engine Peugeot Boxer 2002.5 Service Manual

16-09-2002
Only use products
approved by Automobiles
PEUGEOT.
To ensure best perfor-
mance from components
as important as the power steering and the braking system,PEUGEOT selects and offersquite specific products.
CHECKS Battery
At the start of winter, have your bat-
tery checked by a PEUGEOT dealer. Air filter and pollen filter Have the filter elements replaced
regularly. If you drive in dusty
conditions, change them twice asoften. Brake pads Brake pad wear depends on the style of driving, in particular forvehicles which are used in town,over short distances. It may benecessary to check the thickness ofthe pads, even between services. Handbrake Where the handbrake travel is too great or there is a reduction in theperformance of the system, thehandbrake should be adjusted, evenbetween services. Have the system checked by a
PEUGEOT dealer. Manual gearbox This does not need an oil change. Check the level, according to themanufacturer's servicing schedule. Automatic gearbox This does not need an oil change. Have the level checked by a
PEUGEOT dealer, according to themanufacturer's servicing schedule. Oil filter
Change the filter regularly, in accor- dance with the servicing schedule.
Fuel supply cut-off In a serious collision, a system pre- vents fuel from reaching the engine.
To
re-establish the fuel supply, press
the switch on the angle of the front
left-hand suspension assembly,under the bonnet.
PRACTICAL INFORMATION
144

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Removing and changing a fuse Before changing a fuse, you must establish the cause of the fault and have it cor-
rected. The fuse numbers are indicated on the fuse boxes. ☞Use the special pliers A.
Always change a faulty fuse for one of the same rating.
CHANGING A FUSE The fuse boxes are located in the lower part of the fascia (left and righthand side) and in the engine com-partment. The spare fuses and special pliers A
are fixed to the inside of the lids of the fascia panel fuse boxes.
Fascia panel fuses ☞
Unscrew the bolts, then tilt the cover to access the fuses.
Correct
Incorrect
PRACTICAL INFORMATION
150
Pliers
A

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Engine compartment fuse box Fuse box
To gain access to the fuses in the
engine compartment: ☞ unclip the cover.
Close the cover carefully when you have finished.
PRACTICAL INFORMATION 153
The electrical system of your vehicle is designedto operate with standardor optional equipment.
Before installing other electricalequipment or accessories on yourvehicle, contact a PEUGEOT dea-
ler. PEUGEOT will not accept respon- sibility for the cost incurred inrepairing your vehicle or for recti-fying the malfunctions resultingfrom the installation of accesso-ries not supplied and not recom-mended by PEUGEOT and notinstalled in accordance with itsinstructions, in particular wherethe equipment in questionconsumes more than 10 milliam-peres. * The maxi-fuses provide additio- nal protection for the electrical
systems. All work must be carried
out by a PEUGEOT dealer.
Fuse no. Rating Functions 1* 60 A Passenger compartment 27-fuse box.
2* 50 A Pre-heat box - Heating resistor (2.8 litre engines).
3* 30 A Starting switch.
4* 50 A Anti-lock braking system (ABS).
5* 40 A Cooled air system.
6* 40 A Fan assembly (low speed).
7* 40/60 A Fan assembly (high speed) - Fan assemblyrelay (high speed with air conditioning).

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Fuse no. Rating Functions
8 30 AWash-wipe pump.
9 15 AHeadlamps and fog lamps.
10 15 A Horn - Steering wheel lever control.
11 15 AEngine management control unit (secondary).
14 10 A Right dipped headlamp.
15 10 A Left dipped headlamp.
16 7,5 A Engine management control unit supply - Transponder.
17 10 A Engine management control unit (primary).
18 7,5 A Engine management control unit - Transponder.
19 7,5 A Air conditioning compressor.
20 30 A PTC.
21 15 A Fuel pump.
22 20 A Engine management control unit (primary).
23 10 A Automatic gearbox.
24 15 A Automatic gearbox.
30 15 A Left and right main beam headlamps.
PRACTICAL INFORMATION
154

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Removing and changing a fuse Before changing a fuse, you must establish the cause of the fault and have it cor-
rected. The fuse numbers are indicated on the fuse boxes. ☞Use the special pliers A.
Always change a faulty fuse for one of the same rating.
CHANGING A FUSE The fuse boxes are located in the lower part of the fascia (left and righthand side) and in the engine com-partment. The spare fuses and special pliers A
are fixed to the inside of the lids of the fascia panel fuse boxes.
Fascia panel fuses ☞
Unscrew the bolts, then tilt the cover to access the fuses.
Correct
Incorrect
PRACTICAL INFORMATION
150
Pliers
A

