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Subframe bolts - Torque settings, 2.0HDi

July 20, 2016, 4:42 pm
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Can some kind person please tell me the torque settings for the front subframe bolts on a 2.0Hdi on an 04 plate? I can't find my Haynes, and obviously when I advertise the vehicle for sale, it starts knocking.

Thanks all!
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Front brakes binding

July 21, 2016, 9:23 am
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Hi All

I have a 2007 Berlingo Van 1.6. I had a problem with the rear brakes binding. I have changed the drums and shoes and changed the front disks and pads at the same time as they were quite badly scored.

The rear brakes now seem ok but the front ones are now binding quite badly. The front O/S disk turned a nice straw colour.

I've fully bled the system twice and cleaned the pistons.
I cleaned all the caliper pins and re-greased them.
The ABS light is on and brakes are binding quite badly. They are very hot in a short distance. It's as if they are not backing off after the peddle is released.

If I manually release the caliper the ABS goes out

Any ideas please. I've looked on the forums other posts but cant find any solutions. Huh 

many thanks
Malc.
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Help needed

July 21, 2016, 1:52 pm
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Hi, I was driving my van this evening 2005  Berlingo Diesel 1.9.
I turned it off for 10 minutes and when I restarted van, Fuel gauge
not working, I know that fuel tank is half fuel.
Is this a common problem? Where is the problem likely to be?
Sender unit or dash gauge?
Thanks
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Starting Issues

July 22, 2016, 11:21 am
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Today I've had some starting issues with my 2006 1.6HDi Berlingo and wanted to canvas opinion (I've looked at previous topics).
Issue, couldn't start car,
4 times nothing at all, once with a click (relay) and then started.
3 times with nothing at all, once with a click and then started.
I'm going to test the battery (its at least 4 years old) at rest and with the engine running tomorrow, would you suspect the starter motor yet?
All battery terminals are fine, no corrosion and all earths fine too, wiring to starter fine.

EDIT....Nothing at all means dash lights on
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2.0 HDI Head Gasket swap - Engine in situ

July 23, 2016, 11:39 am
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For a month or so I have been having a problem with the car losing coolant. The cooling system was becoming pressurised on runs and blowing the coolant out of the expansion tank. After prodding around I figured out that the main suspect was the head gasket. There was a continuous stream of tiny bubbles entering the top of the tank.
 All the info I could get about removing the head said that it was an engine out job, or you need to drop the subframe. Well, I decided this weekend to have a go at it.

The first thing I will say is that it is not easy! A LOT has to come off the engine and out of the car, and space is tight. The main issues I found were removing the manifolds. How I did this was to unbolt the exhaust manifold and the bolts holding the turbo to the engine, and then pull the whole assembly back as far as I could. There wasn't enough room to pull the manifold off the studs, but it gave me enough room to access the intake manifold bolts and pull it off. I then locked 2 bolts together on each of the exhaust manifold studs and turned them all off.

Access to the back of the engine is limited, but it is possible to get to everything you need too.

I managed to snap the top off a head bolt when trying to remove it, so spent an hour with a dremmel and stone grinding the shank off.

When putting it back together you have to fit the intake manifold properly before trying to fit the exhaust manifold, otherwise there is no access to the lower nuts.

In all it took me about 9 hours, 6 knuckles, 32,816 profanities, and about £70. After a 20 mile there are no leaks, and the cooling system is no longer pressurising.
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Van wont start now

July 24, 2016, 9:51 am
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Guys and Girls Im starting to think I have bought a pig in a poke. Van was running fine parked it up and went back 10 min later. Wont start. The wiper moves no matter if its off or on ? The gauges and warning lamps look OK and no buzzing ? 
Ony thing I notice is that the Display on the Dash that shows the radio info is really dim now and its lost the date and time ?
This sounds more electrical ? Any help would be great 

**Update**
Just checked the Van again and it has no lights no indicators and no window wipers but has hazard lights , The Elec windows work fine
no blower and the lights for the heaters and window switches are illuminated ?
The heater warning light comes on and goes off fine when i turn the key ?.
Checked the fuses in the fuse box next to the battery and they seem fine as well?
Im lost now ??????????

Mark
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Air Con Issues

July 24, 2016, 11:44 am
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Had my Aircon re gassed by Kwik Fit and although it's a little cooler it still is not cold.

