Replace Peugeot Boxer 2020 Owner's Guide

105
In the event of a breakdown
8► Disconnect hose I and directly connect it
to the tyre valve; the cartridge will thereby be
connected to the compressor and the sealant will
not be injected.
If the tyre needs to be deflated, connect hose
I to the tyre valve and press the yellow button
located in the centre of the compressor switch.
Replacing the cartridge

To replace the sealant cartridge, proceed as
follows:
► Disconnect the hose I.► Turn the cartridge to be replaced anti-clockwise and lift it.► Insert the new cartridge and turn it clockwise,► Reconnect the hose I and connect pipe B to
its location.
The cartridge contains ethylene glycol, which is harmful if swallowed and irritates
the eyes.
It must be kept out of the reach of children.
After use, do not discard the cartridge in standard waste, take it to a
PEUGEOT dealer or an authorised waste
disposal site.
Spare wheel
Parking
► Park the vehicle where it does not block traffic: the ground must be level, stable and
non-slippery.
► If the road is sloping or damaged, place an object under the wheels to act as a chock.► With a manual gearbox, engage first gear then switch off the ignition to block the wheels.► Apply the parking brake and check that the warning lamp is on in the instrument panel.► The passengers must get out of the vehicle and wait where they are safe.► Put on the high visibility vest and signal that the vehicle is immobile by using the devices
envisaged by the legislation in force in the
country where you are driving (warning triangle,
hazard warning lamps, etc.).
► Equip yourself with the tools.
Special feature with pneumatic
suspension
If fitted to the vehicle, activate the vehicle lifting
mode before lifting the vehicle with a jack.


For right-hand drive vehicles, the buttons are
located on the right of the steering wheel.
► With the ignition on, press both buttons 1 and
2 simultaneously for at least 5 seconds.
Their indicator lamps light up, and remain fixed.
► To exit this mode, press buttons 1 and 2
simultaneously for an additional 5 seconds.
Their indicator lamps go out and the system
becomes fully operational again.
This mode is automatically deactivated if you
exceed the speed by about 3 mph (5 km/h).
Once the vehicle is well secured, proceed in the
following order:
1- Getting the tools.
2- Removing the spare wheel from its
housing.
3- Positioning the jack.
4- Replacing the wheel to be repaired.
5- Storing the wheel to be repaired.

107
In the event of a breakdown
8

► Install extended socket A, wheelbrace D and
wheel bar B on the retaining bolt.
► Turn the assembly anti-clockwise to lower the wheel.► Turn to the locking point of the winch, indicated by the hardening of the manoeuvre and
notch G not visible.
► After unrolling the cable completely , take the spare wheel out.
With steel wheels:


► Unscrew handle H.
► Remove caliper I from the outer part of the
steel wheel.
With alloy wheels:


► Unscrew the three fixing bolts K.► Unscrew handle H.► Remove bracket J from caliper I.► Remove the spare wheel and place it near the wheel to be replaced.► If possible, place a chock under the wheel diagonally opposite the wheel to be changed.
3 - Position the jack
Ensure that the jack is stable.
If the ground is slippery or loose, the jack
may collapse - Risk of injury!


Take care to place the jack strictly at jacking point 1 or 2 under the vehicle,
making sure that the jack head is centred at
the contact point on the vehicle. Otherwise,
there is a risk of damage to the vehicle and/or
the jack collapsing.
Make sure that any passengers are safe
(removed, away from the vehicle).
Never put your hands or your head in the
wheel arch.

11 0
In the event of a breakdown
► Lightly tighten using wheelbrace D and wheel
bar B.
► Lower the vehicle using wheelbrace D and
wheel bar B, and then remove the jack.
► Tighten the bolts again using wheelbrace D
and wheel bar B.
Have the tightening of the bolts and the
pressure of the spare wheel checked by
the Manufacturer's dealer network or a
qualified workshop without delay.
Have the punctured wheel repaired and
refitted on the vehicle as soon as possible.
If your vehicle has tyre under-inflation
detection, check the tyre pressures and
reinitialise the system.
5 - Storing the wheel to be
repaired
You must reposition the wheel to be repaired or
the spare wheel under the vehicle to lock the
winch system.
Check that it is securely fastened in its
compartment under the floor.
Improper wheel positioning can compromise
safety.
► Reposition the wheel at the rear of the vehicle.
With steel wheels:


► Hang bracket I on the outer part.► Screw handle H to secure the bracket and
the steel wheel.
With alloy wheels:


► Position bracket J on caliper I.► Screw handle H.► Screw the three fixing bolts K of caliper I onto
the alloy wheel.


