engine Peugeot Boxer Dag 2003.5 Service Manual

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Engine compartment fuse box Fuse box
To gain access to the fuses in the engine compartment: unclip the cover.
Close the cover carefully when you have finished.
PRACTICAL INFORMATION
144
The electrical system of your vehicle is designedto operate with standardor optional equipment.
Before installing other electricalequipment or accessories on yourvehicle, contact a PEUGEOT
dealer. PEUGEOT will not accept respon- sibility for the cost incurred inrepairing your vehicle or for rectify-ing the malfunctions resulting fromthe installation of accessories notsupplied and not recommended byPEUGEOT and not installed inaccordance with its instructions, inparticular where the equipment inquestion consumes more than
10 milliamperes.
* The maxi-fuses provide additional protection for the electrical sys-
tems. All work must be carried out
by a PEUGEOT dealer.
Fuse no. Rating Functions
1* 60 A Passenger compartment 27-fuse box.
2* 50 A Pre-heat box - Heating resistor (2.8 litre engines).
3* 30 A Starting switch.
4* 50 A Anti-lock braking system (ABS).
5* 40 A Cooled air system.
6* 40 A Fan assembly (low speed).
7* 40/60 A Fan assembly (high speed) - Fan assembly relay(high speed with air conditioning).

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Fuse no. RatingFunctions
8 30 A Wash-wipe pump.
9 15 A Headlamps and fog lamps.
10 15 A Horn - Steering wheel lever control.
11 15 A Engine management control unit (secondary).
14 10 A Right-hand dipped headlamp.
15 10 A Left-hand dipped headlamp.
16 7.5 A Engine management control unit supply - Transponder.
17 10 A Engine management control unit (primary).
18 7.5 A Engine management control unit - Transponder.
19 7.5 A Air conditioning compressor.
20 30 A PTC.
21 15 A Fuel pump.
22 20 A Engine management control unit (primary).
23 10 A Automatic gearbox.
24 15 A Automatic gearbox - LPG/CNG operation.
30 15 A Left- and right-hand main beam headlamps.
PRACTICAL INFORMATION 145

Removing and changing a fuse Before changing a fuse, you must establish the cause of the fault and have it cor-
rected. The fuse numbers are indicated on the fuse boxes. Use the special pliers A.
Always change a faulty fuse for one of the same rating.
CHANGING A FUSE The fuse boxes are located in the lower part of the fascia (left andright hand side) and in the enginecompartment. The spare fuses and special pliers A
are fixed to the inside of the lids of the fascia panel fuse boxes. Fascia panel fuses  Unscrew the bolts then tilt the cover to access the fuses.
Correct
Incorrect
PRACTICAL INFORMATION 141
Pliers
A
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PRACTICAL INFORMATION
146
BATTERY
To charge the battery using a battery charger:
Ð Disconnect the battery,
Ð Follow the instructions for use given by the battery charger manufacturer,
Ð Reconnect starting with the negative (Ð) terminal,
Ð Check that the terminals and connectors are clean. If they are covered with sul-
phate (white or greenish deposit), disconnect them and clean them.
To start the vehicle from another battery:
Ð Connect the red cable to the positive (+) terminals of the two batteries,
Ð Connect one end of the green or black cable to the negative (Ð) terminal of the slave battery,
Ð Connect the other end of the green or black cable to an earth point on the bro- ken down vehicle as far as possible from the battery.
Operate the starter, let the engine run.
Wait for the engine to return to idle, then disconnect the cables.
Ð Never disconnect a ter- minal when the engine is running.
Ð Never charge a battery without first disconnecting the terminals.
Ð After every reconnection of the battery, switch on the ignition andwait 1 minute before starting toallow the electronic systems to beinitialised. If slight difficulties areexperienced after this, please
contact a PEUGEOT dealer.
It is advisable to disconnect the battery if the vehicle is not to be used for a period of more than one month.

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TOWING YOUR VEHICLE
Without lifting (4 wheels on the ground)
You must always use a tow bar. The towing eyes are located at the front and the rear under the vehicle's bumpers. Lifting (2 wheels only on the ground) It is preferable to raise the vehicle with a professional lifting device.Special features of the automatic gearbox When towing with four wheels on the ground, the following rules must beobeyed:
Ð lever in position
N,
Ð tow the vehicle at less than 30 mph (50 km/h) over a maximum dis- tance of 30 miles (50 km).
PRACTICAL INFORMATION
148
When towing with the engine switched off, thereis no braking or steeringassistance.

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TOWING A TRAILER,
CARAVAN, BOAT etc.
Only use original PEUGEOT tow bars that have been tested andapproved from the design stage ofyour vehicle. The tow bar must be fitted by a
PEUGEOT dealer.
Your vehicle is primarily designed for transporting people and luggage butit may also be used for towing a
trailer. Driving with a trailer subjects the towing vehicle to more significantstress and its driver must be particu-larly careful. Air density decreases with altitude, thus reducing engine performance.
Above 1 000 metres, the maximum
towing load must be reduced by 10 %
and so on for every 1 000 metres ofaltitude.Driving advice Distribution of loads:
Distribute the
load in the trailer so that the heaviest items are as close as possible to theaxle and the nose weight approachesthe maximum permitted withoutexceeding it. Cooling: Towing a trailer on a slope
increases the temperature of the coolant. As the fan is electrically controlled, its cooling capacity is not dependenton the engine speed.
On the contrary, use a high gear to lower the engine speed and reduceyour speed. The maximum towing load on a long slope depends on the gradient andthe outside temperature. In all cases, pay attention to the coolant temperature. If the warning light comes on, stop
the vehicle and switch off the engineas soon as possible. Tyres:
Check the tyre pressures
of the towing vehicle and of the
trailer, observing the recommendedpressures. Braking: Towing increases the
braking distance. Lights: Check the electrical signal-
ling on the trailer.Side wind: Take into acount the
increased sensitivity to side wind.
PRACTICAL INFORMATION 149

