engine PEUGEOT BOXER 2015 Workshop Manual

136
BLuEHdI
A
nd AdBLuE® AddItIVE
AdBlue® is the brand name of the solution
needed for operation of the SCR system.
BlueHDI vehicles have a specific AdBlue
®
additive tank with a capacity of 15 litres.
It has an exterior filler located behind the
fuel filler flap below the fuel filler cap and
closed with a blue filler cap.
the objective of BlueHDi is to reduce by


up to 90% the emissions of NOx (nitrous
oxides) in the air, using a system that
converts NOx into water vapour and nitrogen
in a dedicated catalytic converter: SCR
(Selective Catalytic Reduction).
this objective meets the "euro 6" emissions


standard adopted by the
european union


aimed at limiting the emissions of pollutants
from internal combustion engines.
the SCR technology used on BlueHDi


engines involves the injection of AdBlue
®
fluid into the exhaust system.this operation can also be carried out
by a PeugeOt dealer or a qualified
workshop.
Scr technology
Filling of the AdBlue® tank can be done
using:
-
5 or 10 litres containers equipped with a
10 centimetre filler tube or the filling kit


available from P
eugeOt dealers,
-
1.89 litre botles that are screwed onto
the filler neck, available from P
eugeOt
dealers,
-
or when at a fuel filling station equipped
with a special

AdBlue
® delivery pump for
heavy or light vehicles.
AdBlue® additive

138
range indicators
Different levels of alert are triggered
according to the remaining driving range
threshold.
You will be informed as each mileage
threshold is reached and the alerts will
change from temporary to permanent.
-

t
he 1st alert is triggered at a remaining
driving range of 1 500 miles (2 400 km).
-


t
he 2nd alert is triggered at a remaining
driving range of 375 miles (600 km).
up to 0 miles, at which point it will be


impossible to restart the engine after a stop.
range greater than 1 500 miles (2 400 km)
No information displayed.
Once the 1 500 miles (2 400 km)
threshold is reached, this warning
lamp comes on temporarily and the
remaining range message is displayed.
every time the ignition is switched on, the
alert is given, together with an audible
signal.
remaining range less than 1 500 miles


(2 400 km) and greater than 375 miles
(600 km)
Once the 350 miles (600 km) threshold
is reached, this warning lamp flashes,
accompanied by a message on the
remaining driving range.
the alert is repeated with an update of the
remaining driving range in steps of 30 miles
(50 km) travelled.
every time the ignition is switched on, the


alert is given together with an audible signal.
At 0 miles the system installed in the
vehicle to meet the emissions standard
will prevent engine starting.
the 0 level of
AdBlue
® additive has been
reached.
Your vehicle's exhaust emissions no longer
meet the "
euro 6" standard and the engine


will not start.
to be able to restart

the vehicle, you must
add at least 3.8 litres of AdBlue
®.
-
Pour the additive into the tank (by the
filler with the blue cap).
-
Switch on the ignition without starting.
-
Wait 10 seconds before starting the


engine.
remaining range less than 350 miles



(600 km) and more than 0 miles Starting prevented, breakdown related to a
lack of AdBlue
®
additive in the special tank
Avoid waiting until the remaining
range is 0 miles!
the alert is repeated when driving until the


AdBlue additive tank has been topped-up
with sufficient additive.
unless the additive in the special additive


tank is topped-up, you risk immobilisation of
the vehicle. Following this, make a further fill to the
special additive tank, the capacity of
which is 15 litres. Or go to a P
eugeOt dealer or a
qualified workshop.
AdBlue® additive

139
Fault with the Scr system
the diagnostic warning lamp
comes on.
every time the ignition is


switched on, the emissions fault
is confirmed by an audible signal and a
message.
If it is a temporary fault, the alert disappears
as soon as the exhaust emissions return to
the levels required by the standard. Fault confirmed
In addition to the previous signals, the
remaining range allowed will be displayed in
miles (kilometres) in the instrument panel.
the alert will be repeated every 30 seconds


with an update of the driving range.
go to a PeugeOt dealer or a qualified
workshop as soon as possible.
Y

ou risk not being able to start the engine. Starting prevented, having covered the
250 miles (400 km)
detection
At each attempt at starting,

the alert is activated and the
message on starting prevention is
displayed.
On the other hand, if the warning lamp
is still on after 30 miles (50 km) of
driving, the fault is confirmed.
An engine start prevention system
will be activated automatically after
250
miles (400 km) travelled following this


confirmation.
go to a PeugeOt dealer or a qualified
workshop.
AdBlue® additive
7
CHeCKS