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PRACTICAL INFORMATION155
BATTERY
To
charge the battery using a battery charger:
- disconnect the battery,
- follow the instructions for use given by the battery charger manufacturer,
- reconnect starting with the negative (-) terminal,
- check that the terminals and connectors are clean. If they are covered with sul- phate (white or greenish deposit), disconnect them and clean them.
To start the vehicle from another battery:
- connect the red cable to the positive (+) terminals of the two batteries,
- connect one end of the green or black cable to the negative (-) terminal of the
slave battery,
- connect the other end of the green or black cable to an earth point on the bro-
ken down vehicle as far as possible from the battery.
Operate the starter, let the engine run. W ait for the engine to return to idle, then disconnect the cables.
- Never disconnect a ter-
minal when the engine is running.
- Never charge a battery without first disconnecting the terminals.
- After every disconnection of the
battery, switch on the ignitionand wait 1 minute before startingto allow the electronic systems tobe initialised. If slight difficultiesare experienced after this, please
contact a PEUGEOT dealer.
It is advisable to disconnect the battery if the vehicle is not to be used for a period of more than one month.

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TOWING YOUR VEHICLE
W ithout lifting (4 wheels on the ground)
Y ou must always use a tow bar.
The towing eyes are located at the front and the rear under the vehicle's bumpers. Lifting (2 wheels only on the ground) It is preferable to raise the vehicle with a professional lifting device. Special features of the automatic gearbox When towing with four wheels on the ground, the following rules must beobeyed: -
lever in position N,
- tow the vehicle at less than
50 km/h over a maximum distanceof 50 km,
- do not add oil to the gearbox.
PRACTICAL INFORMATION 157
When towing with the engine switched off, thereis no braking or steeringassistance.

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TOWING A TRAILER,
CARAVAN, BOAT ETC.
Only use original PEUGEOT tow bars that have been tested andapproved from the design stage ofyour vehicle. The tow bar must be fitted by a
PEUGEOT dealer. Y our vehicle is basically designed
for transporting people and luggage but it may also be used for towing a
trailer. Driving with a trailer subjects the towing vehicle to more significantstress and its driver must be particu-larly careful. Air density decreases with altitude, thus reducing engine performance.Above 1000 metres, the maximumtowing load must be reduced by 10%and so on for every 1000 metres ofaltitude. Driving advice Distribution of loads:
Distribute the
load in the trailer so that the heaviest items are as close as possible to theaxle and the nose weight approachesthe maximum permitted without excee-ding it. Cooling: towing a trailer on a slope
increases the temperature of the coolant. As the fan is electrically controlled, its cooling capacity is not dependenton the engine speed.
On the contrary, use a high gear to lower the engine speed, and reduceyour speed. The maximum towing load on a long slope depends on the gradient andthe outside temperature. In all cases, pay attention to the coolant temperature. If the warning light comes on, stop
the vehicle and switch off the engineas soon as possible. T
yres: check the tyre pressures of
the towing vehicle and of the trailer,observing the recommended pres-sures. Braking: towing increases the braking
distance.Lights: check the electrical signalling
on the trailer.Side wind: take into acount the
increased sensitivity to side wind.
PRACTICAL INFORMATION
158

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TECHNICAL DATA
160
Manual
(5-speed)
PETROL ENGINES
ENGINES
2 litre injection
Cubic capacity (cm 3
) 1998
Bore x stroke (mm) Maximum power 80
EU standard (kW)Maximum power at engine 5 500
speed (rpm)Maximum torque EU standard (Nm) 1 6 8
Maximum torque at engine 3 400
speed (rpm) Fuel Unleadedb
OIL CAPACITY (in litres)Engine (with cartridge replacement) 4 . 7 5
Gearbox-Final drive
MODELS: Model codes GEARBOX

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TECHNICAL DATA161
Manual
Manual
(5-speed) (5-speed) DIESEL ENGINES
ENGINES 2 litre Turbo HDI 2.2 litre Turbo HDI Cubic capacity (cm
3
)1 997 2 178
Bore x stroke (mm)
Maximum power
EU standard (kW) 64 74
Maximum power at engine speed (rpm) 4 0004 000
Maximum torque EU standard (Nm) 1 9 5 2 4 0
Maximum torque at engine 1 900 1 900
speed (rpm) Fuel DieselDiesel
OIL CAPACITY (in litres)
Engine (with cartridge replacement) 5 . 3 5 . 3
Gearbox-FInal drive
MODELS: Model codes GEARBOX