Service Peugeot Boxer 2020 User Guide

96
Practical information
Topping up the engine oil level

► Remove the dipstick before topping up.► Recover the oil filler neck.► Unscrew the filler cap.► Install the oil filler neck in the filler hole.► Top up with oil.► Remove the oil filler neck from the filler hole.► Replace the filler cap.► Replace the dipstick.
Brake fluid
The level of this fluid should be close to
the "MAX" mark. If not, check the brake
pad wear.
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 the following levels regularly in
accordance with the manufacturer's service
schedule. Top them up if required, unless
otherwise indicated.
If a level drops significantly, have the
corresponding system checked by a PEUGEOT
dealer or a qualified workshop.
The fluids must comply with the manufacturer's requirements and with
the vehicle's engine.
Take care when working under the bonnet, as certain areas of the engine
may be extremely hot (risk of burns) and the
cooling fan could start at any time (even with
the ignition off).
If the engine cover is to be removed /
refitted, handle it with care to avoid
damaging the mounting clips.
Used products
Avoid prolonged contact of used oil or fluids with the skin.
Most of these fluids are harmful to health and
very corrosive.
Do not discard used oil or fluids into sewers or onto the ground.
Empty used oil into the containers reserved
for this purpose at a PEUGEOT dealer or a
qualified workshop.
Engine oil
The level is checked, with the engine having been switched off for at least 30
minutes and on level ground, using the dipstick.
It is normal to top up the oil level between two
services (or oil changes). It is recommended
that you check the level, and top up if necessary,
every 3,000 miles (5,000 km).
In order to maintain the reliability of the
engine and emissions control system,
never use additives in the engine oil.
Checking using the dipstick
For the location of the dipstick, please refer
to the illustration of the corresponding engine
compartment.
► Grasp the dipstick by its coloured grip and pull it out completely.
► Wipe the end of the dipstick using a clean, lint-free cloth.

► Reinsert the dipstick and push fully down, then pull it out again to visually check the oil
level: the correct level is between marks A (max) and B (min).
Do not start the engine if the level is:
– above mark A: contact a PEUGEOT dealer or
a qualified workshop.
– below mark B: top up the engine oil
immediately.
Oil grade
Before topping up or changing the engine
oil, check that the oil is suitable for the engine
and complies with the recommendations in
the service schedule supplied with the vehicle
(or available from your PEUGEOT dealer and
qualified workshops).
Use of non-recommended oil may invalidate
the contractual warranty in the event of
engine failure.

97
Practical information
7Topping up the engine oil level

► Remove the dipstick before topping up.► Recover the oil filler neck.► Unscrew the filler cap.► Install the oil filler neck in the filler hole.► Top up with oil.► Remove the oil filler neck from the filler hole.► Replace the filler cap.► Replace the dipstick.
Brake fluid
The level of this fluid should be close to
the "MAX" mark. If not, check the brake
pad wear.
To know how often the brake fluid should be
replaced, refer to the manufacturer's servicing
schedule.
If topping up, clean the cap before
replacing it. Use only DOT4 brake fluid
from a sealed canister.
Power steering fluid
The level of this fluid should be close to the "MAX" mark. Check it, with the
vehicle parked on level ground and with the
engine cold, by reading the level on the filler
neck.
Unscrew the cap secured to the dipstick. To
access the reservoir cap, remove the protective
cover by turning its three fixing screws a quarter
turn, then remove the second cover placed on
the cap.
Engine coolant
It is normal to top up this fluid between
two services.
The check and top-up must only be done with
the engine cold.
A low level presents a risk of serious damage to
the engine.
The level of this fluid should be close to the
"MAX" mark but should never exceed it.
If the level is close to or below the " MIN” mark, it
is essential to top up.
When the engine is hot, the temperature of this
fluid is regulated by the fan.
As the cooling system is pressurised, wait at
least one hour after switching off the engine
before carrying out any work.


To gain access to the tank cap, remove the
protective cover by turning its three fixing screws
a quarter of a turn.
In order to avoid the risk of scalding if you need
to top up in an emergency, wrap a cloth around
the cap and unscrew the cap by two turns to
allow the pressure to drop.
Once the pressure has dropped, remove the cap
and top up to the required level.
Check the coolant level regularly
according to the use of your vehicle
(every 3,000 miles (5,000 km) / 3 months).

