ser Peugeot Boxer 2018 Workshop Manual

126
Diesel engines
1.Windscreen/headlamp wash fluid
reservoir.
2. Power steering fluid reservoir.
3. Coolant tank.
4. Brake and clutch fluid reser voir.
5. Diesel fuel filter.
6. Fusebox.
7. A i r f i l t e r.
8. Dipstick.
9. Engine oil filler cap.
Battery connections:
+ Positive terminal.
- Negative terminal (earth). The Diesel circuit is under very high
pressure.
All work on this circuit must be carried out
only by a
PEUGEOT dealer or a qualified
workshop.
Checking levels
Check all of these levels regularly, in line with
the manufacturer's service schedule. Top them
up if necessary, unless other wise indicated.
If a
level drops significantly, have the
corresponding system checked by a
PEUGEOT
dealer or a
qualified workshop.
If you have to remove/refit the engine
cover, handle it with care to avoid
damaging the fixing clips.
Used products
Avoid prolonged contact of used oil or
fluids with the skin.
Most of these fluids are harmful to health
or indeed very corrosive. Do not discard used oil or fluids into
sewers or onto the ground.
Take used oil to a
PEUGEOT dealer or
a qualified workshop and dispose of it in
the containers reser ved for this purpose.
Engine oil level
Check this regularly and top up as
necessary between two oil changes
(the maximum consumption is 0.5
litres
for 620
miles (1,000 km)). Make the
check with the vehicle standing level,
engine cold, using the dipstick.
Checking using the dipstick
2 marks on the dipstick:
A = MA X
B = MIN
Practical information

127
If you find that the level is above the A mark or
below the B mark, do not star t the engine.
-
I
f the level is above the MAX mark (risk of
damage to the engine), contact a
PEUGEOT
dealer or a
qualified workshop.
-

I
f the level is below the MIN mark, you must
top up the engine oil.
To maintain the reliability of engines and
emission control systems, the use of additives
in engine oil is prohibited.
Topping up the engine oil level Oil change
This must be done at the inter vals specified in
the manufacturer's service schedule. Ask for
advice from a


PEUGEOT dealer.
Refill with engine oil using the procedure
described for topping up.
Check the level after filling (never exceed the
maximum mark). F

T
ake the oil filler funnel.
F
U
nscrew the oil filler cap.
F
P
lace the funnel in the filler hole.
F
T
op up the oil.
F
R
emove the funnel from the filler hole.
F
R
efit the oil filler cap.
F
R
efit the dipstick.
F

R

emove the dipstick before topping up.
Engine oil grade
When topping up, the oil selected must meet
the manufacturer's requirements.
Brake fluid level
The brake fluid must be changed at
the inter vals stated, according to the
manufacturer's service schedule.
Power steering fluid level
The power steering fluid level should
be close to the "MA X" mark.
The vehicle must be parked on level ground
with the engine cold. Unscrew the cap and
gauge assembly and check the level.
Use brake fluid recommended by the
manufacturer, meeting the DOT4


standard.
The level must be between the MIN and MAX
marks on the reservoir.
If fluid has to be added frequently, this
indicates a failure which must be checked by
a

PEUGEOT dealer or a qualified workshop as
soon as possible.
7
Practical information

128
For access to the reser voir filler cap, remove
the protective cover by turning its three fixing
screws a quarter turn, then remove the second
cover fitted to the cap.
Engine coolant level
Check the coolant level regularly.
It is normal to top up this fluid
between two services.
Check the coolant level regularly,
according to the use made of your vehicle
(every 3,000
miles (5,000 km)/3 months);
if necessary, top up using coolant
recommended by the manufacturer.
The check and top up must only be done
with the engine cold.
A low coolant level presents a
risk of
serious damage to your engine.
When the engine is hot, the temperature of the
coolant is regulated by the electric fan. This
may operate with the ignition off; furthermore,
because the cooling system is under pressure,
wait for at least one hour after the engine has
stopped before carrying out any work. F

