engine Peugeot Boxer 2014 Service Manual

Levels and checks
127
7
CHECKS
Manual gearbox
Have the level checked in accordance with
the manufacturer's servicing schedule.
Good practice
To check the main levels and certain
components, in accordance with the
manufacturer's servicing schedule, refer to
the pages of the warranty and maintenance
record which correspond to your vehicle's
engine.
Only use products recommended by
PEUGEOT or products of equivalent quality
and specification.
In order to optimise the operation of units as
important as the braking system, PEUGEOT
selects and offers specific products.
Oil filter
Change the filter regularly, in accordance
with the manufacturer's servicing schedule.
Brake pads
Brake pad wear depends on the style of
driving, in particular for vehicles which are
used in town, over short distances. It may
be necessary to check the thickness of the
pads, even between services.
Brake disc/drum wear status
For any information relating to checking
the brake disc/drum wear status, contact a
PEUGEOT dealer or a qualified workshop.
Parking brake
Where the parking brake travel is too great
or there is a reduction in the performance
of the system, the parking brake should be
adjusted, even between services.
Have the system checked by a PEUGEOT
dealer or a qualified workshop.
If this warning lamp comes on,
have the brake pad wear checked
by a PEUGEOT dealer or a
qualified workshop. In order to avoid damaging the
electrical units, high pressure washing
to clean the engine compartment is strictly
prohibited.
After washing the vehicle dampness, or in
winter, ice may form on the brake discs and
pads: braking efficiency may be reduced.
Make some light brake applications to dry
and de-ice the brakes.

Levels and checks
128
Operating fault
If this alert persists, do not ignore the
warning; it indicates that a fault has occurred
in the exhaust / particle filter system.
Have the whole system checked by a
PEUGEOT dealer or a qualified workshop.
If there is risk of blockage of the
filter, this warning lamp comes on
in the instrument panel.
Saturation / Regeneration Because of the higher exhaust
gas temperature resulting from the
normal operation of the particle filter, it is
recommended that you do not park the
vehicle over inflammable materials (grass,
dry leaves, pine needles, ...) so as to avoid
any risk of fire.
Particle filter system (Diesel)
An addition to the catalytic converter, this
filter makes an active contribution to the
preservation of air quality by the retaining
of the unburnt pollutant particles. Black
exhaust fumes are thus no longer emitted.
Operation
This filter, fitted to the exhaust system,
accumulates particles of soot. The engine
management unit controls the automatic
periodic elimination of the soot particles
(regeneration).
The regeneration procedure is invoked
according to the quantity of particles
accumulated and the driving conditions
of the vehicle. During this phase, you
may notice some unusual phenomena -
increased idling speed, cooling fan running,
increase in smoke and higher exhaust gas
temperature - which does not affect the
operation of the vehicle or the environment. After prolonged idling or driving at very
low speeds, you may occasionally
notice water vapour being emitted from the
exhaust when accelerating. This is of no
consequence to the running of the vehicle or
to the environment. To regenerate the filter, it is advised to
drive as soon as possible, when traffic
conditions and the law permit, at a speed
of at least 40 mph (around 60 km/h), with
an engine speed above 2 000 rpm for about
fifteen minutes (until the warning lamp and/
or the message disappears).
If possible, avoid switching off the engine
before the end of regeneration of the
filter; repeated interruptions could cause
premature deterioration of the engine oil. It
is not recommended to end regeneration of
the filter with the vehicle stationary.
This alert tells you that the particle filter
is starting to fill up (in conditions of urban
driving of exceptionally long duration: low
speeds, traffic jams etc.)