98
Practical information
A clogged passenger compartment filter can adversely affect air conditioning
system performance and generate
undesirable odours.
Oil filter
Change the oil filter each time the engine oil is changed.
Particle filter (Diesel)
In addition to the catalytic converter, this filter
actively contributes to the preservation of
air quality by trapping the unburnt pollutant
particles. Black exhaust fumes are therefore not
emitted.
Operation
This filter, inserted into the exhaust system,
accumulates the carbonaceous particles. The
engine management computer automatically
and periodically manages the removal of
carbonaceous particles (regeneration).
The regeneration procedure is triggered
according to the amount of accumulated
particles and the conditions of use of the vehicle.
During this phase, you may notice certain
phenomena - accelerated idling, triggering of
the cooling fan, increased smoke and increased
temperature at the exhaust - which have no
impact on the operation of the vehicle and the
environment.
Screenwash and headlamp
washer fluid
To check the level or top up this fluid on vehicles fitted with headlamp washers,
immobilise the vehicle and switch off the engine.
Reservoir capacity: approximately 5.5 litres.


To access the filler cap, pull the telescopic filler
neck and unclip the cap.
Fluid specification
The fluid must be topped up with a ready-to-use
mixture.
In winter (temperatures below zero), a liquid
containing an agent to prevent freezing must
be used which is appropriate for the prevailing
conditions, in order to protect the elements of the
system (pump, tank, ducts, jets, etc.).
Filling with pure water is prohibited under
all circumstances (risk of freezing,
limestone deposits, etc.).
AdBlue (BlueHDi)
An alert is triggered when the reserve level is
reached.
For more information on Indicators and in
particular the AdBlue range indicators, refer to
the corresponding section.
To avoid the vehicle being immobilised in
accordance with regulations, you must top up the
AdBlue tank.
For more information on AdBlue
® (BlueHDi),
and in particular on the supply of AdBlue, refer to
the corresponding section.
Checks
Unless otherwise indicated, check these
components in accordance with the
manufacturer's service schedule and according
to your engine.
Otherwise, have them checked by 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.
12 V battery
The battery does not require any maintenance.
However, check regularly that the terminals
are correctly tightened (versions without quick
release terminals) and that the connections are
clean.
For more information on the precautions
to take before any work on the 12 V battery, refer to the corresponding section.
Versions 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
Depending on the environment and the
use of the vehicle (e.g. dusty atmosphere,
city driving), change it twice as often, if
necessary .
Passenger compartment
filter
Depending on the environment and the
use of the vehicle (e.g. dusty atmosphere,
city driving), change it twice as often, if
necessary .

99
Practical information
7A clogged passenger compartment filter can adversely affect air conditioning
system performance and generate
undesirable odours.
Oil filter
Change the oil filter each time the engine
oil is changed.
Particle filter (Diesel)
In addition to the catalytic converter, this filter
actively contributes to the preservation of
air quality by trapping the unburnt pollutant
particles. Black exhaust fumes are therefore not
emitted.
Operation
This filter, inserted into the exhaust system,
accumulates the carbonaceous particles. The
engine management computer automatically
and periodically manages the removal of
carbonaceous particles (regeneration).
The regeneration procedure is triggered
according to the amount of accumulated
particles and the conditions of use of the vehicle.
During this phase, you may notice certain
phenomena - accelerated idling, triggering of
the cooling fan, increased smoke and increased
temperature at the exhaust - which have no
impact on the operation of the vehicle and the
environment.
Following prolonged operation of the
vehicle at very low speed or at idle, you
may, in exceptional circumstances, notice the
emission of water vapour at the exhaust while
accelerating. This has no impact on the
vehicle’s behaviour and the environment.
Due to the high exhaust temperatures
caused by the normal operation of the
particle filter, it is recommended not to park
the vehicle on flammable materials (grass, dry
leaves, pine needles, etc.) to avoid any risk of
fire.
Saturation/Regeneration
If there is a risk of clogging, this warning
lamp comes on, accompanied by a
message on the instrument panel display.
This warning is due to the start of saturation of
the particle filter (exceptionally long urban driving
conditions: reduced speed, traffic jams, etc.).
In order to regenerate the filter, it is
recommended to drive as soon as possible -
when traffic conditions and regulations permit
- at a speed of at least 37 mph (60 km/h), with
an engine speed above 2,000 rpm for about
15 minutes (until the warning lamp and/or the
message disappear).
If possible, avoid switching off the engine
before the end of filter regeneration; repeated
interruptions can lead to early deterioration of the
engine oil. It is not recommended to terminate
the filter regeneration with the vehicle stationary.
Malfunction
If this alert persists, do not ignore this warning;
this indicates that a malfunction has occurred in
the exhaust system/particle filter assembly.
Have the assembly 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.
Unless there is a leak in the circuit, a drop in the
brake fluid level indicates that the brake pads
are worn.
If this warning lamp comes on, have the
brake pads checked by a PEUGEOT
dealer or a qualified workshop.
After washing the vehicle, moisture, or in wintry conditions, ice can form on the
brake discs and pads: braking efficiency may
be reduced. Gently dab the brakes to dry and
defrost them.

