjcle to be started. I Make SlXe that the jump leads wII not come into contact with the fan, drive- belts or other moving parts of the engine. I Start the engine using the booster • battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then d iSCOf'lnect the jump leads in the reverse order 01 connection. Tum off the tights etc.

Roadside repairs o.g Wheel changing Some of the detaJls shown here will vary according to model. For instance, the location of the spare wheel and jaCk Is not the same on at] vehicles. However, the basic principles apply to all vehicles. Waming : Do not change 8 wheel In 8 situation where you risk being hit by other traffIC. On busy roads, try to stop in a lay-by or a gateway. Be wary o( passing traffic while changi ng the wh_1 - it ;s easy to become distracted by the job in hand. Preparation o When a puncture occurs, stop as soon as it Is safe to do SO. D Park 0f1 firm level ground, if possible, and well out of the way of other traffic. D Use hazard warning lights if necessary. o If you have one, use a warning triangle 10 alert other drtvers of your presence. o Appfy the handbrake and engage fll'St Of reverse gear. o Chock the wheel diagonally opposite the one being removed -a chock is provided Wl the tool kit for this purpose. o "the ground is soft, use a ltat piece of wood to spread the load under the jack.. 3 At the rear of the load area, 11ft up the floor covering and use the wheelbrace to lower the spare wheel cradle . 6 On models with steel wheels, remove the wheel trimlhub cap (as applicable). 9 Securely tighten the wheel bolts in a diagonal sequence then refit the wheel trimIhub cap (as applicable). Changing the whee l 1 The jack and wheelbrace are stored betWnd the drivef's seat on Van models ... 4 Disengage the cradle from the lifting hook and slide the spate wheel out from under the vehicle. On Multispace and Combi models, remove the wheel chock from the centre of the spant ~ (on Van models. the chock is stored befljnd the ciiver's seat). 7 USing the wheelbrace, slacken each wheel bolt by half a turn . On models with alloy wheels, use the special tool to undo the locking wheel nuts. Fi nally ... o Remove the wheel chock. . • • and behind a cover panel on the rear right -hand side on Muttispace and Combi models. 5 Position the jack on firm ground below the reinforced area on the sill Qndicated by a triangle - arrowed). Using the wheelbrace, extend the lack until the jack head correctty engages with the siB. Using the chock supplied, chock the wheel diagonally opposite the one being removed. 8 Raise the jack until the wheel Is clear of the ground, then unscrew the wheel bolts and remove the wheel. Place the wheel lM"Ider the vehicle sia in case the jack falls. F"r! the spare wheel and saew in the bolts. Ughtly tighten the bolts with the wheel brace, then Iowef the vehide to the gromd. o Stow the jack and tools in the correct locations In the vehicle. o Check the tyre pressure on the wheel Just fitted. If it Is low, or if you don't have a pressure gauge With you, drive sloWly to the nearest garage and Inflate the tyre to the right ~e. o Have the damaged tyre or wheel repaired as soon as possible.

2002 PEUGEOT PARTNER Service and Repair Manual

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