F
or access to the tank filler cap, remove the
protective cover by turning its three fixing
screws a

quarter turn.
F
T
o avoid the risk of scalding, place a cloth
around the cap, then loosen the cap by
a
quarter turn to release the pressure.
F

W
hen the pressure has dropped, remove
the cap and top up the level with coolant.
To p p i n g u p
The level must be between the MIN and MAX
marks on the expansion bottle.
As close as possible to the MAX mark is
recommended.
If more than 1
litre of fluid is required to top
up the level, have the system checked by
a
PEUGEOT dealer or a qualified workshop.
Screenwash and headlamp
wash level
To check the level or top up the fluid
on vehicles fitted with headlamp
washers, immobilise the vehicle and
switch off the engine.
Capacity of the reservoir: approximately
5.5


litres.
F

F

or access to the reser voir filler cap, pull on
the telescopic filler pipe and unclip the cap.
Practical information

129
Checks
These operations allow your vehicle to be
kept in good working order. Ask for advice
from a PEUGEOT dealer or refer to the
manufacturer's service schedule included
in the handbook pack.
Battery
The battery does not require any
maintenance.
However, check regularly that the
terminals are correctly tightened
(models without quick release
terminals) and that the connections
are clean. Models equipped with Stop & Start are
fitted with a
12 V lead-acid battery of
specific technology and specification.
Its replacement should be carried out
only by a PEUGEOT dealer or a qualified
workshop.
Air filter
At the start of winter, have your battery checked
by a PEUGEOT dealer or a qualified workshop.
For best quality cleaning and to prevent
freezing, this fluid must not be topped up or
replaced with plain water.
In wintry conditions, the use of an alcohol or
methanol based fluid is recommended.
Refer to the manufacturer's
ser vice schedule for details of
the replacement inter val for this
component.
Depending on the environment (e.g. dusty
atmosphere) and the use of the vehicle (e.g.
city driving), replace it twice as often if
necessary .
Passenger compartment
filter
Refer to the manufacturer's
ser vice schedule for details of
the replacement inter val for this
component. Depending on the environment (e.g. dusty
atmosphere) and the use of the vehicle (e.g.
city driving), replace it twice as often if
necessary
.
Oil filter
Change the oil filter each time the
engine oil is changed.
Refer to the manufacturer's
ser vice schedule for details of
the replacement inter val for this
component.
Particle filter (Diesel)
A clogged passenger compartment
filter may have an adverse effect on
the per formance of the air conditioning
system and generate undesirable odours.
As an addition to the catalytic converter,
this filter makes an active contribution to the
preser vation of air quality by retaining unburnt
pollutant particles. Black exhaust fumes are
also eliminated.
7
Practical information

130
Operation
This filter, fitted in 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 triggered
depending on the amount of particles
accumulated and the vehicle use conditions.
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. 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, etc.) so as to
avoid any risk of fire.
Saturation/Regeneration
If there is risk of blockage of the
filter, this warning lamp comes on in
the instrument panel.
This alert tells you that the particle filter is
starting to saturate (in conditions of urban
driving of exceptionally long duration: low
speeds, traffic jams, etc.).
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
37

mph (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 the filter regeneration;
repeated interruptions could cause premature
deterioration of the engine oil. It is not
recommended to end regeneration of the filter
with the vehicle stationary.
Malfunction
If this alert persists, do not ignore the warning;
it indicates that a fault has occurred in the
exhaust system/particle filter assembly.
Have the whole system checked by
a
PEUGEOT dealer or a qualified workshop.
Manual gearbox
The gearbox does not require any
maintenance (no oil change).
Brake pads
Brake wear depends on the style
of driving, particularly in the case
of vehicles used in town, over short
distances. It may be necessary to
have the condition of the brakes
checked, even between vehicle
services.
If this warning lamp comes on, have
the brake pad wear checked by
a
PEUGEOT dealer or a qualified
workshop.
Practical information