140
refilling / topping-up the
AdBlue® additive
Precautions to take
use

only AdBlue® additive that meets the
ISO 22241 standard.
the AdBlue® additive is an urea-based
solution.
this liquid is non-flammable, colourless and


odourless.
to be kept in a cool area.
containers (5 or 10 litres) and bottles


(1.89 litres) of AdBlue
®
Please check the use-by date.
Read the instructions on the label.
ensure that you have a suitable filler pipe,


which may or may not be supplied with the
container. Park the vehicle
-
Before topping-up, ensure that the
vehicle is parked on a flat and level


surface.
open the filler
-
Open the fuel filler flap.
-

t
urn the blue cap a 6th of a turn anti-
clockwise.
-
Remove the blue cap downwards.
top-up
-
Obtain a bottle of AdBlue®. After first
checking the use-by date, read carefully
the instructions on use on the label
before pouring the contents of the bottle
into your vehicle's AdBlue
® tank.
Important: if your vehicle's AdBlue
®
tank is completely empty - which is
confirmed by the alert messages and the
impossibility of starting the engine, you
must add at least 3.8 litres (so two 1.89 litre
bottles).
-
After emptying the bottle, wipe away any
spillage around the tank filler using a


damp cloth.
If any additive is split or splashed,
wash immediately with cold water or
wipe with a damp cloth.
If the additive has crystallised, clean it off
using a sponge and hot water.
AdBlue® additive

142
A. Positive metal point on your vehicle
B.
Slave battery
c.

e
arth on your vehicle
Make connections only to the points


indicated and illustrated above. Failure
to observe this instruction introduces
the risk of short-circuit!Starting from another
battery
B
AttErY
c
harging the battery using a
charger
- 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. -
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.
Discharged battery

143
Access to the battery
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.
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.
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. 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
P
eugeOt dealer or a qualified workshop.
Discharged battery
QuICK HeLP
8

145
the three fuseboxes are located in the
dashboard on the left-hand side, in the
right-hand 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 P
eugeOt
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 FuSEPeugeOt 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 P
eugeOt 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 P
eugeOt
dealer network.
dashboard, left-hand side,
fuses
Remove the bolts and tilt the box to access
the fuses.
QuICK HeLP
8
Failed fuse

146FusesA (amps) Allocation
12 7.5Right-hand dipped headlamp
13 7.5Left-hand dipped headlamp
31 5
engine compartment control unit relay - Dashboard control unit relay (ig\
nition switch +)
32 7.5Cabin lighting (battery +)
33 7.5Battery check sensor on Stop & Start version (battery +)
34 7.5Minibus interior lighting - Hazard warning lamps
36 10Audio system -

Air conditioning controls - Alarm -
tachograph - Battery cut-off control unit -

Additional heating programmer (battery +)
37 7.5Brake lamp switch -
third brake lamp Instrument panel (ignition +)
38 20Central door locking (battery +)
42 5ABS control unit and sensor -

ASR sensor - DSC sensor - Brake lamp switch
43 20Windscreen wiper motor (ignition switch +)
47 20Driver's electric window motor
48 20Passenger's electric window motor
49 5Parking sensors control unit - Audio system - Steering mounted controls - Centre and side switch panels\
-
Auxiliary switch panel - Battery cut-off control unit (ignition switch +)
50 7.5Airbags and pre-tensioners control unit
51 5
tachograph - Power steering control unit - Air conditioning - Reversing lamps - W

ater in Diesel sensor -
Air flow sensor (ignition switch +)
53 7.5Instrument panel (battery +)
89 -Not used
90 7.5Left-hand main beam
91 7.5Right-hand main beam
92 7.5Left-hand front foglamp
93 7.5Right-hand front foglamp
Failed fuse

148
Fuses in the engine compartment
Remove the nuts and tilt the box to access
the fuses.
refit the cover carefully after checking or

replacing fuses. Fuses
A (amps) Allocation
1 40ABS pump supply
2 50Diesel pre-heat unit
3 30Ignition switch - Starter motor
4 40Fuel heater
5 20/50Cabin ventilation with additional programmable heating
(battery +)
6 40/60Cabin fan maximum speed (battery +)
7 40/50/60 Cabin fan minimum speed (battery +)
8 40Cabin fan assembly (ignition switch +)
9 15Rear 12 V socket (battery +)
10 15Horn
11 -Not used
14 15Front 12 V socket (battery +)
15 15Cigarette lighter (battery +)
16 -Not used
17 -Not used
18 7.5
engine management control unit (battery +)
19 7.5Air conditioning compressor
20 30Screenwash/headlamp wash pump
21 15Fuel pump supply
22 -Not used
23 30ABS electrovalves
24 7.5Auxiliary switch panel - Door mirror controls and folding


(ignition switch +)
30 15Door mirror heating
Failed fuse

161
PuncturE rEPAIr KItrepairing the tyre
- Apply the parking brake.
-

u
nscrew 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 5 bar.
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 stowed

in a bag located in one of the front door
pockets.
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 af

fix 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.
QuICK HeLP
8
Puncture