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2001 1.9 diesel - injector problems! Please help! - BrokenBerlingo
Any Citroen experts out there?

I bought a Berlingo Diesel on a 51 plate at the tail end of last year. It has the 1.9 DW8 engine with electronic engine management (Non HDI) and has done around 30,000 miles. I bought it because of the supposed reliability of PSA diesel engines..

Earlier this year it broke down with all the symptoms of a failed injector (Very rattly, lack of power and smoke).

A diesel injection specialist replaced one of the injectors but it broke down a few days later. Another injector was replaced but it broke down again. A few days later another breakdown and the garage replaced the final two injectors.

The car ran OK for a month or so before breaking down with the same symptoms. However, this time the fault cleared itself after being turned off and allowed to "rest". The car was taken to a main dealer who interrogated the ECU and found that a "Lift sensor failure" had been recorded. They replaced the Lift sensor and also the engine speed sensor and cleared the fault code from the ECU.

The car has since failed a further three times with the same syptoms! I'm waiting for a call back to see when the garage will be able to look at the car again.

Normally, the engine runs very well but the power from the engine feels very "bouncy" at around 2000 rpm (But only when moving)...I'd always put this down to a soft engine mounting and am unconcerned but could this be related?

I'm obviously getting very frustrated at this now! Are there any Citroen experts out there with any ideas as to what this could be? ECU? Fuel pump? Dodgy wiring/connectors? Sensors?

If anyone works for Citroen I'd be most grateful if you could check and see whether this is a known problem and what the solution is!

Edited by Dynamic Dave on 12/07/2008 at 15:23

Berlingo woes! Please help! - BrokenBerlingo
Just to add:

The vehicle is a Multispace and fuel contamination has been ruled out.
Berlingo woes! Please help! - smoke
Where abouts are you? If you are near Gt Missingden in bucks, then give Louis Barbour a ring (no link). He is a citroen specailist and very well regarded, he may be able to help.

Rignall Garage
Rignall Road
Great Missenden
Bucks
HP16 9AW
01494 864112
Berlingo woes! Please help! - RichardW
Odd that all 4 injectors have now been replaced, since there is only 1 lift sensor, and it's integral with No 3 injector....

Sounds to me like a bad connection somewhere that is causing the ECU to lose the signal from the lift sensor, and put the engine into the default position - max ignition advance, hence it sounding like a bag of spanners.

The DW8 engine is basically the old XUD with a couple of sensors and an ECU controlling the amount of advance the pump gets (previously mechanically controlled within the pump). There have been a few instances of the system going haywire, but it seems generally reliable, given how many have been built! I wonder if this is the reason, though, that the previous owner got rid...?
--
RichardW

Is it illogical? It must be Citroen....
Berlingo woes! Please help! - BrokenBerlingo
Well, the lift sensor is on No 4 Injector (Or is it No 1?). Anyway, it's on the injector at the gearbox end of the engine..

From what I can gather signals are sent from the "Lift sensor" and the "Engine speed sensor" back to the ECU which then adjusts an actuator on the injector pump accordingly. Is my understanding correct or are there other sensors/actuators involved in the process?

Is it possible that the actuator on the injection pump could be sticking? Does the "Throttle position sensor" (Or any other sensor come to that) play any part in the ignition timing?

(You are right about it sounding like a "bag of spanners", by the way!)


Berlingo woes! Please help! - RichardW
Have a look on this thread where someone was having trouble with a Synergie:

www.andyspares.com/discussionforum/topic.asp?TOPIC...5

Not exactly the same engine, but gives some good background on the system. There is probably a TPS, but as it gives 'lift sensor' as the error code, this suggest the fault lies with a cable connection. Or the ECU.... You could try taking it to a Cit dealer (I know!) and getting them to upload the latest version of software - I know of another Berlingo that was fixed by this.




--
RichardW

Is it illogical? It must be Citroen....
Berlingo woes! Please help! - BrokenBerlingo
So is it quite likely that the engine "wobble" around 2000 rpm is unconnected?
Berlingo woes! Please help! - Bromptonaut
The DW8 engine is basically the old XUD with a couple
of sensors and an ECU controlling the amount of advance the
pump gets (previously mechanically controlled within the pump).


Ahh, answer to the Q I was about to post as I'm on verge of purchasing a 1.9 Berlingo myself. Is this the 1868cc unit presently offered in the Berlingo and Pug Partner?. As I read the reply its got a hybrid electric/mechanical injection system.
Any other key differences from the 1905/1769cc versions of the XUD?.

.
Berlingo woes! Please help! - BrokenBerlingo
I'm not sure. Mine is the 1868cc version with the DW8 engine (ie the Non-HDI version)

From what I can gather it's basically a refined version of the XUD with a few electronic bits added.

For what it's worth I'd still recommend getting one, despite the problems I am encountering.


Berlingo woes! Please help! - Taxi
Hello to everyone.
I have just joined this forum ( BIG HELLO )
Ok I have just bought the berlingo Multispace with the 1868cc engine in it. 03 plate.
I did notice that the rocker top looks like it has been altered from what I remember of the XUD engine.
Can I ask a few questions here.
Is the heads the same ?
Same starters ?
alternators etc ?
I am asking this as I have bought this to use as a Taxi.
I do have a Berlingo van P reg , I got the newer one as this handled loads & loads of miles with no trouble and quite easy for bits and to
work on, I thought the new one would just be the same.
I honestly never heard of the DW8 engine until reading this forum.
To wrap this up in a nutshell will my old van be able to donate parts to my newer Multispace ?
I know body panels are not the same but was hoping I could use the Box, Head, starter, alternator, injectors ...etc if I ever needed to do so,
if I was stuck in an emergency repair.

