engine PEUGEOT BOXER 2021 Repair Manual

146
Technical data
Glossary of labels
This section contains all of the text written on the
labels present in the vehicle.
For the Identification markings, refer to
the corresponding section.
In the engine compartment

A
Original paintwork
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 oil
Transmission
Radiator Brakes
Screenwash Power steering
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

160
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

,
–

V
ehicle 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 does not rise or rises very slowly

.
When the oil exits through this opening, the unit
is bled.
►

Retighten screw 587

and refit cap 257. Check
that the tipper lowers correctly.
Detailed diagram of the UD2386 hydraulic
unit


Diagnostics
Electrical faults

162
Audio system
Audio system

Multimedia audio system -
Bluetooth
® telephone
The system is protected in such a way that it will only operate in your vehicle.
For safety reasons, the driver must only
carry out operations that require close
attention with the
vehicle stationary.
When the engine is switched off and to
prevent discharging of the battery, the
system switches off after activation of energy
economy mode.
First steps
On/off, volume setting.
Select FM and AM wavebands.
Select USB or AUX source.
Display the list of connected telephones.
Rotate: scroll through a list or adjust radio
station.
Press: confirm the option displayed in the
screen.
Information on the current radio station or
media.
Select pre-set stations.
FM-A, FM-B, FM-C, AM-A, AM-B, AM-C.
Display the menu and set the options.
Radio buttons 1 to 6:
Select a pre-set radio station.
Long press: pre-set a station.
Random (shuffle) play
Repeat play.
Mute/pause the volume.
Automatic frequency search down. Select the previous USB track.
Press and hold: rewind.
Automatic frequency search up. Select the next USB track.
Press and hold: fast forward.
Abandon the current operation.
Go up one level (menu or folder).
Steering mounted controls
Activate/deactivate the pause function of USB/iPod, AUX and Bluetooth® sources.
Activate/deactivate the mute function of the
radio.
Activate/deactivate the microphone during a
telephone conversation.
Toggle up or down: increase or decrease the volume for voice announcements and
music, hands-free and text message reading
sources.
Activate voice recognition. Pause a voice message to start a new
voice command.
Pause voice recognition.
Accept an incoming call. Accept a second incoming call and put
the active call on hold.
Activate voice recognition for the telephone
function.
Pause a voice message to give another voice
command.
Pause voice recognition.
Radio, toggle up or down: select next/
previous station.
Radio, toggle up or down continuously: scan up/
down frequencies until you release the button.

169
Touch screen audio and telematics system
12Touch screen audio and telematics system


Multimedia audio system -
Bluetooth
® telephone - GPS
navigation
The system is protected in such a way
that it will only operate in your vehicle.
For safety reasons, the driver must only
carry out operations that require close
attention with the
vehicle stationary.
When the engine is switched off and to
prevent discharging of the battery, the
system switches off after activation of energy
economy mode.
First steps
Use the buttons arranged below the touch
screen to access the main menus, then press
the virtual buttons of the touch screen.
The screen is of the "resistive" type; it is necessary to press firmly, especially for
so-called "dragging" gestures (scanning a list,
moving the map, etc.). A simple light touch will
not be enough. Pressing with more than one
finger is not recognised.
The screen can be used with gloves. This
technology allows use at all temperatures.
To clean the screen, use a soft non-abrasive cloth (e.g. spectacles cloth)
without any additional product.
Do not use sharp objects on the screen.
Do not touch the screen with wet hands.
In very hot conditions, the volume may
be limited to protect the system. The
return to normal takes place when the
temperature in the passenger compartment
drops.
The system may also enter standby mode
(with the screen and sound off) for 5 minutes
or more.
Press: on / off.
Rotation: Adjust volume (each source is
independent).
Turn the screen on / off.
Activate / deactivate volume ( mute / pause).
Radio, rotation: search for a radio station.
Media, rotation: select the previous / next
track.
Press: confirm the option displayed on the
screen.
Activate, deactivate, configure certain control functions of the system and the
vehicle.
Abandon the current operation. Go up one level (menu or folder).
Glossary
VOLUME
Adjusting the volume by rotating.
RADIO
Access the radio menu.
MEDIA
Access the media menu and the different music
sources.
N AV
Access the navigation menu.
PHONE
Access the telephone menu.
MORE
Access the vehicle information.
BROWSE, TUNE, SCROLL
Turn the button to:
–

scroll through a menu or a list.
–


select a radio station.

