start Peugeot Boxer 2020 Service Manual

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.

103
Practical information
7If 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.

104
In the event of a breakdown
Temporary puncture repair kit
This temporary puncture repair kit is stored in a
bag, placed in one of the front doors.


It includes:– a cartridge A, containing the sealant, equipped
with:
• a filling pipe B,• a sticker C indicating "50 mph (80 km/h) max.", which the driver must apply within
their field of vision (on the dashboard) after
having repaired the tyre,
– a quick user guide for the repair kit,– a compressor D equipped with a pressure
gauge and connections,
– adapters, for the inflation of various
components.
Repairing a tyre
► Apply the parking brake.


► Unscrew the cap of the tyre valve, remove filling hose B and screw ring E onto the valve.► Make sure compressor switch F is in position 0 (off).► Start the engine.► Insert plug G into the nearest socket on the
vehicle.
► Operate the compressor by setting switch F
to position I (on).
► Inflate the tyre to a pressure of 5 bar .To obtain a more accurate reading, it is
recommended to check the pressure value on
pressure gauge H, with the compressor off.
► 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 forwards by approximately 10 metres,
to disperse the sealant inside the tyre.
► Then repeat the inflation procedure:• if a pressure of at least 3 bar is not reached within 10 minutes, stop your vehicle: the tyre
is too damaged and could not be repaired.
Contact a PEUGEOT dealer or a qualified
workshop.
• if the tyre pressure has reached 5 bar,
restart immediately.
► After driving for approximately 10 minutes, stop and check the tyre pressure again.► Restore the correct pressure in accordance with the label on the driver's side pillar and
contact a PEUGEOT dealer or a qualified
workshop as soon as possible.
This puncture repair kit and the replacement cartridges are available
from a PEUGEOT dealer.
Checking and restoring
pressure
The compressor can only be used to check and
restore pressure.


► 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.

109
In the event of a breakdown
84 - Replacing the wheel to
be repaired
► Remove the wheel trim (depending on version) by levering with screwdriver E.► Unlock the bolts using wheelbrace D and
wheel bar B.
For more information on Positioning the
jack, refer to the corresponding section.
► Make sure that the jack is stable and correctly positioned on the underbody.

► Using wheelbrace D and wheel bar B, extend
the jack sufficiently to release the wheel.
To clear the wheel easily, a space of about 2 to 3 cm is needed between the
ground and the tyre.
If the wheel is badly punctured/crushed,
increase the space but do not operate the
jack to its maximum lifting position.


► Unscrew the bolts completely and remove the wheel to be repaired.► Make sure that the spare wheel contact surfaces, the bolts and bolt housings are clean
and free of impurities that could cause loosening
of the fixing bolts.
Do not grease the bolts before screwing
them on: they could unscrew themselves
spontaneously.


► Fit the spare wheel by aligning the 2 holes M with the 2 corresponding shafts N.► Start screwing the bolts by hand.

Screw the bolts in this order.

11 9
In the event of a breakdown
8

FusesA (amperes)Allocation
1 40ABS pump supply
2 50Diesel pre-heating unit
3 30Ignition switch - Starter
4 40Diesel heater
5 20/50Passenger compartment ventilation with programmable additional heating (+ battery)
6 40/60
Maximum speed passenger compartment cooling fan unit (+ battery)
740/50/60Minimum speed passenger compartment cooling fan unit (+ battery)
8 40Passenger compartment cooling fan unit (+ key)
9 15Rear 12 V socket (+ battery)
10 15Horn

120
In the event of a breakdown
FusesA (amperes)Allocation
14 15Front 12 V socket (+ battery)
15 15Cigarette lighter (+ battery)
19 7.5Air conditioning compressor
20 30Screenwash/headlamp wash pump
21 15Fuel pump supply
23 30ABS solenoid valves
24 7.5Auxiliary control panel - Door mirror control and folding (+ key)
30 15Door mirror defrosting
12 V battery
Procedure for starting the engine using another
battery or charging a discharged battery.
Lead-acid starter batteries
Batteries contain harmful substances
such as sulphuric acid and lead.
They must be disposed of in accordance
with regulations and must not, in any
circumstances, be discarded with household
waste.
Take used remote control batteries and
vehicle batteries to a special collection point.
Protect your eyes and face before
handling the battery.
All operations on the battery must be carried
out in a well ventilated area and away from
naked flames and sources of sparks, so as to
avoid the risk of explosion or fire.
Wash your hands afterwards.
Accessing the battery
The battery is located under the left-hand front
floor.


► Unscrew the 6 access flap retaining screws.
► Lift or completely remove the access flap.

121
In the event of a breakdown
8

► Tilt lever 1 downwards to release the
terminals.
► Remove terminals 2 from the negative (-)
terminal.
Wait approximately 6 minutes after
switching off the ignition before
disconnecting the battery.
Do not disconnect the terminals while the
engine is running.
Do not charge a battery without disconnecting
the terminals first.
Close the windows and the doors before
disconnecting the battery.
After reconnecting the battery, turn on the ignition and wait 1 minute before starting the engine, to enable the electronic systems to
initialise. If minor problems nevertheless persist
following this operation, contact a PEUGEOT
dealer or a qualified workshop.
It is recommended to disconnect the (-) terminal of the battery if the vehicle is to be left unused for more than one month.
The description of the battery charging
procedure is only indicative.
After prolonged battery disconnection, it may be
necessary to reinitialise the following functions:
– the display parameters (date, time, language, distance and temperature units),– the stations of the audio system,– the central locking.Some settings are cancelled and must be
entered once again; contact a PEUGEOT dealer.
If the vehicle is equipped with a tachograph or
an alarm, it is recommended that the (-) terminal of the battery (located under the floor on the
left-hand side, in the cab) be disconnected if the
vehicle is not going to be used for more than 5
days.
Starting using another
battery
Never start the engine by connecting a
battery charger.
Never use a 24 V or higher battery booster.
Check beforehand that the backup battery
has a nominal voltage of 12 V and a capacity
at least equal to that of the discharged
battery.
The two vehicles must not be in contact with
each other.
Switch off all the electrical consumers on both
vehicles (audio system, wipers, lighting, etc.).
Make sure that the jump leads are not close
to the moving parts of the engine (fan, belt,
etc.).
Do not disconnect the (+) terminal while the
engine is running.


A. Positive metallic terminal of your vehicle
B. Backup battery
C. Earth of your vehicle
The positive metallic terminal A is accessible
through a flap located on the side of the fuse
box.
Connect only to the terminals indicated
and illustrated above. In case of
non-compliance, risk of short circuit!

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.