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  1. 
locate the + terminal of the battery

undo it

and put it aside
    • locate the + terminal of the battery

    • undo it

    • and put it aside

    • You can definitely undo the - terminal as well or even disconnect both. I undo the + terminal because it is the quickest.

  2. 
unscrew the screw on the side, 13mm key

undo the cover locking clip

remove the cover
    • unscrew the screw on the side, 13mm key

    • undo the cover locking clip

    • remove the cover

    • I have to work on the injection pump on this Partner. That's why the timing covers are not present.

  3. 
under the car, unscrew and remove the 13mm nut holding the resonator

then unscrew the 2 collars, 7mm key

unclip the resonator tab on the battery holder
    • under the car, unscrew and remove the 13mm nut holding the resonator

    • then unscrew the 2 collars, 7mm key

    • unclip the resonator tab on the battery holder

    • I have a bolt on my car instead of the clip, it doesn't change anything.

  4. 
remove the resonator

There will probably be hoses to unclip, they are caught in clamps fixed to the resonator.
    • remove the resonator

    • There will probably be hoses to unclip, they are caught in clamps fixed to the resonator.

    • Place a cloth over the flow meter to avoid damaging it.

  5. 
unscrew the retaining screw at the crosspiece, Torx T20 key

unscrew the clamp at the air box

remove the sleeve
    • unscrew the retaining screw at the crosspiece, Torx T20 key

    • unscrew the clamp at the air box

    • remove the sleeve

  6. 
remove the nut from the excitation wire, 8mm wrench and that of the wire + battery, 13mm wrench

dislodge the excitation wire

dislodge the wire + battery
    • remove the nut from the excitation wire, 8mm wrench and that of the wire + battery, 13mm wrench

    • dislodge the excitation wire

    • dislodge the wire + battery

  7. 
unscrew the 3 starter fixing screws, 8 mm Allen key

The screw that is furthest back does not come out completely; the clutch fork control prevents it from being removed. Just unscrew it, the starter will come out without any problem.

There is a tab that is taken on the gearbox and fixed by a screw from the starter. We will put it aside and put it back in place during reassembly.
    • unscrew the 3 starter fixing screws, 8 mm Allen key

    • The screw that is furthest back does not come out completely; the clutch fork control prevents it from being removed. Just unscrew it, the starter will come out without any problem.

    • There is a tab that is taken on the gearbox and fixed by a screw from the starter. We will put it aside and put it back in place during reassembly.

    • take off the starter

    • and remove it

  8. 
compare starter part numbers to ensure they are compatible
    • compare starter part numbers to ensure they are compatible

    • OEM number: 5802W5 .

  9. 
put the starter in place

It has a centering pin.

screw in the 3 screws by hand
    • put the starter in place

    • It has a centering pin.

    • screw in the 3 screws by hand

    • Be careful to put the tab correctly in its housing. It serves as a support for stapling hoses and wires.

    • finish tightening with the Allen key

    • I don't have the torque but you have to tighten it quite hard.

  10. 
put the wire terminal + battery in place

and tighten the nut, 13mm wrench

do the same for the excitation wire, 8mm key
    • put the wire terminal + battery in place

    • and tighten the nut, 13mm wrench

    • do the same for the excitation wire, 8mm key

  11. 
position the sleeve

tighten the collar on the air box, 7mm wrench

screw the retaining screw onto the crosspiece, T20 torx key
    • position the sleeve

    • tighten the collar on the air box, 7mm wrench

    • screw the retaining screw onto the crosspiece, T20 torx key

  12. 
remove the cloth and put the resonator in place

fit and tighten the retaining nut at the bottom, 13mm wrench

staple the resonator leg to the battery holder
    • remove the cloth and put the resonator in place

    • fit and tighten the retaining nut at the bottom, 13mm wrench

    • staple the resonator leg to the battery holder

  13. 
tighten the clamp at the metering butterfly, 7mm wrench

tighten the collar at the air box, 7mm wrench
    • tighten the clamp at the metering butterfly, 7mm wrench

    • tighten the collar at the air box, 7mm wrench

    • Remember to reclip the hoses into their clips on the resonator.

  14. 
reconnect the + terminal of the battery

test that the car starts

put the engine cover in place, screw in the screw on the side (13mm wrench) and put the clip in place on top
    • reconnect the + terminal of the battery

    • test that the car starts

    • put the engine cover in place, screw in the screw on the side (13mm wrench) and put the clip in place on top

Finish Line

a_bosc2000

Member since: 11/03/2019

28,441 Reputation

147 Guides authored

2 Comments

Hello, is the procedure the same for my Berlingo 1.9 D 70 hp van from 2004? Thank you.

septdetable - Reply

Hello, yes it's the same thing

a_bosc2000 -

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