TU5JP4 Engine

Engine 1.6 16V TU5JP4 (110 HP) – Experiences, problems, fuel consumption and buying tips

Key points in short (TL;DR)

• Old-school reliability: This is one of the best petrol engines PSA Group (Peugeot/Citroën) has ever made. Far more reliable than the newer VTi (Prince) engines.
• Ideal for LPG: The engine handles LPG very well, which is a lifesaver for your budget considering the fuel consumption in larger vehicles like the Berlingo.
• Cheap maintenance: No dual-mass flywheel, no turbo, no expensive injectors, no DPF filter.
• Performance: In the heavy Berlingo it’s decent around town, but on the highway it lacks “breath” and a sixth gear – it’s noisy at 130 km/h.
• Main weaknesses: Coil pack (ignition), oil leaks from the valve cover and sometimes noisy hydraulic lifters on cold start.
• Verdict: If you want low running costs and don’t chase performance, this is a “gold mine” among used cars.

Contents

• Technical specifications
• Reliability and maintenance
• Specific parts and costs
• Fuel consumption and performance
• Additional options and modifications (LPG & Tuning)
• Gearbox
• Buying used and conclusion

Technical specifications

Specification	Value
Engine code	TU5JP4 (NFU)
Displacement	1587 cc
Power	80 kW (110 HP) @ 5800 rpm
Torque	147 Nm @ 4000 rpm
Fuel type	Petrol (Gasoline)
Injection system	MPI (Multi-Point Injection) – Indirect
Induction	Naturally aspirated (No turbo)
Number of valves	16 (DOHC – double overhead camshaft)
Engine block	Cast iron (grey cast)

Reliability and maintenance

Does this engine have a timing belt or a chain?

The TU5JP4 engine uses a timing belt. This is actually good news compared to the newer “Prince” engines which have problematic chains. The timing system is simple and reliable.

What are the most common failures on this engine?

Although it is very reliable, age takes its toll. Here’s what usually fails:

• Coil pack: This is the “Achilles’ heel” of this engine. The coil pack is molded as a single unit for all four spark plugs. Symptoms are rough running, loss of power, “Check Engine” light and running on 3 cylinders. Fortunately, replacement is simple (two bolts) and not too expensive.
• Oil leak from valve cover: The gaskets on the camshaft covers harden over time. Oil then leaks directly onto the spark plugs or the exhaust manifold (you can smell burning oil in the cabin).
• Hydraulic lifters: If you hear “ticking” or “clattering” when the engine is cold, which disappears once it warms up, those are the hydraulic lifters. This is often the result of poor-quality oil or overly long service intervals. It’s not an urgent failure, but it’s annoying.
• Throttle body: It can get dirty, which leads to unstable idle or stalling when stopping at traffic lights. Cleaning usually solves the problem.

At what mileage should the major service be done?

The recommended interval for the major service (replacement of timing belt, tensioner, water pump and coolant) is every 80,000 to 100,000 km or 5 years, whichever comes first. Although the manufacturer sometimes states longer intervals (e.g. 120,000 km), gambling is not advised because a snapped belt leads to piston-to-valve contact (catastrophic engine failure).

How many liters of oil does this engine take and which grade is recommended?

The sump holds about 3.2 to 3.5 liters of oil with filter change. The recommended grade is 5W-40 (fully synthetic, e.g. Total Quartz 9000). For high-mileage engines that consume a bit more oil, it’s acceptable to switch to 10W-40, but 5W-40 is better for cold starts and protection of the hydraulic lifters.

Does it consume oil between services?

In general, the TU5JP4 is not known for oil consumption if it’s in good condition. Consumption up to 0.5 liters per 10,000 km is negligible. If it consumes more (e.g. 1 liter per 2–3 thousand km), the usual cause is valve stem seals that have hardened with age, since these engines are now getting old. This manifests as bluish smoke at first start or after long idling.

Specific parts (Costs)

Does the engine have a dual-mass flywheel?

No. This engine uses a classic solid flywheel. This is a huge advantage because a clutch kit is dramatically cheaper (it falls into the “not expensive” category), and it eliminates one of the most costly failures on modern cars.

What kind of injection system does it have and are the injectors problematic?

It uses a classic MPI (Multi-Point Injection) system into the intake manifold. Petrol injectors are very robust and rarely fail. If a problem occurs (rough running), ultrasonic injector cleaning is often enough, and that’s a cheap procedure.

Does this engine have a turbocharger?

No, this is a naturally aspirated engine. No turbocharger, no intercooler, no hoses bursting under pressure. Fewer parts = fewer worries.

