PEUGEOT BOXER 2003 Owner's Manual

05-05-2003
ARDUOUS CONDITIONS OF USE
¥ Continuous door-to-door use.
¥ Town use (e.g. taxi).¥ Repeated short journeys, with the engine cold at low temperatures.
¥ A prolonged stay under the following conditions : - countries with temperatures often above +30 ¡C,- countries with temperatures often below -15 ¡C,- countries with a dusty atmosphere,- countries whose lubricants or fuels do not conform to our recommendations.
It is necessary to follow an "Arduous Conditions" service schedule which includes special operations and shorter service intervals: ¥ Every 12 000 miles (20 000 km) or every year for petrol vehicles. ¥ Every 12 000 miles (20 000 km) or every year for petrol or LPG/UNG dual-fuel vehicles.W arning, LPG/UNG checks every 6 000 miles (10 000 km) or every 6 months.
¥ Every 10 000 miles (15 000 km) or every year for 2.8 litre Diesel vehicles with HDI / TED direct injection.
PEUGEOT SERVICING
24

05-05-2003
PEUGEOT SERVICING25
A, B AND C SERVICE LEVELS AND THE INTERMEDIATE VISIT
: All driving conditions: Arduous conditions * According to country.
1st Level
Operations Description of operation serviceABCIntermediate
DRAIN/REFILL- Engine oil - Bleed fuel filter (diesel) - Oil filter - Fuel filter* (petrol)REPLACE- Fuel filter element (diesel)- Air filter element- Spark plugs (petrol)- Engine oil (check + top-up) - Manual gearbox oil (check + top-up) - Battery (check + top-up) if cap is removable LEVEL- Screen wash (check + top-up)- Coolant (check + top-up) - Brake fluid (check + top-up) - Power steering fluid (check + top up according to specification) - Operation of lights and indicators - Condition of glass, headlamp and light lenses and mirrors - Horn - Windscreen washer jets - Condition of wiper blades - Condition and tension of the ancillary drive belts - Handbrake and clutch - Condition of hydraulic circuits (hoses and covers) CHECK- Condition of rubber boots and gaiters - Brake pads - Play in hubs, link rods, ball joints, flexible mountings- Shock absorbers- Rear drum brake lining wear- Condition and pressure of tyres (including spare wheel) - Emission control check as per current legislation (petrol) - Smoke opacity (diesel) - Passenger compartment filter (according to specification) - Visual check of the whole vehicle
SERVICE*- Courtesy vehicle
ROAD TEST

05-05-2003
26
DIESEL
DIESEL
PETROL PETROL
(1) Minimum grade: Petrol engine: ACEA A3 and API SH/SJ; Diesel engines ACEA B3 and API CF/CD.
ACEA = Association des Constructeurs EuropŽens Automobiles (Association of European Automobile Manufacturers)
API= American Petroleum Institute.
If oil is used which does not conform to the ACEA A3-B3 standards, this requires the "Arduous Conditions" servicing schedule to be followed, which involves shorter intervals between services.
* The 5W30 Fuel Economy oil may not be used for the 2.8 litre HDI and TED engines.
TRADE NAMES OF SUITABLE AND RECOMMENDED ENGINE LUBRICANTS IN EUROPE (1)

05-05-2003
Recommended lubricants The oils which appear in the table opposite are suitable for most pur-poses. The diagram opposite states the optimum range of viscosity depen-ding on the temperatures at whichthe oils are to be used. It is also possible to use "superior quality" synthetic oils. In the absence of semi-synthetic or
synthetic oils, oils of API SH/SJ qua-lity (for petrol engines), or CD/CFquality (for diesel engines) may beused by following the "ArduousConditions" servicing schedule,which specifies shorter intervals. Do not hesitate to ask for advice
from a PEUGEOT dealer to maintaindriving pleasure and to minimise themaintenance cost of your vehicle. For countries outside Europe, please
contact a local PEUGEOT dealer.
PEUGEOT SERVICING27
ONLY ONLY
Manual ESSO Gear Oil BVTO TA L TRANSMISSION BVGearbox 75W80 PR 9736.41 75W80
ONLY
Automatic ATF 4HP20
Gearbox PR 9736.22
Other recommended products
Power steering FLUIDE DA PR 9730.A1
Brake fluid PEUGEOT DOT4 Coolant
PROCOR TM108/GLYSANTIN G33 or REVKOGEL 2000
ONLYProtection to minus 35C