TECHNICAL DATA151
Manual Manual Manual Manual Auto. Manual
(5-speed) (5-speed) (5-speed) (5-speed) (4-speed) (5-speed) PETROL DIESEL
ENGINES 2 litre 2 litre 2.2 litre 2.8 litre 2.8 litre
injection Turbo HDI Turbo HDI Turbo HDI Turbo TED
Cubic capacity (cm3
)1 998 1 997 2 178 2 798 2 798
Maximum power EU standard (kW)80 64 74 93.5 90
Maximum power at engine speed(rpm)5 500 4 000 4 000 3 600 3 600
Maximum torque EU standard (Nm)168 195 240 300 285
Maximum torque at engine speed (rpm)3 400 1 900 1 900 1 800 1 800
FuelUnleaded Diesel Diesel Diesel Diesel
OIL CAPACITY (in litres) Engine (with cartridge replacement) 4.75 5.3 5.3 7 Ð 7
Gearbox-Final drive Ð Ð Ð Ð Ð Ð
ENGINE GEARBOX
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TECHNICAL DATA
152
COMBI consumption In accordance with directive 99/100 in MPG (litres/100 km)
Engine Gearbox Model Urban Inter-urban Mixed Emission codes of CO
2
by weight (g/Km)
2 litre injectionManual
2 litre Turbo HDI Manual
2.2 litre Turbo HDIManual
2.8 litre Turbo HDI*Manual
2.8 litre Turbo HDI*Automatic
2.8 litre Turbo TEDManual Ð Ð Ð Ð Ð
* The values shown for the 2.8 litre Turbo HDI engine were measured with a starting cycle in 2nd gear. Fuel consumption values correct at time of printing. 290C/330M 27.6 (10.2) 36.2 (7.8) 32.4 (8.7) 230
330MH 26.6 (10.6) 34.9 (8.1) 31.1 (9.0) 239
290C/330M 17.8 (15.9) 25.7 (11.0) 22.1 (12.8) 301
330MH 17.5 (16.1) 25.3 (11.2) 21.7 (13.0) 306
290C/330M 24.8 (11.4) 33.2 (8.5) 29.4 (9.6) 253 330MH 24.6 (11.5) 32.8 (8.6) 29.1 (9.7) 255
290C/330M 26.6 (10.6) 33.2 (8.5) 30.4 (9.3) 246 330MH 26.0 (10.9) 32.1 (8.8) 29.4 (9.6) 254
330M 21.1 (13.4) 28.8 (9.8) 25.4 (11.1) 295
330MH 20.6 (13.7) 28.2 (10.0) 25.0 (11.3) 301
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TECHNICAL DATA153
* The values shown for the 2.8 litre Turbo HDI engine were measured with a starting cycle in 2nd gear. Fuel consumption values correct at time of printing.
MINIBUS consumption In accordance with directive 99/100 in MPG (litres/100 km)
Engine Gearbox Model Urban Inter-urban Mixed Emission codes of CO
2
by weight (g/Km)
2 litre injection Manual
2 litre Turbo HDI Manual 290C 26.6 (10.6) 34.9 (8.1) 31.1 (9.0) 239
2.2 litre Turbo HDIManual
2.8 litre Turbo HDI*Manual
2.8 litre Turbo HDI*Automatic
290C 17.5 (16.1) 25.3 (11.2) 21.7 (13.0) 306
330MH 17.3 (16.3) 24.8 (11.4) 21.4 (13.2) 311
290C 24.6 (11.5) 32.8 (8.6) 29.1 (9.7) 255
330MH 24.1 (11.7) 32.1 (8.8) 28.5 (9.9) 260
290C 26.0 (10.9) 32.1 (8.8) 29.4 (9.6) 254
330MH 25.4 (11.1) 31.1 (9.0) 28.8 (9.8) 261
290C 20.6 (13.7) 28.2 (10.0) 25.0 (11.3) 301
330MH 20.3 (13.9) 27.6 (10.2) 24.6 (11.5) 307
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Engine2 litre injection
Cubic capacity (cm 3
) 1 998
Petrol maximum power: EU standard (kW) 80 to 5 500 rpm
Maximum torque: EU standard (Nm) 168 to 3 400 rpm
Fuel Unleaded/LPG/CNG
Gearbox Manual (5-speed)
Petrol consumption (in litres) Urban 15.9
Inter-urban 11.0
Mixed 12.8
Emission of CO 2by weight (g/km)
301
Weights and towing loads (in kg) Kerb
weight 2 010 2 060 2 080 2 130 Gross vehicle weight
(GVW) 3 300 3 500 3 300 3 500
Payload 1 290 1 440 1 220 1 370Gross train weight
(GTW)* 5 300 5 500 5 300 5 500
Unbraked trailer 750 750 750 750Braked trailer
(within GTW) 2 000 2 000 2 000 2 000
Recommended nose weight 80 80 80 80
TECHNICAL DATA 165
TECHNICAL DATA FOR THE PETROL/LPG OR CNG DUAL-FUEL VERSION
Models Van Extended van
* The speed of a towing vehicle is limited to 60 mph (100 km/h).
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