Could it be the pollen filter?

Could it be they never put enough gas in there?

Anything else ?

Cheers.
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Help needed with clutch

July 25, 2016, 10:29 am
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Hi all I need a new clutch in my 2.0 hdi berlingo. I have looked at my gearbox and the only code I can see is BE4 but all the clutch kits say BE4R is there any difference between them or is the BE4R kit same as BE4  Huh
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persistent injector problems

July 26, 2016, 1:00 am
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good morning all.
I need your help! My diesel has 230,000 miles and has been maintained from new to a high standard.
Recently, it started with injector failure. First one was replaced. Then shortly after, a second failed, so all were replaced with reconditioned. Within a thousand miles, one of these failed. This was replaced.  Now, another has failed twice in the hundred miles and my mechanic is scratching his head....any ideas what could cause this persistent failure? I've been told possible fuel pump, grinding it's self up and clogging the injectors? This is now costing me serious money, so just want to sort it. Thanks in advance! Chris
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Berlingo wheel nut sizes?

July 26, 2016, 1:44 pm
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So I got myself a wheel wrench that comes in 17 & 19mm. None of them fit on the wheel nuts that hold the wheel trims (2003 600DX 1.9). I don't have a caliper yet, so does anyone know what size they are?

Thanks.
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what size Brake pads & disc

July 27, 2016, 11:21 am
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Thought I would replace my brake pads as I saw a special offer on brake pads & disc with free delivery

but when I looked at the web page there was two sizes. . .  

Thickness [mm]19/ Width [mm]137/ Height [mm]52  &  Thickness [mm]19/ Width [mm]137/  Height [mm] 57 
the same with the Disc
Diameter [mm] 283 / Brake Disc Thickness [mm] / 26 Height [mm] 34.2 &  Diameter [mm] 266 / Brake Disc Thickness [mm]22 / Height [mm] 34.5

Trying to find out what is the right size to order

2007 Berlingo desire 1.6hdi
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Towbar installation epic

July 27, 2016, 11:22 am
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So my first time installing a towbar.
I've got a 1.9 diesel multispace forte 
I'm installing the Bosal towbar from PF Jones
Bosal Swan Neck Towbar Kit
I started on the driver's side and initially I found the mudguard blocked access to the mounting holes but after releasing it and partially taking it off I managed to get the bolts and sleeves inserted.
I then reattached the mudguard and put the first section of the towbar on and did the bolts up finger tight.
See attached pics.
I'm stopping for supper now but will take pictures as I do it to help others and update the thread with progress.

.jpg   20160727_190213.jpg (Size: 1.3 MB / Downloads: 12)

.jpg   20160727_190222.jpg (Size: 1.28 MB / Downloads: 10)
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Bulkhead question

July 28, 2016, 12:11 am
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Hi everyone, 
I hope this is in the right bit-I have done a couple of searches but didn't show up what I was looking for.

I have an 07 Berlingo van. I am looking to change the bulkhead (drivers side only) to a mesh or half steel half mesh one.

I've found one second hand that came out of a Mk1 van-would this fit my one?

Is removing the original and changing it a big job? (it isn't ply lined and no side door)

There is also a tailgate guard made for a Berlingo Multispace 2000-woud this fit my van?

Sorry for all the questions and thanks for any advice you can give.


eta someone has just pointed out the lack of access to the rear should I be in an accident-if I had two bolted in bulkheads. Need to think again!
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Steering wheel cover.

July 28, 2016, 1:04 pm
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Leather steering wheel cover off amazon. £10. 
beats fitting an expensive aftermarket £80 leather all singing wheel.
took me two hours to fit.  easy peasy to fit. 
and it cost (did a say!?) A tenner!
off amazon......a tenner.  Smile

[Image: 20160728_181918_zpsx133grhm.jpg]
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order of injectors

July 30, 2016, 3:21 am
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hi all.  could you tell me what order the injectors are numbered on the 1.6 hdi?
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Fuel smell in cab and engine knock