05-05-2003
1 -Coolant temperature gauge.
2 - Coolant temperature warning light.
3 - Door open warning light.
4 - Speedometer.
5 - Left-hand direction indicator.
6 - Side lights and dipped beamheadlamps indicator light.
7 - Main beam headlamps indicatorlight.
8 - Right-hand direction indicator. 9 -
Rev counter.
10 - Low fuel level warning light.
11 - Fuel gauge.
12 - Brake fluid level warning light.
13 - Traction control (ASR) warning
light.
14 - Passenger air bag disarmed warning light.
15 - Trip distance recorder display
control and zero reset button. 16 -
Front air bags warning light.
17 - Anti-lock braking system (ABS) warning light.
18 - Automatic gearbox temperatureor fault warning light.
19 - Low coolant level warning light.
20 - Service indicator, oil levelgauge, automatic gearbox
display, clock and total distance
recorder.
21 - Diesel engine pre-heatingwarning light.
22 - Engine oil pressure warninglight.
23 - Battery charge warning light.
24 - Clock setting button.
25 - Engine diagnostics warninglight.
26 - Front brake pad wear warninglight.
27 - Handbrake warning light.
28 - Water in diesel filter warning
light.
29 - Electronic immobiliser keywarning light.
INSTRUMENTS AND CONTROLS
28
PETROL-DIESEL MANUAL AND AUTOMATIC GEARBOX
INSTRUMENT PANELS

05-05-2003
Low coolant level warning light Illumination of this warning light indicates that the coolant level is too
low.
Stop immediately.
W arning: allow the engine to cool before topping up.
The cooling circuit is pressurised.
To avoid any risk of scalding, unscrew the cap by two turns to allow the pressu-
re to drop.When the pressure has dropped, remove the cap and top up the level.
Contact a PEUGEOT dealer.
INSTRUMENTS AND CONTROLS 29
Engine oil pressure warning light This comes on for a few seconds when the ignition is switched on. Illumination of this warning light while the engine is running indicates
that the oil pressure or level is too low.
Stop immediately. If there is a lack of oil in the lubrication circuit, top it up.
Contact a PEUGEOT dealer as soon as possible.
INSTRUMENTS AND CONTROLS A permanently lit warning light or one that flashes while the engine is
running indicates an operating fault. The illumination of certain warning lights may be accompanied by a bleep and a message on the multi-
function display. Do not ignore this warning: contact your PEUGEOT dealer as soon as possible.
Handbrake warning light This comes on for a few seconds when the ignition is
switched on.Illumination of this warning light indi-cates that the handbrake is applied
or has not been released correctly.Coolant temperature warning light This comes on for a few seconds when the ignition is
switched on.Illumination of this warning light indi-cates an abnormal increase in thecoolant temperature.
Stop immediately.
Contact a PEUGEOT dealer.

05-05-2003
Anti-lock braking system (ABS) warning light If the warning light remains on or comes on above 7 mph (12 km/h), this
indicates an ABS system fault. Nevertheless, the vehicle retains conventional assisted braking.
Contact a PEUGEOT dealer.
Traction control (ASR) warning light
If the warning light remains on or comes on while the engine is running
and the vehicle is moving, contact a PEUGEOT dealer. It flashes when the system comes into operation and comes on perma-
nently when the system is disarmed.
Diesel engine pre-heating warning light This comes on when the ignition is switched on. Wait until it goes out before operating the starter.
Engine autodiagnostics warning light This comes on when the ignition is switched on. If it comes on while the engine is running, it indicates:
- an emission control system fault,
or
-a particulate emission filter fault.
If it flashes while the engine is running, this indicates an injection or ignition sys-
tem fault. There is a risk of destruction of the catalytic converter (petrol engineonly).
Contact a PEUGEOT dealer as soon as possible.
INSTRUMENTS AND CONTROLS
30
Battery charge warning light This comes on when the ignition is switched on.
If it comes on while the engine is run-ning, it may indicate: - faulty operation of the charging cir- cuit,
- slack battery or starter terminals,
-a cut or slack alternator belt,
- an alternator failure.
Contact a PEUGEOT dealer.
Low brake fluid level warning light Illumination of this warning light while the engine is
running indicates that the handbrakeis applied or has not been released
correctly, or that the brake fluid level
is too low.
Simultaneous illumination of the ABS warning light and the low brake fluidlevel warning light indicates a brakeforce distribution system fault.
Stop immediately.
Contact a PEUGEOT dealer.