Regards Steve
Berlingo woes! Please help! - Taxi
Is this thread still alive ?
I would like to know if the Old berlingo will be a good "donar" vehicle.
or is it best to simply part with it ?
maybe this post is to old and no 1 looks at it anymore !
can anyone tell me if the newer 1.9 berlingo engine anything like the XUD one.
Regards
Berlingo woes! Please help! - Carrow
Just flicking through some parts books, and the head gaskets are different, so would guess the heads are different, the glow plugs are different and the clutches have different part numbers as well. Probably better to part with it, in my opinion.
Berlingo woes! Please help! - killie
Hi
I' m thinking of buying the Berlingo Multispace for Use as A taxi In the Glasgow area
was wondering if you could let me know what kind of Fuel economy you are currently getting ?
also how do you find the Multispace as a Taxi room inside for the Pasengers etc
Thanks for any Info
Regards
Ian.H
Berlingo woes! Please help! - Corrib12
Ian, my '03 Multispace HDi has done 44K miles with no mechanical problems. I ran two previous Multispaces with the non-turbo motor and they did 42K and 49K respectively without trouble. All ran on Millers' full synthetic oil from new.
I found the original Michelin tyres very hard and noisy so have nothing but praise for the Vredestein Quatracs which replaced them: half the noise, better on wet roads etc. The Multispace is definitely a van dressed up as a car so it's somewhat basic. The sliding doors need watching and your passengers will find them a bit fiddly. Applying silicone spray regularly to the runners etc. definitely helps.
For your job, I'd get the Citroen roof rack, too. Very solid, means you can take an immense amount of stuff both on top and inside. Fitting a tow bar adds essential protection to the rear bodywork. Lost count of the people who have bumped me in car parks, discovered their fronts dinged, and my tow bar-protected back end untouched!
Once run-in, say by 15K miles, there's bags of torque for overtaking and it purrs along at 75-80 on motorways. Have averaged 43-46mpg overall. Only failure with the running gear has been one track rod end, replaced at 37K service.
Having once run a Renault R4 and a Citroen 2CV, the Multispace is the grown-up version of those two..a superb vehicle overall and unbeatable for the money.
Berlingo woes! Please help! - killie
Hi
Thanks for the Info.
Had a lok at one in the Showroom the other day and the Rear doors did stick a bit when open and closing them
good Tip about the Silicone Spray..
Considered a Pucasso but Im sure it will be a Multispace I will go for.
Thanks again
Ian.H
Berlingo woes! Please help! - Taxi
Hello.
Well I have ran one of these as a Taxi since I began this reply.
the rear door seems to be a problem with the more "drunk community"
they cant get the jist of having to push the button on the handle to close the door....lol.
When you say "Push the button" they look everywhere apart from the right place.
Overhead storage is nice to hide radio, servalance unit and extra 12v supply.

The vehicle is good for the job in a GREAT many ways, seating high up for the elderly
easy access for the "pink fluffy dice", overall good pink fluffy dice
I did have a problem ( well maybe )
I was driving it home and it developed a deisel knock or something similar to that.
It knocked as if the timing was out ,then I turned it off and started it again it was OK.
It was either injector going off or air or (well I dont know)...hehehehehe
It ran OK the next trip..and has done since, but now I am worried
Is this a fault ? what could it be ?
Under 49 thousand miles upto today......any ideas
I am worried as it is a working car.
Regards Steve

{As you're relatevly new here, you may not be aware of the site rules on swearing. I suggest you review those rules by looking at one of the posts at the top of the discussion page. If there is ever a next time, remember it is far easier for me to delete your post than edit it. Thanks in advance DD}
Berlingo woes! Please help! - Taxi Al
I use the DW8 Berlingo as a Taxi done 176,000 with it but a lot of the parts a different to the XUD engine eg:starter motor not the same brake discs not the same etc...
Berlingo woes! Please help! - brayer
hi there
i work as a master technician in a peugeot dealer ,as you know this is the same vehicle as a peugeot partner,this is a know problem with this engine all you need to do is ask your citroen dealer to download new software in to the engine ecu ,the fault is caused by the advance solenoid in the injector pump locking up,when turning off ignition this resets it.and the fault goes away for a while.i'm surprised they haven't done this yet but i see no mention of it in your message.also be very careful of the oil level in this engine as being slightly overfilled will cause rattling and smokeing problems.hope this is some help
regards
paul bray
Berlingo woes! Please help! - Taxi
Thanks mate.
Your message is a big help honest.
Funny you mention the oil level !!!
When parked on hills or uneven ground sometimes I get a low oil indication.
( Only two squares on dash lights and the rest dashes )
I know all the didgits should be squares to indicate correct oil level.
When I dip it , it is to the correct level.
Can you tell me any more info about the bit you wrote.
**"download new software in to the engine ecu ,the fault is caused by the advance solenoid in the injector pump locking up"**
Do they charge for this ? even though it is a design fault.
You said "when turning off ignition this resets it.and the fault goes away for a while" !
Do you mean if I dont get the updated software it will re occur ?
It hasnt so far but I am a little worried incase it does.
Any additional info or tips would be great.
Thanks for the reply, Now you have me thinking ! Hmmmmmm

Steve
Berlingo woes! Please help! - Taxi
Just a quick quote here.
the bit I wrote
QUOTE*"Funny you mention the oil level !!!
When parked on hills or uneven ground sometimes I get a low oil indication.
( Only two squares on dash lights and the rest dashes )
I know all the didgits should be squares to indicate correct oil level.
When I dip it , it is to the correct level."QUOTE*
Later it was OK and showed all squares in the illumination wher parked elsewhere.
Regards Steve