► Install extended socket A, wheelbrace D and
wheel bar B on the retaining bolt.
► Turn the assembly clockwise to completely wind up the cable and raise the wheel as far as
possible under the vehicle.
► Check that the wheel is flat against the floor of the vehicle and that the notch G of the winch
is visible.
► Store the tools and the wheel trim (depending on version).
For more information on the Identification markings of the
vehicle, and in particular the tyre pressure
label, refer to the corresponding section.
Changing a bulb
The headlamps have polycarbonate lenses with a protective coating:
► do not clean them using a dry or
abrasive cloth, nor with a detergent or
solvent product,
► use a sponge and soapy water or a pH neutral product,► when using a high pressure washer on persistent marks, do not keep the lance
directed towards the lamps or their edges for
too long, so as not to damage their protective
coating and seals.
Changing a bulb must only be done with
the ignition off and after the lamp has
been switched off for several minutes - Risk
of serious burns!
► Do not touch the bulb directly with your fingers, use a lint-free cloth.
It is essential only to use anti-ultraviolet
(UV) type bulbs, so as not to damage the
headlamp.
Always replace a failed bulb with a new bulb
with the same type and specification.
In some weather conditions (e.g. low
temperature or humidity), the presence
of misting on the internal surface of the glass
of the headlamps and rear lamps is normal; it

111
In the event of a breakdown
8Changing a bulb
The headlamps have polycarbonate lenses with a protective coating:
► do not clean them using a dry or
abrasive cloth, nor with a detergent or
solvent product,
► use a sponge and soapy water or a pH neutral product,► when using a high pressure washer on persistent marks, do not keep the lance
directed towards the lamps or their edges for
too long, so as not to damage their protective
coating and seals.
Changing a bulb must only be done with
the ignition off and after the lamp has
been switched off for several minutes - Risk
of serious burns!
► Do not touch the bulb directly with your fingers, use a lint-free cloth.
It is essential only to use anti-ultraviolet
(UV) type bulbs, so as not to damage the
headlamp.
Always replace a failed bulb with a new bulb
with the same type and specification.
In some weather conditions (e.g. low
temperature or humidity), the presence
of misting on the internal surface of the glass
of the headlamps and rear lamps is normal; it
disappears after the lamps have been on for a
few minutes.
Types of bulb
Various types of bulb are fitted on the vehicle. To
remove them:


Type A All-glass bulb: pull gently as it is fitted by
pressure.
Type B Bayonet bulb: press on the bulb then
turn it anti-clockwise.
Type C Cylindrical bulb: ease the contacts apart.
Type D Halogen bulb: release the retaining
spring from its housing.
Front lamps


1.Main beam headlamps
2. Dipped beam headlamps
3. Direction indicators
4. Sidelamps / Daytime running lamps
► Open the bonnet and engage the bonnet stay securely.► To access the lamps and bulbs, pass your hand behind the lamp unit.

11 3
In the event of a breakdown
8

► Remove the screw, located in the wheel arch.► Remove the protective flap.

► Remove the fixing clip and disconnect the electrical connector.► Turn and remove the bulb holder.► Change the bulb taking care to align the metal part with the grooves on the lamp.
The replacement of halogen bulbs must
be done with the headlamps switched off
a few minutes beforehand (risk of serious
burns). Do not touch the bulb directly with
your fingers; use a lint-free cloth.
When each operation has been completed,
check the operation of the lighting.
Direction indicator side
repeaters
Type A, W16WF - 16W

► Move the glass of the mirror to access the screws.► Remove the two fixing screws.► Pull the bulb holder to release it from the pins.► Pull the bulb out and change it.
Left-hand and right-hand
sidelamps
Type A, W5W - 5W

► If fitted on the vehicle (dimension L4), remove the two fixing screws.► Pull the bulb holder to release it from the pins.► Pull the bulb out and change it.
Courtesy lamps
Type C, 12V 10W - 10W

11 5
In the event of a breakdown
8

► Remove the six fixing screws from the bulb holder.► Open the three retaining tabs and pull the bulb holder out of its housing.► Change the bulb.► Carry out the operations in reverse order to reposition each bulb.
Number plate lamps
Type C, C5W - 5W

► Press the dot, indicated by the arrow, and remove the clear plastic.► Remove the faulty bulb by separating the two contacts.► Once the bulb is replaced, make sure that the new bulb is locked between the two contacts.► Replace the clear plastic and press down to lock it.
Third brake lamp
Type A, W5W - 5W (x 4)

► Remove the two fixing screws from the lamp unit.► Pull the lamp unit out towards you.

► Remove the bulb holder by pinching the two tabs inwards.► Remove the faulty bulb by pulling on it.► Change the bulb.

11 6
In the event of a breakdown
Changing a fuse

The three fuseboxes are located on the
dashboard on the left-hand side, in the pillar
on the right-hand side and in the engine
compartment.
The designations provided are only for the fuses
that can be replaced by the user. For any other
work, visit a PEUGEOT dealer or a qualified
workshop.
Professional repairers: for full information
on the fuses and relays, consult the
wiring information and diagrams available
from a PEUGEOT dealer.
Removing and fitting a fuse


Good
Failed
Before changing a fuse, the cause of the fault
must be found and rectified. The numbers of the
fuses are indicated on the fuse box.
Always replace a faulty fuse with a fuse of
the same rating.
PEUGEOT accepts no responsibility for
the cost incurred in repairing your vehicle
or for rectifying malfunctions resulting from
the installation of accessories not supplied or
not recommended by PEUGEOT and not
installed in accordance with its
recommendations, in particular when the
combined power consumption of all of the
additional equipment connected exceeds 10
milliamperes.
Left-hand side dashboard
fuses
► Remove the screws and tilt the casing to access the fuses.

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.

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.