175
Touch screen audio and telematics system
12Help
Access information about assistance services
and other specialised services.
Finish
Validate the settings.
Limitation
Speed limitation (if known).
To see the difference between the desired arrival
time and the estimated arrival time.
Switch between a 3D map and a 2D map.
Go to..., Display the map, Plan a route,
Services, Settings, Help, Finish.
When the navigation system starts for the first
time, the "Driving mode" as well as detailed
information on the current position is displayed.
Touch the centre of the screen to open the main
menu.
Details
The route summary provides an overview of the
route, the remaining distance to the destination
and an estimate of the remaining travel time.
With the RDS-TMC data, the route summary
also shows the traffic information concerning
delays along the route.
Modify route
The navigation system helps you to get to your
destination as quickly as possible by displaying a
faster alternative route when it is available.
Finish
Validate the settings.
Instructions
Navigation instructions for the next part of the
trip and the distance to the next instruction. If the second instruction is less than 150 metres from
the first one, it is immediately displayed instead
of the distance.
Touch this part of the status bar to repeat the last
voice instruction.
Updating maps
To get a map update, proceed as follows: – Map refresh guarantee: if a new map
becomes available within 90 days of the first
use of the system, you can download it once
for free.
–

Map update: you can purchase a new
version of the map loaded on the system.
T

o install a map update on the system, perform
the following four steps:
–

Prepare a USB device.
–


Install TomTom HOME and create a
MyTomTom account.
–

Download the map.
–


Install the new map.
Use a USB device and not a mass
storage device (telephone or media
player).
To protect the system, do not use a USB hub.
Prepare a USB device
The preparation of the USB device
must be done with the engine running
and the vehicle stationary.
In order to update the map, you must have
a USB device that meets the following
requirements:
–

The USB device must be empty
.
–

The USB device has 16 GB of available
space.
–


Use only USB devices formatted to F
AT32
(File Allocation Table).
–

Do not lock the USB device and check that
files can be saved to it.
T

o prepare the USB device, proceed as follows:
►

Make sure that the map to be updated is
active on the vehicle's navigation system.
If the navigation system has multiple maps and
you want to update a map that is not currently
active, you will need to activate it.
►


Select "
Change map" in the "Settings" menu
of the navigation application.
►

Select "
Navigation updates" in the
"Settings" menu.
►

Y

ou must indicate whether you want to
prepare a USB device to download updates.
►

Select "
Ye s".
►

Insert the USB device into the USB socket
located in the central storage space

and
which is dedicated to data transfer.
The system starts preparing the USB device.

176
Touch screen audio and telematics system
– If the system continues to ask you to
insert a USB device, make sure that the
USB device meets the above requirements,
and then try again.
–

If you connect multiple USB devices, the
system prompts you to remove devices
so that only the device to be prepared is
connected.
–


If there is not enough space on the USB
device, you are prompted to use another USB
device.
–


If you connect a USB device that contains
files, the system warns you that files on the
USB device may be deleted.
When the USB device is ready

, the message
below appears:
"Navigation updates"
The preparation of the USB device is
finished.
You can now safely remove the USB device.
►

Remove the USB device.
You are now ready
to download the new map to your USB device.
Install TomTom HOME
To install "TomTom HOME" and create a
"MyTomTom" account, perform the following
steps:
►

Download and install the T

omTom HOME
application on a computer via this link:
tomtom.com/getstarted
►

Select and download T

omTom HOME, then
follow the on-screen instructions.
Choose a secure Wi-Fi network rather
than a 3G/4G network to download the
application to a computer.
►

Connect the USB device to the computer
.
"TomTomHome" starts automatically.
►

Select "
Log in " in the upper right corner of
"TomTom HOME".
►

Select "
Create an account" and enter your
information to create a "MyTomTom" account.
To receive map updates, you must have a "MyTomTom" account.
Once the account is created, you must indicate
whether you want to link your system to your
account. The prepared USB device represents
your system.
►

Select "
Link device", then "Close".
You are now ready to download a map to your
USB device.
Download a map
Connect the USB device to the computer.
Select a map to download
–

T
o check if you can download a map for free
with the map refresh guarantee, select " Tools"
and then "Map refresh guarantee " in "TomTom
HOME".
–

T
o purchase a map update, select " Buy
maps" in "TomTom HOME".
–

If you have already purchased an update,
select "

