ESP PEUGEOT BOXER 2021 Service Manual

101
Practical information
7Charging the traction
battery (Electric)
To charge, connect the vehicle to a domestic
charging unit or a fast public charger (superfast
charging).
For a full charge, follow the desired charging
procedure without interrupting it, until it ends
automatically.
To stop charging at any time, press the locking
button on the remote control for 5 seconds
and remove the charging nozzle. For superfast
charging, also refer to the fast public charger.
The display of information linked to the charging
is integrated into the rear view mirror. For more
information on the Display integrated into the
rear view mirror , refer to the corresponding
section.
As a safety measure, the engine will not start if the charging cable is plugged into
the vehicle's charging connector.
Cooling the traction battery
The cooling fan in the engine
compartment comes on during charging to
cool the on-board charger and the traction
battery.
Balancing the traction battery voltage
After carrying out a full charge (100%)
at least once per week, we recommend not
using the vehicle for about 4 hours.
This time allows the voltage to balance across
all of the traction battery's cells (ensuring a
level voltage across all of its cells).
This process helps keep the traction battery in
good condition and aids in the calculation of
its charging level.
Completely discharged traction
battery
T
o preserve the lifespan of the traction battery
and avoid damaging it, make sure that it is
never completely discharged (0%).
When the charge level drops to 15%, the
message "LOW POWER MODE" appears
on the display integrated into the rear view
mirror. If this message appears while driving,
avoid heavy acceleration and charge the
vehicle as soon as possible.
Long-term parking
Before parking the vehicle for an
extended period, carry out a full charge of the
traction battery.
Park the vehicle in a place where the
temperature will be between 0°C and 45°C
(parking in a place which will experience
extreme temperatures can damage the
traction battery).
Disconnect the cable from the (-) terminal of
the 12
V accessory battery.
Check the level of charge in the traction
battery periodically and charge it if necessary.
When parking the vehicle for more than one
month, keep the level of charge above 50%.
When parking the vehicle for a very long
period, charge the vehicle every 2 months.
Do not leave the charging cable connected.
Lack of use of the traction battery temporarily
affects its performance. At the end of the
parking period, carry out several charge/
discharge cycles to restore the normal
operation of the traction battery.
Precautions
Our electric vehicles have been developed in
accordance with the recommendations on the
maximum limits for electromagnetic fields, as
issued by the International Commission on Non-
Ionizing Radiation Protection
(ICNIRP - 1998
Guidelines).
Wearers of pacemakers or equivalent
devices
Ask your doctor about what precautions you should take, or ask the manufacturer
of your implanted electro-medical device about
whether its operation is guaranteed in an
environment which complies with the ICNIRP
recommendations.
If in doubt
Accelerated charging: do not remain
inside or near the vehicle, or near the
charging cable or charging unit, even for a
short time.

104
Practical information
Installation tips
► To fit the snow chains during a journey, stop
the vehicle on a flat surface at the side of the
road.
►
Apply the parking brake and position any
wheel chocks under the wheels to prevent
movement of the vehicle.
►


Fit the snow chains following the instructions
provided by the manufacturer

.
►

Move off gently and drive for a few moments,
without exceeding 31

mph (50 km/h).
►

Stop the vehicle and check that the snow
chains are correctly tightened.
It is strongly recommended that you
practise fitting the snow chains on a level
and dry surface before setting off.
Avoid driving with snow chains on roads that have been cleared of snow to avoid
damaging the vehicle's tyres and the road
surface. If the vehicle is fitted with alloy
wheels, check that no part of the chain or its
fixings is in contact with the wheel rim.
Towing a trailer

The type-approved towable weights are entered
in your vehicle's registration certificate, as well
as on the manufacturer's plate.
For more information on the Technical
characteristics of the vehicle and
particularly on weights and towable loads,
refer to the corresponding section.
You will then have information on your vehicle's
ability to tow a trailer, a caravan, a boat, etc.
These values are also given in the sales
brochures.
We recommend using genuine
PEUGEOT towbars and their harnesses
that have been tested and approved from the
design stage of your vehicle, and having a
PEUGEOT dealer fit the towbar.
These genuine towbars are compatible with
the operation of the rear parking sensors and
the reversing camera, if your vehicle is so
equipped.
If the towbar is not fitted by a PEUGEOT
dealer, it must still be fitted in accordance with
the vehicle manufacturer's instructions.
Electric motor
An electric vehicle cannot under any
circumstances be fitted with a towing device.
It is therefore not possible to tow a trailer or
caravan.
Towbar with quickly detachable towball
Presentation
This genuine towball can be easily and quickly
fitted or removed. These operations do not
require any tools.

105
Practical information
7

1.Carrier
2. Connection socket
3. Safety eye
4. Detachable towball
5. Locking / unlocking wheel
6. Key lock with removable cap
7. Key reference label
For more information on the Technical
data of the vehicle, and in particular on
the weights and towed loads, refer to the
corresponding section.


A. Locked position; the locking wheel is in contact with the towball (no gap).
B. Unlocked position; the locking wheel is no longer in contact with the towball (gap of
around 5 mm).
Observe the legislation in force in the
country where you are driving.
Before each use
Check that the towball is correctly locked,
verifying the follow points:
–

the green mark on the wheel is in line with
the green mark on the towball,
–


the wheel is in contact with the towball,
–


the key lock is closed and the key removed;
the wheel can no longer be operated,
– the towball must not be able to move in its
carrier; test by shaking it with your hand.
During use
Never release the locking system with a
trailer or load carrier on the towball.
Never exceed the maximum authorised
weight for the vehicle (the Gross Vehicle
Weight - GVW), the trailer, or the sum of the
two (the Gross Train Weight - GTW).
Following use
When travelling without a trailer or load on a
towbar-mounted carrier, the towball must be
removed and the protective plug inserted in the
carrier. This measure applies particularly where
the towball might obscure visibility of the number
plate or its lighting.

