Citroën Berlingo Electrique/Service Manual

__TOC__ This service manual is created and maintained by Berlingo Electrique users. Vehicle production numbers The vehicle production numbering system used on the Berlingo contains a replacement part number and the manufacturing country. The number is found on the driver's door hinge pillar and the format is as follows. <Replacement Part Number><Manufacturing Country> <Unknown> For Example: 08849FV 10445EQPAxx 08849 = Replacement Part Number and represents the number of production days (where 330 days/year) FV = Manufacturing Country Service schedule Procedure Manufacturer'sRecommendedServiceInterval Best PracticeRecommendedServiceInterval Cost Hours Battery Watering Overcharge = 1000AH Overcharge = 500AH £15 @ Aug 2007 0.5 hours Motor Brush Replacement ? 10kmiles £100 @ Aug 2007 2 hours Technical Information On Board Diagnostic Format The Berlingo Electrique uses the OBD-II (http://en.wikipedia.org/wiki/On-board_diagnostics) Simulation of Drive Train A good simulation of the vehicle drive train is given at (http://www.docstoc.com/docs/44374842/Modeling-and-Simulation-of-different-Hybrid-Electric-Vehicles-in) Fault finding and repairs Problem Summary Solution Cost Battery cell manufacturing weakness, causing short-circuit and a steam explosion. This is only a problem for vehicles with replacement part numbers of 07945 or earlier. Replace faulty cells. The most common problem - failure to charge. See click on Faults on External Site Door light switch stops working. Replacement £3 (parts) Door locks become difficult to use. Replacement Radiator fan stops working. Replacement Petrol heater does not work after a period of inactivity. 1) Refill with fuel2) If fuel ok reset heater £0 Charges to 50% and then the Electrical Fault lamp comes on and the car cannot be charged any more. See click on Fault-finding on External Site Cooling pump impeller is stuck. See click on Fault-finding on External Site Charger short circuits and becomes unusable while the rest of the car works perfectly. See click on Fault-finding on External Site The motor goes in jerks or it does not recharge in overrun. See click on Fault-finding on External Site See also brush replacement. Reduced range (caused by cold batteries) in winter. See click on Fault-finding on External Site Damage to the batteries . See click on Fault-finding on External Site Excessive noise from engine bay when stopped (vacuum pump comes on for more than about 15 sec in about 2 minutes Check vacuum hoses. If hoses are in good condition check the blue plastic cap of the vacuum regulator on the right side of the vacuum pump which is accessible from under the car near the front right wheel well. The cap splits and creates a leak. Replace with another cap that fits tightly, or repair cap with silicone caulk and let cure over night. Don't touch the regulation screw (nut) under the cap. Only after this repair consider pump replacement. replace vacuum pump. Parts = £160?Aug 2007Labour=? hrs External links An extensive web page is available at http://www.berlingo-e.co.uk Additional resources are available from the UK Battery Vehicle Society. Data-sheets The best information seems to be from http://www.berlingo-e.co.uk and click "Manuals". Parts Supplies Part Description Replacement Notes 12v Aux Battery UK No: 063 Less than half the cost of Citroen's replacement.