Does this model have a DPF filter or an EGR valve?

Petrol engines of this type do not have a DPF filter (that’s reserved for diesels). They do have an EGR valve, but on petrol engines it causes far fewer problems than on diesels. Even if it clogs, the symptoms are mild (slightly worse idle, poorer throttle response), and cleaning is simple and cheap.

Fuel consumption and performance

What is the real fuel consumption in city driving?

Here we come to a downside. The Citroën Berlingo is heavy and aerodynamically similar to a brick. In city driving, expect consumption between 9 and 11 liters per 100 km, depending on traffic and how heavy your right foot is. In winter it can go up to 12 liters. This engine likes to rev, and that costs fuel.

Is this engine “lazy” for the weight of the body?

For an empty Berlingo, the engine is perfectly adequate. However, since the torque of 147 Nm is reached only at a high 4000 rpm, it can feel “lazy” at low revs. If you load up the family and luggage, you will feel the lack of power on climbs, where you’ll have to shift down and keep the engine above 3500 rpm.

What is the engine like on the highway and at what rpm does it cruise at 130 km/h?

The gearbox is short-geared to compensate for the lack of power relative to the vehicle’s weight. Because of that, at 130 km/h in 5th gear, the engine spins at about 4000 to 4200 rpm. This results in increased cabin noise and fuel consumption that on the highway hardly drops below 8.5 liters.

Additional options and modifications

Is this engine suitable for LPG conversion?

Absolutely YES. This is one of the best engines for LPG conversion. It has a metal intake manifold (on older versions) or a quality plastic one, hydraulic lifters that self-adjust valve clearance and a simple injection system. With a good sequential LPG system, running on gas is the most economical option for a Berlingo.

How much can this engine be safely “chipped” (Stage 1)?

On naturally aspirated petrol engines, chipping (remap) is a waste of money. You might gain 5 to 8 HP at best, which you won’t really feel in everyday driving. Better throttle response is possible, but don’t expect miracles like with turbo engines.

Gearbox

Which gearboxes are fitted?

With this engine in the Berlingo II you almost exclusively get a 5-speed manual gearbox (MA5 series or the reinforced BE4). There were versions with an automatic gearbox (AL4), but they are extremely rare in the Berlingo.

What are the most common gearbox failures?

Manual gearbox: Generally durable, but not particularly precise.
1. Gear linkage rods: Over time they develop play, so the gear lever becomes “wobbly”, like you’re stirring soup. A linkage repair kit is cheap.
2. Input shaft bearing: If you hear a humming noise that disappears when you press the clutch, that’s a bearing in the gearbox. It’s not urgent, but it requires opening the gearbox.

Automatic gearbox (AL4): If you come across one – avoid it. It’s known for problems with solenoids and overheating, and overhaul is very expensive.

Cost of clutch and flywheel replacement?

As mentioned, there is no dual-mass flywheel. Replacing the complete clutch kit (pressure plate, disc, release bearing) is a routine and financially affordable job. This falls under regular maintenance at around 150,000 – 200,000 km, depending on driving style (city driving wears the clutch disc faster).

At what mileage should the gearbox be serviced?

Although manufacturers often say that oil in a manual gearbox is “lifetime fill”, real-world experience says otherwise. It is recommended to change the gearbox oil (about 2 liters of 75W-80) every 60,000 to 80,000 km. This will preserve the synchros and make shifting easier in winter.

Buying used and conclusion

When buying a Berlingo with the 1.6 16V engine, pay attention to the following:

• Cold start: The engine should start instantly. If it cranks for a long time or runs unevenly for the first few seconds, suspect the coil pack, spark plugs or dirty injectors.
• Engine sound: Listen for hydraulic lifters (tick-tick-tick). If the sound doesn’t disappear after a minute or two of running, the engine was probably driven with poor-quality oil or has very high mileage.
• Expansion tank: Check if there are traces of oil in the coolant (“mayonnaise”). Although the head gasket is not as common a problem as on some other engines, it does happen.
• Test drive: Floor the throttle at low revs. There should be no hesitation or jerking.

Final verdict

The Citroën Berlingo 1.6 16V (TU5JP4) is an excellent choice for: Families and small business owners who mostly drive locally, want low maintenance costs and plan to install LPG. They are ready to sacrifice low fuel consumption in exchange for cheap parts.

It’s not for you if: You drive 30,000+ km per year exclusively on the highway. The noise and high fuel consumption at 130 km/h will wear you out – in that case, the 1.6 HDi diesel is a better, although riskier, option.