Update my device" in "TomTomHOME".
Download a map
If a map update is available for your system, it is
listed as an available update.
If your system already has the most
recent map, no updates are available.
►

Select the map to download, then select
"

Update and install "; the map will be
downloaded and installed on your USB device.
►

Select "
Done" once the process is finished.
Install the map
The new map must be downloaded
with the engine running and the
vehicle stationary.
Once you have downloaded a map to your USB
device, you can install it on your system.
►

Insert the USB device containing the new
map into the USB socket

located in the central
storage space and which is dedicated to data
transfer to the system.
The system detects the presence of a new
map on the USB device. It may also contain
an update of the navigation software if it is
necessary for the new map.
►

Y

ou must indicate whether you want to
update the system.
►

Select "
Start".
If the USB device contains new software,
the system starts by updating the navigation
software. Once the software is updated, the
system must restart.
►

Select "
OK".

184
ALPINE® X902D system
ALPINE® X902D system

Multimedia audio system -
Bluetooth
® telephone- GPS
navigation
For safety reasons, the driver must only
carry out operations that require close
attention with the vehicle stationary.
When the engine is switched off and to
prevent discharging of the battery, the
system switches off after activation of energy
economy mode.
For further information, refer to the
ALPINE user guide at:
https://www.alpine-europe.com
First steps
Use the buttons arranged below the touch
screen to access the main menus, then press
the virtual buttons on the touch screen.
Touch control: press a touch screen button
or list item gently with your fingertips to avoid
damaging the screen.
Swipe: move your finger gently across the
screen in a sweeping motion.
Drag and drop: tap an item on the screen and
move it with your finger to the chosen location,
then remove your finger.
You cannot zoom out by pinching the screen with
two fingers or zoom in by moving your fingers
apart.
To clean the screen, use a soft, non-abrasive cloth (e.g. spectacles cloth)
without any additional product.
Do not use sharp objects on the screen.
Do not touch the screen with wet hands.
Access the menu screen. Press and hold the button for 5 seconds
to turn the system off.

Display the navigation maps screen.
Press this button again to go to the
navigation menu screen.
Press and hold this button for 2 seconds
to access the return home route screen (if
the home address is not yet set, a screen is
displayed to set the address).
Decrease volume.
Increase volume.
View the phone menu screen.
When you receive a call, press the button
to start a conversation.
Smartphone voice commands via the
system.
Radio: automatic step-by-step frequency
search up/down for radio stations.
Media: previous/next track selection.
Display the audio/visual screen.
If the audio/visual screen is already
displayed, this button is used to change the
source.
Press and hold the button for 2 seconds to return
to the favourites screen.
Activate/deactivate the mute mode.

191
Alphabetical index
Deactivating the passenger airbag 34, 37
Dimensions
11 3
Dipstick

81
Direction indicators

23
Display screen, instrument panel

8, 47
Domestic charging (Electric)

102–103
Drive selector (Electric)

47
Driving

69–70
Driving aids camera (warnings)

53
Driving aids (recommendations)

52
Driving economically

6
DSC

29
Dynamic stability control (DSC)

57–58
E
EBA 29
EBFD
29
Eco-driving (advice)

6
Electric motor

5, 6, 8, 69, 76,
81, 102, 105, 109
Electric windows

18
Electronic brake force distribution (EBFD)

29
Emergency warning lamps

28
Emissions control system, SCR

86
Engine compartment

108–109
Engine, Diesel

69, 80, 108
Engines

135–136
Environment

6, 42
ESP/ASR

30
F
Filling the AdBlue® tank 83, 87
Filling the fuel tank
68
Filter, air

84
Filter, Diesel fuel

85
Filter, oil

84
Filter, particle

84
Filter, passenger compartment

23, 84
Fittings, front

43–46
Fittings, interior

43–46
Flap, fuel filler

68
Flashing indicators

23
Fluid, brake

110–111
Fluid, engine coolant

110–111
Fluid, power steering

110–111
Foglamps, front

23
Foglamps, rear

23
Front doors

16
Fuel

6, 69
Fuel consumption

6
Fuel tank

68
Fuses

101
G
Gauge, fuel 68
Gearbox, manual
47, 49, 85
Glove box

43–45
H
Hazard warning lamps 28
Headlamp flash
23
Headlamps, dipped beam

23
Headlamps, main beam

23
Head restraints, front

18
Heating

35–36
Heating, additional

39–40
High voltage

69
Hill Descent Control

31
Hill start assist

77–78
Horn

28
I
Immobiliser, electronic 43
Indicator, coolant temperature
14
Indicator, engine oil level

13
Indicators, direction

23
Inflating tyres

85
Information, vehicle

151, 159
Infrared camera

53
Instrument panel

53
Instruments and controls

4
Intelligent Traction Control

31
J
Jack 136, 145

192
Alphabetical index
K
Key with remote control 43
Kit, hands-free
137, 177–178
L
Lane Departure Warning System
(LDWS)
87–88
Level, AdBlue®