107
Practical information
7Roof-mounted carrying
systems


For safety reasons and to avoid damaging the
roof, it is imperative to use a carrying system
(roof bars or roof rack) approved for the vehicle.
Roof bars can only be fitted on H1 or H2 height
versions of vans, combis and minibuses. On
minibuses, check the presence of a roof air
conditioning unit.
The carrying device must be fixed to the
anchorage points on the roof of the vehicle: 6,
8 or 10, depending on the wheelbase of the
vehicle.
Observe the fitting instructions and the
conditions of use in the guide supplied with the
carrying device.
Maximum roof load, evenly distributed:
150 kg, for all versions, within the limits
of the gross vehicle weight (GVW).
Roofs cannot be equipped with a
carrying system on H3 height versions.
Strictly observe the legal provisions in
force concerning the maximum volume
measurements.
For more information on the Technical
data of the vehicle, and in particular on
the dimensions, refer to the corresponding
section.
Bonnet
Opening
Before doing anything under the bonnet,
deactivate the Stop & Start system to
avoid the risk of injury related to an automatic
change to START mode.
Electric motor
Take care with objects or clothing that
could be caught in the blades of the cooling
fan or in certain moving components - risk of
strangulation and serious injury!
Before carrying out any work under the
bonnet, you must switch off the ignition
and

disconnect the nozzle from the charging
connector
if it is connected.
On the inside
This operation must only be done with the
vehicle stationary and the driver’s door open.


► Pull the control located on the side of the
dashboard towards you.

109
Practical information
7All work must be carried out only by a
PEUGEOT dealer or a qualified workshop
Electric motor

1.Screenwash and headlamp washer reservoir
2. Engine coolant reservoir
3. Power steering fluid reservoir
4. Brake and clutch fluid reservoir
5. Heating
circuit fluid reservoir
6. Fusebox
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

111
Practical information
7Check the coolant level regularly
according to how much you use your
vehicle (every 3,000 miles (5,000 km)/3
months).
(Electric)
Do not top up the coolant.
If the level is close to or below
the
"MIN" mark, it is essential to contact a
PEUGEOT dealer or a qualified workshop.
Heating circuit fluid
( Electric)
Do not top up the heating circuit fluid.
Contact a PEUGEOT dealer or a qualified
workshop.
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.

11 2
Practical information
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 .
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.
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 it checked by a PEUGEOT dealer or a
qualified workshop.

11 4
Practical information
Driving with worn or damaged tyres reduces the
braking and road holding performance of the
vehicle. Regularly check the condition of the
tyres (tread and sidewalls) and rims as well as
the presence of the valve caps.
When the wear indicators no longer appear set
back from the tread, the depth of the grooves is
less than 1.6 mm; replace the tyres as soon as
possible.
Using different size wheels and tyres from those
specified can affect the lifetime of tyres, wheel
rotation, ground clearance, the speedometer
reading and have an adverse effect on road
holding.
Fitting different tyres on the front and rear axles
can cause the ESC to mistime.
Always mark the direction of rotation on the tyres
that will be stored when fitting winter or summer
tyres. Store them in a cool, dry place and away
from direct exposure to the sun's rays.
Winter or 4-seasons tyres can be
identified by this symbol on their
sidewalls.
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.
Its capacity allows a driving range of
approximately 2,500 miles (4,000 km), which
may vary considerably depending on your
driving style.
An alert system is triggered once the reserve
level is reached: it is then possible to drive for a
further 1,500 miles (2,400
km) before the tank is
empty and the vehicle is immobilised.
For more information on the Warning
and indicator lamps and the associated
alerts, or the Indicators, please refer to the
corresponding sections.
Once the AdBlue® tank is empty, a device
required by law prevents the engine from
being restarted.
If the SCR system is faulty, the level of
emissions from the vehicle will no longer meet
the Euro 6 standard and the vehicle starts
polluting the environment.
In the event of a confirmed SCR system
malfunction, it is essential to visit a
PEUGEOT dealer or a qualified workshop as
soon as possible. After 250 miles (400 km),
a device is automatically activated to prevent
the engine from starting.
In both cases, a range indicator indicates
the distance that can be travelled before the
vehicle is immobilised.

123
In the event of a breakdown
84 - Replacing the wheel to
be repaired
► Remove the wheel trim (depending on
version) by levering it off with screwdriver E
.
►

Loosen the bolts using wheelbrace D

and
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 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 the fixing
bolts to become loose.
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 on by hand.

Screw on the bolts in this order.

124
In the event of a breakdown
► Tighten initially using wheelbrace D and bar
B.
►

Lower the vehicle using wheelbrace D

and
bar B, then remove the jack.
►

T
ighten the bolts again using wheelbrace D
and 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.
Vehicle fitted with a tyre under-
inflation detection system
The spare wheel is not fitted with a pressure
sensor. Tyre under-inflation detection will not
work on this tyre. An alert may be issued by
the system.
Check the tyre pressures and reinitialise the
system.
For more information on Tyre under-inflation
detection, refer to the corresponding section.
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.
►

T
urn the assembly clockwise to completely
wind up the cable and raise the wheel as far as
possible under the vehicle.