Fuel
129
7
CHECKS
Low fuel level
When the fuel tank level E
(Empty) is reached, this warning
lamp comes on. At this moment,
you have around 10 to 12 litres
in the reserve, depending on the capacity
of the tank, the engine type, the driving
conditions and the profile of the road. Refuel
without delay to avoid running out of fuel.
The capacity of the fuel tank is
approximately 90 litres.
Fuel tanks of different capacities, 60 and
125 litres, may be fitted.
REFUELLING
In low temperatures
In mountainous and/or cold areas, it is
advisable to use a "winter" type fuel suited
to low or minus temperatures. With Stop & Start, never refuel with
the system in STOP mode; you must
switch off the ignition with the key. The fuel tank must be filled
with the engine
off.
- Open the fuel filler flap.
- Support the cap with one hand.
- With the other hand, insert the key, then turn it anticlockwise.
- Remove the cap and hook it onto the clip located on the inside of the flap.
A label affixed to the inside of the flap
reminds you of the type of fuel to be used.
When filling the fuel tank, do not continue
after the 3rd cut-off of the nozzle. This could
cause malfunctions.
- After filling the fuel tank, lock the cap and close the flap.

Fuel
130
FUEL SYSTEM
CUT-OFF
Following an impact and before
restoring the supply, check that there is
no leak of fuel or sparks so as to avoid any
risk of fire. In the event of a collision, a device
automatically cuts off the fuel supply to the
engine and the vehicle's electrical supply.
It switches on the hazard warning lamps and
the courtesy lamps, as well as unlocking the
doors. To restore the fuel supply, press the first
button located under the glove box.
Then, to restore the electrical power supply,
press the second button, located in the
battery compartment under the driver's floor
(Minibus).
On other versions the second button
is replaced by a fuse; contact a
PEUGEOT dealer or a qualified workshop.

131
QUICK HELP
8
Discharged battery
A. Positive metal point on your vehicle
B. Slave battery
C. Earth on your vehicle
Starting from another battery
- Connect the red cable to the metal point A then to the positive (+) terminal
of the slave battery B .
- Connect one end of the green or black cable to the negative (-) terminal of the
slave battery B .
- Connect the other end of the green or black cable to the earth point C on your
vehicle.
- Operate the starter, let the engine run.
- Wait for the engine to return to idle, then disconnect the cables.
Charging the battery using a charger
- Go to the battery located in the front left floor.
- 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
sulphate (white or greenish deposit),
disconnect them and clean them.
BATTERY

132
Discharged battery
The charging operation must be carried
out in a ventilated area away from
naked flames or any possible sources of
sparks to eliminate the risk of explosion and
fire.
Do not attempt to charge a frozen battery: it
must first be thawed to eliminate the risks of
explosion. If the battery has frozen, before
charging it have it checked by a specialist
who will check that the internal components
have not been damaged and that the
container is not cracked, which could mean
that there is a risk of a leak of toxic and
corrosive acid.
Proceed with a slow charge charge at low
current for a maximum pf about 24 hours to
avoid damaging the battery. The batteries contain harmful
substances such as sulphuric acid and
lead. They must be discarded in accordance
with the provisions of the law and must not,
in any circumstances, be discarded with
household waste.
Take used batteries to a special collection
point.
Before disconnecting the battery, you must
wait for 2 minutes after switching off the
ignition.
Never disconnect a terminal when the
engine is running.
Never charge a battery without first
disconnecting the terminals.
Close the windows and doors before
disconnecting the battery.
After every reconnection of the battery,
switch on the ignition and wait 1 minute
before starting to allow the electronic
systems to be initialised. If slight difficulties
are experienced after this, please contact a
PEUGEOT dealer or a qualified workshop.
Unscrew the 6 access cover retaining
screws.
Lift off or remove completely the access
cover.
Press lever
1 downwards to spread the
clamp.
Remove the terminal 2 from the negative (-)
post.
Access to the battery