05-05-2003
Water in diesel filter warning light
This comes on for a few seconds when the ignition is switched on. Illumination of this warning light indicates that there is water in the die-
sel filter.
There is a risk of damage to the injection system.
Contact a PEUGEOT dealer as soon as possible.
INSTRUMENTS AND CONTROLS 31
Passenger air bag disarmed warning light This comes on for a few seconds when the ignition is switched on. If the passenger air bag is disarmed, the warning light comes on when the ignition is switched on and stays on.
In all cases, if the warning light flashes, contact a PEUGEOT dealer.
Low fuel level warning light The warning light comes on for a few seconds when the ignition is swit- ched on.Illumination of this warning light while the engine is running indicates
that the fuel level is low.When the warning comes on, you have at least 8 litres of fuelleft.
Air bag warning light The warning light comes on for a few seconds when the ignition is swit- ched on.Illumination of this warning light while the engine is running indicates:
- a front air bag fault, or- a side air bag fault.
Contact a PEUGEOT dealer.
Front brake pad wear warning light Lighting of this warning light while the engine is running
and the vehicle is moving and whenyou press the brake pedal indicatesextreme wear of the front brakepads.
Contact a PEUGEOT dealer as soon as possible.
Electronic immobiliser key warning light This comes on for a few seconds when the ignition
is switched on. Flashing of this warning light, after the ignition has been switched on,
indicates an operating anomaly. If this warning light comes on (per- manently) after the ignition is swit-ched on, check the identification of
the key.
Contact a PEUGEOT dealer as soon as possible.

05-05-2003
INSTRUMENTS AND CONTROLS
32
Automatic gearbox temperature or fault warning light This comes on for a few seconds when the ignition is switched on. Illumination or flashing of this warning light while the engine is runningand the vehicle is moving indicates an automatic gearbox fault or an
excessive automatic gearbox temperature.
Stop immediately.Allow the engine to run at idle (lever in position Nor P) until the warning light
switches off.
Contact a PEUGEOT dealer as soon as possible. Door open warning light This comes on for a few seconds when the ignition is switched on. Illumination of this warning light indicates that one or more doors are
open or have not been closed correctly.
The warning light switches off when all of the doors are closed correctly.
Coolant temperature gauge When the needle is in zone A, the
temperature is correct. When the needle is in zone B, the
temperature is too high.
Stop immediately.W arning: allow the engine to cool
before topping up.The cooling circuit is pressurised.
To avoid any risk of scalding, uns-
crew the cap by two turns to allow the pressure to drop. When the pressure has dropped, remove the cap and top up the level.
Contact a PEUGEOT dealer.

05-05-2003
INSTRUMENTS AND CONTROLS
32
Automatic gearbox temperature or fault warning light This comes on for a few seconds when the ignition is switched on. Illumination or flashing of this warning light while the engine is runningand the vehicle is moving indicates an automatic gearbox fault or an
excessive automatic gearbox temperature.
Stop immediately.Allow the engine to run at idle (lever in position Nor P) until the warning light
switches off.
Contact a PEUGEOT dealer as soon as possible. Door open warning light This comes on for a few seconds when the ignition is switched on. Illumination of this warning light indicates that one or more doors are
open or have not been closed correctly.
The warning light switches off when all of the doors are closed correctly.
Coolant temperature gauge When the needle is in zone A, the
temperature is correct. When the needle is in zone B, the
temperature is too high.
Stop immediately.W arning: allow the engine to cool
before topping up.The cooling circuit is pressurised.
To avoid any risk of scalding, uns-
crew the cap by two turns to allow the pressure to drop. When the pressure has dropped, remove the cap and top up the level.
Contact a PEUGEOT dealer.