131
Brake disc wear
For information on checking brake
disc wear, contact a PEUGEOT
dealer or a
qualified workshop.
Parking brake
If excessive travel or a loss of
e ffectiveness of this system is
noticed, the parking brake must
be checked, even between two
services.
This system must be checked by a
PEUGEOT
dealer or a
qualified workshop.
Diesel fuel filter
The Diesel fuel filter is located under the
bonnet, close to the brake fluid reser voir. If this warning lamp comes on, the
filter must be purged to remove
water.
You can also purge the fuel filter
regularly, every time the engine oil
is changed.
Purging water from the filterThe HDi engines use advanced technology.
All work must be done by personnel that
have had special training, which can be
ensured by going to a
PEUGEOT dealer or
a


qualified workshop.
Only use products recommended by
PEUGEOT or products of equivalent
quality and specification.
In order to optimise the operation of
components as important as those in the
braking system, PEUGEOT selects and
offers very specific products.
After washing the vehicle, dampness, or
in wintry conditions, ice can form on the
brake discs and pads: braking efficiency
may be reduced. Make light brake
applications to dry and defrost the brakes.
F

C

onnect a

transparent pipe to the head of
the purge screw 1 .
F

P

lace the other end of the transparent pipe
in a

container.
F

L

oosen the purge screw 2 .
F

S

witch the ignition on.
F

W

ait until the supply pump stops running.
F

S

witch the ignition off.
F

T

ighten the purge screw 2 .
F

R

emove and then empty the transparent
pipe and the container.
F

S

tart the engine.
F

C

heck that there are no leaks.
7
Practical information

132
Freezing of the AdBlue®
AdBlue® freezes at temperatures below
around -11°C.
The SCR system includes a
heater for the
AdBlue
® tank, allowing you to continue
driving in very cold conditions.
Topping up with AdBlue®
Before topping up, please read the
following warnings carefully.
Precautions for use
AdBlue® is a urea-based solution. This fluid
is
non-flammable, colourless and odourless
(stored in a
cool place).
In the event of contact with the skin, wash the
affected area with soap and running water. In
the event of contact with the eyes, immediately
rinse the eyes with large amounts of water
or with an eye wash solution for at least
15

minutes. If a burning sensation or irritation
persists, get medical attention.
If swallowed, immediately wash out the mouth
with clean water and then drink plenty of water.
In certain conditions (high exterior temperature,
for example), the risk of ammonia being
released cannot be excluded: do not inhale
the vapours. Ammonia has an irritant effect on
mucous membranes (eyes, nose and throat).
AdBlue® (BlueHDi engines)
To respect the environment and ensure
compliance with the Euro 6 standard, without
adversely affecting the per formance or fuel
consumption of Diesel engines, PEUGEOT
has taken the decision to equip its vehicles
with a
system that associates SCR (Selective
Catalytic Reduction) with a
Diesel particle filter
(DPF) for the treatment of exhaust gases.
SCR system
Using a liquid called AdBlue® containing urea, a
catalytic converter turns up to 85% of nitrogen
oxides (NOx) into nitrogen and water, which are
harmless to health and the environment.
The AdBlue
® is contained in a special tank with
a
capacity of approximately 14 litres.
It has an exterior filler located behind the fuel
filler flap below the fuel filler cap and closed
with a

blue filler cap .
An alarm system is triggered once the
remaining range is 1,500
miles (2,400 km), in
other words once the reser ve level is reached. Once the AdBlue
® tank is empty, a
regulatory device prevents the engine
from being restarted.
If the SCR system is faulty, the level of
emissions from your vehicle no longer
meet the Euro 6

regulations: your vehicle
becomes polluting.
In the event of a

confirmed fault with the
SCR system, you must go to a
PEUGEOT
dealer or a

qualified workshop as soon
as possible: having travelled 250 miles
(400 km), a device will be triggered
automatically to prevent the engine from
starting.
Practical information