100
Practical information
reading and have an adverse effect on road holding.
Fitting different tyres on the front and rear axles
can cause the ESC to mistime.
AdBlue® (BlueHDi
engines)


To respect the environment and ensure
compliance with the Euro 6 standard, without
adversely affecting the performance or fuel
consumption of its 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® that contains
urea, a catalytic converter turns up to 85% of
the nitrogen oxides (NOx) into nitrogen and
Brake disc wear
For information on checking brake disc
wear, contact a PEUGEOT dealer or a
qualified workshop.
Manual parking brake
If you notice excessive brake lever travel
or decreased effectiveness, the parking
brake must be adjusted, 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 reservoir.
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.
Bleeding the water in the filter

► Couple a clear hose to the bleed screw 1head.► Place the other end of the clear hose in a container.► Loosen bleed screw 2.► Switch on the ignition.► Wait for the scavenge pump to stop.► Switch off the ignition.► Tighten bleed screw 2.► Remove, then drain the clear hose and the container.► Start the engine.► Check that there are no leaks.
HDi engines make use of advanced
technology. Any intervention requires a
special qualification guaranteed by the
PEUGEOT dealer network or a qualified workshop .
Wheels and tyres
The inflation pressure of all tyres,
including the spare wheel, must be
checked on "cold” tyres.
The pressures indicated on the tyre pressure
label are valid for "cold" tyres. If you have driven
for more than 10 minutes or more than 6 miles
(10 kilometres) at over 31 mph (50 km/h), add 0.3 bar (30 kPa) to the values indicated on the
label.
Under-inflation increases fuel
consumption. Non-compliant tyre
pressure causes premature wear on tyres and
has an adverse effect on the vehicle's road
holding - risk of an accident!
Driving with worn or damaged tyres reduces the
braking and road holding performance of the
vehicle. It is recommended to regularly check the
condition of the tyres (tread and sidewalls) and
wheel rims as well as the presence of the valves.
When the wear indicators no longer appear set
back from the tread, the depth of the grooves is
less than 1.6 mm; it is imperative to replace the
tyres.
Using different size wheels and tyres from those
specified can affect the lifetime of tyres, wheel
rotation, ground clearance, the speedometer

101
Practical information
7reading and have an adverse effect on road
holding.
Fitting different tyres on the front and rear axles
can cause the ESC to mistime.
AdBlue® (BlueHDi
engines)


To respect the environment and ensure
compliance with the Euro 6 standard, without
adversely affecting the performance or fuel
consumption of its 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® that contains
urea, a catalytic converter turns up to 85% of
the nitrogen oxides (NOx) into nitrogen and
water, which are harmless to health and the
environment.
The AdBlue
® is contained in a special tank
holding about 19 litres.
It has an external filler neck, located in the fuel
filler flap under the filler neck of the fuel tank,
closed by a blue cap.
Its capacity allows a driving range of
approximately 3,700 miles (6,000 km) (which
may vary considerably depending on the
driving style and the type of vehicle).
An alert system is triggered when the remaining
range reaches 1,500 miles (2,400 km), i.e. once
the reserve level has been reached.
Once the AdBlue® tank is empty, a
system required by legislation prevents
starting of the engine.
If the SCR system is defective, the level of emissions from your vehicle will no longer
meet the Euro 6 standard: 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:
after travelling a distance of 250 miles (400
km), a system will be triggered automatically
to prevent engine starting.
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.
Supply of AdBlue®
It is recommended that the AdBlue® be topped
up as soon as the first alert is issued indicating
that the reserve level has been reached.
For the correct operation of the SCR
system:
– Use only AdBlue® fluid that meets the ISO
22241 standard.
– Never transfer AdBlue® to another container
as it would lose its purity.
– Never dilute AdBlue® with water.
It is possible to obtain AdBlue
® from a PEUGEOT
dealer or a qualified workshop.
You can also visit a service station equipped with AdBlue® pumps specially
designed for passenger vehicles.
Recommendations on storage
AdBlue® freezes at about -11°C and deteriorates
above +25°C. Containers should be stored in a
cool area and protected from direct sunlight.
Under these conditions, the fluid can be kept for
at least a year.
If the fluid has frozen, it can be used once it has
completely thawed out at room temperature.

