oil Peugeot Boxer 2020 User Guide

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

134
Technical data
Colour
Code
Varnish
B
FOR TROUBLESHOOTING ONLY.
C
DANGER
AUTOMATIC ENGINE STARTING. REMOVE
THE IGNITION KEY WHEN THE BONNET IS
OPEN.
D


1 - WARNING
GENUINE LUBRICANTS AND FLUIDS
Engine oilTransmission
Radiator Brakes
Screenwash Power steering
GENUINE LUBRICANTS AND FLUIDS
CONSULT THE
MAINTENANCE
AND WARRANTY
GUIDE.PROTECT YOUR
EYES.
2 - SAFETY
The use of genuine replacement parts, fluids
and lubricants, as well as observing the servicing
schedules, guarantees the reliability and safety
of your vehicle over time, so maintaining it in its
original condition.
3 - DANGER
KEEP OUT
OF THE
REACH OF
CHILDREN. DO NOT
APPROACH
FLAMES.
DO NOT
TOUCH.
DO NOT
REMOVE
THE CAP
WHEN THE
ENGINE IS
HOT. EXPLOSION.
CORROSIVE
LIQUID.
MAY START
AUTOMATICALLY EVEN
WITH THE ENGINE
SWITCHED OFF. DO NOT
OPEN GAS
UNDER
HIGH
PRESSURE.
AUTOMATIC ENGINE
STARTING. REMOVE THE
IGNITION KEY WHEN THE
BONNET IS OPEN.HIGH
VOLTAGE
In the fuel filler flap

DANGER REMOVE SLOWLY.
FUEL VAPOURS MAY CAUSE INJURY.
On the rear bench seat

A
Push the backrest before folding it down.
B
PULL TO OPEN.
C
PULL LEVER 1 TO PARTIALLY TILT THE
BACKREST.
PULL LEVER 2 TO FOLD THE BACKREST
FULLY.

145
Special features
10Tipper truck

The lifting of the tipper is provided by a hydro-
electric unit powered by the vehicle's battery.


The ascent or descent is done by holding the
corresponding buttons of the magnetic and
removable remote control located on a support
inside the cab.
The lifting of the tipper is powered by unit's
motor.
The descent is powered by a solenoid valve
opening the strut's oil return.
An anti-drop system makes the descent of the
tipper safe whether static or lifting.
Safety recommendations

Never drive with the tail board down.
Ensure that there are no people or
obstacles present (on the ground and higher
up) when unloading.
Never leave the tipper raised when not in use.
Always tip with the upper part of the rear tail
board locked.
Observe the payload on the tare plate on the
vehicle.
Regularly check that the suspensions are in
good condition and that the tyres are inflated
to the recommended pressure.
Spread the load evenly in the tipper.
Transport homogeneous products which flow
easily.
Never drive, even slowly, with the tipper
raised.
Tip on a flat and hard surface: sloping or loose ground can cause a displacement
of the centre of gravity which affects the stability
of the whole unit.

146
Special features
Specifications
EquipmentDetails
Tipper truck Tipper truck bed consisting of 2 high strength steel blanks, 2.5 mm thickness, zinc-coated, joined by
central and longitudinal laser welding.
Body-coloured tipper truck.
Structure of the tipper truck 2 main sidemembers in galvanised high strength steel.
1 ram-head crossmember made of steel tube.
Galvanised high strength steel crossmembers. Assembly protected against corrosion by the application
of a powder paint coating.
Sub-frame 2 “C”-shaped sidemembers in high strength steel, 2.5 mm thickness, secured internally by widened lower
wing.
Mounted on base vehicle with high strength steel stamped brackets.
1 ram-foot crossmember made of steel and mechanically-welded tube, hot-dip galvanised.
1 rear hinge crossmember in galvanised steel.
Support stops on sidemember ends.
Rear lamp protection grille.
Truck side guards and wing supports in galvanised steel.
Boards High strength steel boards, 15/10 thickness, cold-formed and assembled by continuous laser welding.
Anti-corrosion protection guaranteed by a powder coating treatment.
Locking handles with reinforced zinc coating, integrated in the recess of the board.
Ladder-carrier Galvanised steel rails. Panels and crossmembers in lacquered steel with crimped bolts.
Electropump unit 12 Volts/2 kW.
Operating temperature: -20 to +70°C.
Hydraulic ram Expansion, nitride rod, 3 bodies, Diam: 107 mm.
Maximum pressure: 20 bar.
Hydraulic oil ISO HV 46 type mineral or equivalent.
Dimensions
This adaptation is available only on L2 single
cab; refer to the table below for the specifications
of the tipper truck.
Tipper truck (in mm)
Useable length 3,200
Overall length 3,248
Useable width 2,000
Overall width 2,100
Height of boards 350
Weight of the conversion (in
kg) 550
For the L2 chassis cab specifications,
refer to the Dimensions section of the
platform version.
Weights and towed loads
(kg)
The braked trailer weight with load transfer can be increased, provided that the equivalent of this
load is removed from the vehicle so as not to
exceed the GTW. Warning! Towing using a lightly
loaded vehicle can adversely affect roadholding.
The kerb weight is equal to the unladen weight +
driver (75 kg) + tank full to 90%.

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.

150
Special features
SymptomsElectricHydraulic Verification/Check
The oil flows back through the oil breather pipe. XOil level too high.
X Tolerance of the oil breather pipe membrane too high, to be
replaced.
Valid only for UD2386 units.
The fuse blows while lowering. XReplace the lowering coil.