134
Refilling
F Insert the AdBlue® pump nozzle and refill
the tank until the nozzle stops automatically. Important:
-

N
ever pour AdBlue
® into the Diesel fuel
tank.
-

T

o avoid over flowing the AdBlue
® tank,
it is recommended:
•

T

o do a

top up between 10

and
13

litres using the AdBlue
® container
or bottle.
Or
•

I

f filling in a

ser vice station, to stop
after the first automatic shut-off of
the nozzle.
-
I

f 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 4

litres.
If any AdBlue
® is splashed, or if there are
any spillages on the side of the body, rinse
immediately with cold water or wipe with
a

damp cloth.
If the fluid has crystallised, clean it off
using a

sponge and hot water.
F

O

btain an


AdBlue
® container or bottle. After
first checking the use-by date, read the
instructions on the label carefully before
pouring the contents of the container or
bottle into your vehicle's AdBlue tank.
Or F

R
efit the blue cap to the tank filler and turn it
1/6 of a turn clockwise, to its stop.
F
C
lose the fuel filler flap.
Important: In the event of a top-up after
running out of AdBlue , you must wait
about five minutes before switching on the
ignition, without opening the driver's
door, unlocking the vehicle or inser ting
the key in the ignition switch .
Switch on the ignition, then wait for
10 seconds before starting the engine.
Practical information

135
Temporary puncture
repair kit
This temporary puncture repair kit is kept
in a bag and stowed in one of the front door
pockets.
It consists of:
-

a c
artridge A , containing the sealant fluid,
equipped with:
•

a f
illing hose B ,
•

a
n adhesive sticker C showing "max.
50
mph (80 km/h)" that the driver
must apply in a
visible place (on the
dashboard) after having repaired the tyre,
-

a q
uick guide to use of the repair kit,
-

a c
ompressor D equipped with a pressure
gauge and unions,
-

a
daptors, for the inflation of various items.
Repairing a tyre
F Apply the parking brake.
F
U
nscrew the tyre valve cap, remove the
filling hose B and screw the ring E onto the
valve.
F

S
tart the engine.
F

C
heck that the switch F on the compressor
is in position 0 (of f ). F

I
nsert the connector G into the nearest
power socket on the vehicle.
F

S
witch on the compressor by placing the
switch F in position I (o n),
F

I
nflate 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.
8
In the event of a breakdown

136
F If a pressure of at least 3 bar is not
reached within 5 minutes, disconnect the
compressor from the valve and the power
socket, then move the vehicle for ward by
approximately 10
metres to distribute the
sealant fluid inside the tyre.
F

T
hen repeat the inflation operation:
•

i
f a pressure of at least 3 bar is not
reached within 10
minutes, switch off your
vehicle: the tyre has suffered too much
damage and it could not be repaired.
Contact a
PEUGEOT dealer or a qualified
workshop.
•

i
f the tyre has been inflated to a pressure
of 5
bar, set off again immediately.
F

A
fter driving for approximately 10 minutes,
stop and check the pressure of the tyre
again.
F

A
djust the pressure to the value given on
the label on the driver's door pillar, and
contact a
PEUGEOT dealer or a qualified
workshop as soon as possible.
This puncture repair kit and replacement
cartridges are available from PEUGEOT
dealers.Checking and adjusting the
pressure
The compressor can only be used to check and
adjust the pressure.
F

D
isconnect the hose I and connect it to the
tyre valve directly; the cartridge will then be
connected to the compressor and the filling
fluid will not be injected.
If it is necessary to deflate the tyre, connect the
hose I to the tyre valve and press the yellow
button, placed in the centre of the switch on the
compressor.
Replacing the cartridge
To replace the sealant cartridge, proceed as
follows:
F

D
isconnect the hose I .
F

T
urn the cartridge to be replaced
anticlockwise and lift it,
F

I
nsert the new cartridge and turn it
clockwise,
F

R
econnect the hose I and attach hose B in
its location.
The cartridge contains ethylene glycol, a
product which is harmful if swallowed and
which causes irritation to the eyes.
It must be kept out of the reach of children. After use, do not discard the cartridge
into the environment, take it to an
authorised waste disposal site or
a
PEUGEOT dealer.
In the event of a breakdown