102
Practical information
If the AdBlue® tank is completely empty
– which is confirmed by the message
"Top up AdBlue: Starting impossible" – it is essential to add at least 5 litres.
After refilling
► Refit the blue cap to the tank filler and turn it clockwise as far as it will go (one sixth of a turn).► Close the fuel filler flap.
Do not dispose of AdBlue® containers in
the household waste.
Place them in a container reserved for this
purpose or take them back to where you
bought them.
Never store AdBlue® containers in your
vehicle.
Precautions for use
AdBlue® is a urea-based solution. This fluid is
non-flammable, colourless and odourless (when
kept 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. Seek
medical attention if you feel a persistent burning
sensation or irritation.
If swallowed, immediately wash out the mouth
with clean water and then drink plenty of water.
In certain conditions (high temperature, for
example), the risk of release of ammonia cannot
be excluded: do not inhale the fluid. Ammonia
vapours have an irritant effect on mucous
membranes (eyes, nose and throat).
Store AdBlue® out of the reach of
children, in its original container.
Procedure
Before starting the top-up procedure, ensure that
the vehicle is parked on a flat and level surface.
In wintry conditions, ensure that the temperature
of the vehicle is above -11 °C. Otherwise the AdBlue® may be frozen and so cannot be poured
into its tank. Park the vehicle in a warmer area
for a few hours to allow the top-up to be carried
out.
Never put the AdBlue® into the Diesel
fuel tank.
If any AdBlue® is splashed, or if there are
any spillages on the bodywork, 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.
Important: in the event of a top-up after
an AdBlue breakdown, you must wait
about 5 minutes before switching on the ignition, without opening the driver's door,
unlocking the vehicle or bringing the
electronic key into the passenger
compartment.
Switch on the ignition, then wait for 10
seconds before starting the engine.
► Switch off the ignition and remove the key from the switch to switch off the engine.

► Turn the blue cap of the AdBlue® tank a 6th of
a turn anti-clockwise and remove it.
Filling up
► With a container of AdBlue®: after checking
the expiry date, read the instructions on the
label carefully before pouring the contents of the
container into the vehicle's AdBlue tank.► With an AdBlue® pump: introduce the nozzle
and fill the tank until the nozzle automatically
cuts out.
In order not to overfill the AdBlue® tank:– Add between 10 and 13 litres using AdBlue® containers.– Stop after the nozzle’ s first automatic cut-out, if you are refilling at a service station.
The system only registers AdBlue® top-ups of 5 litres or more.

122
In the event of a breakdown
► Connect the red cable to metallic terminal A,
then to the (+) terminal of backup battery B.
► Connect one end of the green or black cable to the negative (-) terminal of backup battery B.► Connect the other end of the green or black cable to earth point C of your vehicle.► Operate the starter , let the engine run.► Wait for the engine to return to idle and disconnect the cables.
Charging the battery using a
battery charger
► Access the battery, located in the left-hand front floor.► Disconnect the battery .► Follow the instructions for use provided by the manufacturer of the charger.► Reconnect starting with the (-) terminal.► Check the cleanliness of the terminals. If they are covered with sulphate (whitish or greenish
deposit), remove and clean them.
The charging operation must be carried
out in a well-ventilated area and away
from naked flames and any sources of sparks
so as to avoid the risk of explosion or fire.
Do not try to recharge a frozen battery: it
must first be thawed to avoid the risk of
explosion. If it has frozen, before charging it,
have the battery checked by a specialist who
will check that the interior components have
not been damaged and that the container is
not cracked, which would involve a risk of
leakage of toxic and corrosive acid.
Perform a slow charge at low amperage for
about 24 hours maximum to avoid damaging
the battery.
The presence of this label, in particular with the Stop & Start system, indicates
the use of a 12 V lead-acid battery with
special technology and specification; the
involvement of a PEUGEOT dealer or a
qualified workshop is essential when
replacing or disconnecting the battery.
After refitting the battery at a PEUGEOT dealer or a qualified workshop, the Stop
& Start system will only be active after a
continuous period of immobilisation of the
vehicle, a period which depends on the
climatic conditions and the state of charge of
the battery (up to about 8 hours).
Towing
General recommendations
Observe the legislation in force in the
country where you are driving.
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
arm; rope and straps are prohibited.
The towing vehicle must move off gently.
When the vehicle is towed with its engine
off, there is no longer braking and steering
assistance.
A professional towing service must be
called if:
– Broken down on a motorway or main road.– Not possible to put the gearbox into neutral, unlock the steering, or release the parking
brake.
– Not possible to tow a vehicle with an automatic gearbox, with the engine running.– Towing with only two wheels on the ground.– Four-wheel drive vehicle.– No approved towbar available.
Towing your 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 towbar to the removable towing eye.