July 30, 2016, 5:08 am
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I'm new here so hope this in the right place.
I noticed a knocking noise coming from the top end of the engine. Its a 1.4 petrol. I had a good listen around but couldn't pin point where it was coming from, so I thought it may be tappets, or fuel injectors. I checked the tappets and couldn't find a problem. This has been going on for months, and as it wasn't affecting how the car drove, I put it down to old age. Anyway, last October on the way back home on the motorway my Wife said she could smell petrol fumes in the cab, and I noticed it too. So I had a look around on this forum and other places, where the general consensus appeared to be injector seals.
I know I should have dealt with a fuel smell a bit quicker, but time has flown by, and it wasn't that bad.
 After lots of sniffing and searching under the bonnet I couldn't see any problems, but ordered some new seals, and today with a decent weather window and my haynes manual decided to change them.
I was a little bit concerned about disconnecting the battery, as I had read a lot of horror stories about the ecu, but did it anyway. Took off the air box, throttle body and the coil pack to get at the fuel rail. I noticed a lot of soot on a couple of the sparkplug HT shrouds. I wondered if the plugs were loose, and indeed they were, 3 out of the 4 were not tightened correctly, one very loose.
I removed and checked them all, put them in and tightened them up properly. I decided the injectors could wait for another day, as I thought I had found the problem.
 Putting the coil pack back on was a bit strange as there didn't seem to be a positive seating, so fiddled about with this for a bit, but have found that after putting the bolts back in its all seated correctly. Put it all back together and now it is all fixed. Connected the battery negative back on, and its all still working - phew.
Both faults have now gone, no fuel smell and no knocking noise. 
I didn't even consider spark plugs, so there you go. Hope this saves someone a bit of head scratching.
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Water in foot wells

August 2, 2016, 8:49 am
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Hi
Am new on the forum, but was wondering if anyone can help with an ongoing problem I'm experiencing...

Have a 2003 Berlingo which is suffering from major ingresses of water to both foot wells (mainly passenger side, but also sometimes driver side).

It's basically when we've had a lot of rain - but also when there is surface road water (it's parked on the road) which is splashed over the bonnet. This can sometimes result in an inch or more of water in the foot well - with subsequent carpet soaking etc. It's 'dirty' water, so I know it's not from the air con or similar.

I've had it checked over at a garage a number of times. They've checked the vents, cleared any muck from the channels and the scuttle etc. But each time the problem re-occurs. When pouring water over the windscreen it seems to flow out of the drainage channels and down through the wheel arches (sorry am not mechanically minded!).

I can't see any water dripping from under the glove compartment or through the dashboard. Also I can't see any evidence of it coming through the door seals either. It's almost as if it's rising up through the floor! The carpet sloping up towards the glove box seems to remain relatively dry.

Any thoughts or suggestions would be greatly appreciated as it'll be like an aquarium inside at this rate and it's not even winter!
Cheers
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Rear Light Cluster Replacement

August 2, 2016, 11:54 pm
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So my drivers side light cluster has been leaking and now it's broken and I think the easiest solution is a whole new light cluster!

But.. I have a Berlingo 07 Van, any ideas if the Berlingo Car light cluster will fit straight in or will I need a specific one?

Thanks for the help!!
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Cruise control Help, advice and pictures wanted

August 3, 2016, 3:19 am
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Last weekend me and my mate tried to activate the cruise control on my 2006 1.6 HDi 75 Desire. 

We obtained a cruise stalk, and plugged it it, we set up lexia and activated it in the engine ECU and also in another location (I can't remember where, but it wasn't clocks) took the blingo for a quick test drive and the cruise stalk had no effect at all, there was no visual tell tale, and it didn't activate (over 30mph in 4th gear)

So.... Have I missed something? I've read and read about it on this forum, have I got the wrong clocks? Do I need to activate a setting in clocks?

My mate wants to take the clutch pedal out to gain access to the clutch pedal switch, he thinks bridging the connections will activate cruise, is this a possibility?

Does anybody here have cruise control fitted but nothing displays in the dash? Where should the cruise control tell tale be?

I realise this has been asked numerous times, but I can't find a definitive answer. 

Prehaps a start to end tutorial, with all the different possibilities would be in order and made into a sticky for newbies?

I look forward to hearing your replies. 

Ray.
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Steering rack

August 3, 2016, 10:48 am
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Will a steering rack from a Citroen Berlingo petrol fit a Berlingo diesel 2.0 HDI?
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