83
Level, brake fluid

82
Level, engine coolant

14, 82
Level, engine oil

81
Level, heating system fluid

83
Level, power steering fluid

82
Levels

110–111
Levels and checks

109–111
Lighting dimmer

8
Low fuel level

68
Lumbar

18
M
Mains socket (domestic network) 71
Maintenance (advice)
70, 88
Maintenance, routine

53, 83
Manoeuvring aids (recommendations)

52
Mat

53
Menu

15, 171–172, 146, 149, 151
Menus (audio)

171–172
Mirror, rear view 8
Mirrors, door
22, 61
Motor, electric

81, 109
O
Oil change 81
Oil consumption
81
OIl, engine

109–111
On-board tools

119–124
Opening the bonnet

79
Overhead storage

43–46
P
Pads, brake 85
Paint
89
Parking brake

46, 85
Pedestrian horn (Electric)

29, 42
Player, USB

163–164, 172–173
Port, USB

163–164, 172–173
Power indicator (Electric)

6
Pressures, tyres

85
Pre-tensioning seat belts

33
Protecting children

62–65
Public fast charging station

71
R
Radar (warnings) 53
Radio
135, 143, 145
Radio, digital (Digital Audio
Broadcasting - DAB)

144
Range, AdBlue®

14–15, 83
Recharging the traction battery
(Electric)

69, 101–103
Recovery

104
Regeneration of the particle filter

84
Remote control

13
Replacing bulbs

97
Replacing fuses

101
Replacing the air filter

84
Replacing the oil filter

84
Replacing the passenger compartment filter

84
Resetting the service indicator

13
Reversing camera

53
S
Safety, children 62–65
Screen, colour
143
Screen menu map

171–172, 146, 149, 151
Screenwash fluid

110–111
SCR (Selective Catalytic Reduction)

86
Seat belts

60–61
Seat belts, rear

33
Seats, heated

19
Seats, rear

36

193
Alphabetical index
Sensors (warnings) 53
Service indicator
13
Servicing

13, 83
Settings, equipment

15, 21
Sidelamps

23
Silent vehicle warning sound (Electric)

29, 42
Snow chains

103–104
Socket, auxiliary

136, 145
Socket, Jack

136, 145
Sockets, auxiliary

43–45
Speed limiter

83–84
Speed limit recognition

82–83
Speedometer

53
Stability control (ESC)

29
Stability control (ESP)

30
Starting a Diesel engine

69
Station, radio

135, 143
Steering mounted controls, audio

134, 142
Steering wheel adjustment

21
Stickers, customising ~ Stickers,
expressive

89
Stop & Start

23, 31, 26, 33, 76–77, 79, 84, 104
Storage

43–45
Sunshine sensor

23
Super-fast charging (Electric)

102–103, 109
T
Tables of engines 136–137
Table, writing
43–45
Tank, fuel

68
Technical data 136–137
Telephone
137, 177–178
Temperature, coolant

14
Tools

119–124
Topping-up AdBlue®

87
Touch screen

141, 156
Touch screen audio-telematic system

141, 156
Towball, quickly detachable

104–106
Towbar with quickly detachable
towball

104–106
Towed loads

107
Towing another vehicle

104
Traction battery (Electric)

97–98, 109
Traction control (ASR)

57–58
Traffic information (TA)

135
Trip computer

22
Type of bulbs

97
Tyres

85
Tyre under-inflation detection

78–79
U
Under-inflation (detection) 78–79
USB
163–164, 172–173
V
Vehicle data recording and privacy 159
Ventilation
35–36
Voice commands

166–168, 180–182
W
Wallbox (Electric) 71
Warning and indicator lamps
9
Warning lamps

9
Warning lamp, seat belts

60–61
Warnings and indicators

9
Washing

53
Washing (advice)

70, 116–117
Weights

107
Wheel, spare

85, 119–124
Window controls

18
Wipers

26
Wipers, automatic rain sensitive

26