Failed fuse
134
The three fuseboxes are located in the
dashboard on the driver's side, in the
passenger's side pillar and in the engine
compartment.
The descriptions provided cover only the
fuses that can be replaced by the user. For
any other replacement, go to a PEUGEOT
dealer or a qualified workshop.
Removing and fitting a fuse
Before changing a fuse, the cause of the
fault must be found and rectified. The fuse
numbers are indicated on the fusebox.
Always replace a faulty fuse with a fuse
of the same rating.
CHANGING A FUSE PEUGEOT does not accept any
responsibility for expenses incurred
by repairs to your vehicle or for any
malfunctions resulting from the installation
of additional accessories which are not
supplied or recommended by PEUGEOT
and which are not installed in accordance
with its instructions, in particular when
the combined consumption of all of the
additional equipment connected exceeds
10 milliamperes.
Good
Failed
Information for technicians: for
complete information on the fuses and
relays, refer to the wiring diagrams in the
workshop procedures via the PEUGEOT
dealer network.
Driver's side dashboard fuses
Remove the bolts and tilt the box to access
the fuses.

Failed fuse
137
QUICK HELP
8
Fuses in the engine compartment
Remove the nuts and tilt the box to access
the fuses. Fuses
A (amps) Allocation
1 40 ABS pump supply
2 50 Diesel pre-heat unit
3 30 Ignition switch
4 20 Additional programmable heating
5 20 Cabin ventilation with additional
programmable heating
6 40/60 Cabin fan maximum speed
7 40/50 Cabin fan minimum speed
8 40 Cabin fan assembly
9 20 Screenwash pump
10 15 Horn
14 7.5 RH main beam
15 7.5 LH main beam
18 7.5 Engine management
19 7.5 Air conditioning compressor
20 30 Headlamp wash pump
21 15 Fuel pump supply
23 30 ABS electrovalves
30 15 Front foglamps

Puncture
148
PUNCTURE REPAIR KIT Repairing the tyre
- Apply the parking brake. Unscrew the tyre valve cap, remove the filling hose B
and screw the ring E onto the valve, - start the engine,
- insert the connector G
into the nearest
power socket on the vehicle,
- switch on the compressor by placing the switch F in position I (on),
- inflate the tyre to a pressure of 4 bars.
To obtain a more accurate reading, you are
advised to check the pressure value on the
pressure gauge H , with the compressor off.
- check that the switch F on the
compressor is in position 0 (off),
This temporary puncture repair kit is located
at the front of the passenger compartment.
It consists of:
- a cartridge A
, containing the sealant
fluid, equipped with:
● a filling hose B ,
● a sticker C indicating "max. 80 km/h",
which the driver must affix in full view
(on the dashboard) after repairing the
tyre,
- a quick guide to use of the repair kit,
- a compressor D equipped with a
pressure gauge and unions,
- adaptors, for the inflation of various items.

Being towed or towing
150
TOWING
Towing the vehicle
The removable towing eye is located in the
tool box under the front passenger seat.
Unclip the cover using a flat tool.
Screw the removable towing eye in fully.
Attach the approved towing bar to to the
removable towing eye.
Place the gear lever in neutral.
Towing another vehicle
The fixed towing eye is located on the right
below the bumper.
Attach the approved towing bar onto the
fixed eye.
Failure to observe this requirement
may result in damage to certain braking
components and the lack of some braking
assistance systems when the engine is re-
started.
General recommendations
Observe the legislation in force in your
country.
Ensure that the weight of the towing vehicle
is higher than that of the towed vehicle.
The driver must remain at the wheel of the
towed vehicle and must have a valid driving
licence.
When towing a vehicle with all four wheels
on the ground, always use an approved
towing bar; rope and straps are prohibited.
The towing vehicle must move off gently.
When towing a vehicle with the engine off,
there is no longer any power assistance for
braking or steering.
In the following cases, you must always call
on a professional recovery service:
- vehicle broken down on a motorway or fast road,
- four-wheel drive vehicle,
- when it is not possible to put the gearbox into neutral, unlock the
steering, or release the parking brake,
- towing with only two wheels on the ground,
- where there is no approved towing bar available...