148
Special features

– Never work under a tipper body that is not supported,– Switch off the power supply to the electro-hydraulic unit using the circuit breaker,– Vehicle stationary, engine off.
For safety reasons, we very strongly
advise against doing anything under the
tipper body while it is being operated or while
it is being serviced.
Maintenance
Reservoir
Regularly check and top up the engine oil level.
Change the oil once a year. If the oil contains
water, change it.
Regularly check the condition of the hose and
ensure the hydraulic system is properly sealed.
Pump and motor
No servicing required. The rolling elements are
permanently lubricated and the bearings are
lubricated by the pumped oil.
Lubrication
The pins of the tipper truck and the ram do not
contain lubricant. Regularly lubricate the hinges
and the grab handles of the side boards as well
as the retaining hooks of the rear board.
Sub-frame and tipper truck
For maximum service life, you are advised to
maintain your tipper truck by regularly washing it
using a power washer.
Carry out any required paint touch-ups quickly to
prevent the spread of rust.
After 8 months of use, check the tightening torque of the connection
between the chassis and the underbody (in
accordance with the manufacturer's
bodybuilding recommendations).
Cleaning the slide valve
► Loosen cap 244A , taking care with the ball
and retrieving it.
► Using a wide screwdriver , unscrew the banjo
bolt/piston assembly.► Check that the piston slides freely and remove any foreign bodies. Use a magnet to
remove any metal filings.
► Refit the assembly and make sure that the piston slides freely. Retain the ball with a little
grease on the cap for refitting.
► Bleed the hydraulic unit.
Bleeding the hydraulic unit
► Unscrew hexagonal cap 257.► Loosen internal screw 587 by half a turn,
using a 6 mm hex key.
► Operate the unit for a few seconds by pressing the raise button.
The tipper truck does not rise or rises very
slowly. When the oil exits through this opening,
the unit is bled.
► Retighten screw 587 and replace cap 257.
Check that the tipper truck lowers correctly.
Detailed diagram of the UD2386 hydraulic unit


Diagnostics
Symptoms ElectricHydraulic Verification/Check
The hydraulic unit does not work. XPower harness and unit relay.
X Control harness (control unit).
X Circuit-breaker.
Very noisy unit, rises slowly. XSuction strainer clogged or crushed at the bottom of the tank.
Very noisy new unit, rises quickly. XPump alignment, change the unit.
The ram lowers by itself. XLowering valve crushed or blocked.
The ram does not lower. XYes, check the slide valve and bleed.
Refer to the "Maintenance" section.
X No, check the coil and the electrical connections of the valve.
X No, replace the solenoid valve.
X No, check the alignment of the ram.
The unit works but its pressure does not increase. XSlide valve jammed if no solenoid valve on the unit.
Refer to the "Maintenance" section.
X Pressure relief device, setting, dirt.
X Pump seal out of service.
X Motor/pump coupling.
X Pump loose from its support.
The hydraulic unit does not work. XSolenoid valve blocked, replace it or retighten the nut behind the
strainer.
The control unit does not work. XCheck connection and contacts.
Emulsion in the tank. XIncorrectly positioned return pipe.
X Insufficient oil level.

149
Special features
10Diagnostics
SymptomsElectricHydraulic Verification/Check
The hydraulic unit does not work. XPower harness and unit relay.
X Control harness (control unit).
X Circuit-breaker.
Very noisy unit, rises slowly. XSuction strainer clogged or crushed at the bottom of the tank.
Very noisy new unit, rises quickly. XPump alignment, change the unit.
The ram lowers by itself. XLowering valve crushed or blocked.
The ram does not lower. XYes, check the slide valve and bleed.
Refer to the "Maintenance" section.
X No, check the coil and the electrical connections of the valve.
X No, replace the solenoid valve.
X No, check the alignment of the ram.
The unit works but its pressure does not increase. XSlide valve jammed if no solenoid valve on the unit.
Refer to the "Maintenance" section.
X Pressure relief device, setting, dirt.
X Pump seal out of service.
X Motor/pump coupling.
X Pump loose from its support.
The hydraulic unit does not work. XSolenoid valve blocked, replace it or retighten the nut behind the
strainer.
The control unit does not work. XCheck connection and contacts.
Emulsion in the tank. XIncorrectly positioned return pipe.
X Insufficient oil level.