2002 PEUGEOT BOXER servicing

16-09-2002
ARDUOUS CONDITIONS OF USE
¥ Continuous door-to-door use.
¥ Town use (e.g. taxi).¥ Repeated short journeys, with the engine cold at low temperatures.
¥ A prolonged stay under the following conditions : Ð countries with temperatures often above +30 ¡C,Ð countries with temperatures often below -15 ¡C,Ð countries with a dusty atmosphere,Ð countries whose lubricants or fuels do not conform to our recommendations.
It is necessary to follow an "Arduous Conditions" service schedule which includes special operations and shorter service intervals: ¥ Every 20 000 km or every year for petrol vehicles. ¥ Every 20 000 km or every year for petrol or LPG/UNG dual-fuel vehicles.W arning, LPG/UNG checks every 10 000 km or every 6 months.
¥ Every 15 000 km or every year for Diesel vehicles with HDI / TED direct injection.
PEUGEOT SERVICING
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PEUGEOT SERVICING27
A, B AND C SERVICE LEVELS AND THE INTERMEDIATE VISIT
: All driving conditions: Arduous conditions * According to country.
1st Level
Operations Description of operation serviceAB C Intermediate
DRAIN/REFILL- Engine oil - Bleed fuel filter (diesel) - Oil filter - Fuel filter* (petrol)REPLACE- Fuel filter element (diesel)- Air filter element- Spark plugs (petrol)- Engine oil (check + top-up) - Manual gearbox oil (check + top-up) - Battery (check + top-up) if cap is removable LEVEL- Screen wash (check + top-up)- Coolant (check + top-up) - Brake fluid (check + top-up) - Power steering fluid (check + top up according to specification) - Operation of lights and indicators - Condition of glass, headlamp and light lenses and mirrors - Horn - Windscreen washer jets - Condition of wiper blades - Condition and tension of the ancillary drive belts - Handbrake and clutch - Condition of hydraulic circuits (hoses and covers) CHECK- Condition of rubber boots and gaiters - Brake pads - Play in hubs, link rods, ball joints, flexible mountings- Shock absorbers- Rear drum brake lining wear- Condition and pressure of tyres (including spare wheel) - Emission control check as per current legislation (petrol) - Smoke opacity (diesel) - Pollen filter (according to specification) - Visual check of the whole vehicle
SERVICE*- Courtesy vehicle
ROAD TEST

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(1) Minimum grade: Petrol engines ACEA A3 and API SH/SJ; Diesel engines ACEA B3 and API CF/CD. ACEA= Association des Constructeurs EuropŽens Automobiles (Association of European Automobile
Manufacturers). API= American Petroleum Institute. If oil is used which does not conform to the ACEA A3-B3 standards, this requires the "Arduous Co nditions"
servicing schedule to be followed, which involves shorter intervals between services. *This Fuel Economy oil can only be used in engines designed for its use.
28TRADE NAMES OF APPROVED AND RECOMMENDED ENGINE LUBRICANTS IN EUROPE(1)
PETROL DIESEL DIESEL PETROL

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RECOMMENDATIONS FOR APPROVED LUBRICANTS The oils which appear in the table opposite are suitable for most pur-poses. The diagram opposite states the optimum range of viscosity depen-ding on the temperatures at whichthe oils are to be used. It is also possible to use "superior quality" synthetic oils. In the absence of semi-synthetic or
synthetic oils, oils of API SH/SJ qua-lity (for petrol engines), or CD/CFquality (for diesel engines) may beused by following the "ArduousConditions" servicing schedule,which specifies shorter intervals. Do not hesitate to ask for advice
from a PEUGEOT dealer to maintaindriving pleasure and to minimise themaintenance cost of your vehicle. For countries outside Europe, please
contact a local PEUGEOT dealer.
PEUGEOT SERVICING29
ONLY ONLY
Manual ESSO Gear Oil BVTO TA L TRANSMISSION BVGearbox 75W80 PR 9736.41 75W80
ONLY
Automatic ATF 4HP20
Gearbox PR 9736.22
Other approved products
Power steering FLUIDE DA PR 9730.A1
Brake fluid PEUGEOT DOT4 Coolant
PROCOR TM108/GLYSANTIN G33 or REVKOGEL 2000
ONLYProtection to minus 35C

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Minimum Check the level with the dipstick and
top it up. The figure shown is onlycorrect if the vehicle has been onlevel ground, with the engine stop-ped, for 10 minutes. Minimum oil level gauge fault Flashing of the segments indicates a fault in the oil level gauge or a lack ofoil. There is a risk the engine will be dama- ged.
Contact a PEUGEOT dealer. Maximum oil level gauge fault Flashing of the squares indicates a fault in the oil level gauge or a surplus of oil. There is a risk the engine will be dama- ged.
Contact a PEUGEOT dealer.
INSTRUMENTS AND CONTROLS35
Instrument panel display After switching on the ignition, three functions are shown in succession: -
service indicator (see correspon- ding section),
- engine oil level indicator,
- total distance recorder (total andtrip distances).
Engine oil level indicator When the ignition is switched on, the engine oil level is indicated for a fewseconds, after the servicing informa-tion. Maximum Check the level using the dipstick to confirm whether the display is correct;a surplus of oil can cause damage tothe engine.
Contact a PEUGEOT dealer without
delay. T
rip recorder zero reset
With the ignition on, press the but-ton. Excessive oil level Check the level using the dipstick to confirm whether the display is correct, asurplus of oil can cause damage to theengine.
Contact a PEUGEOT dealer without
delay.

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PRACTICAL INFORMATION143
CHECKING THE LEVELS Oil level ☞ Check the level regularly and top
up between changes. The maxi-mum consumption is 0.5 l per1000 km. Check the level with the vehicle level, engine cold, using the dips-tick.
Dipstick
There are two marks onthe dipstick: A= maximum.
Never fill past this mark.B = minimum.
To maintain the reliability
of engines and emission control systems, the useof additives in engine oilis prohibited.
Oil change According to the information given in
"PEUGEOT SERVICING" .
W ARNING: avoid used oil from
coming into prolonged contact withthe skin.
V iscosity selection
In all cases, the oil selected must meet the manufacturer's require-ments. Brake fluid level: - the level must always be between the MINIMUM and MAXIMUM
marks in the reservoir.
- if the level drops substantially,
contact a PEUGEOT dealer imme-
diately.
Fluid change: - must be carried out according to the manufacturer's servicing sche-dule.
- use fluids approved by the manu-
facturer, which fulfil DOT4 stan-dards.
W ARNING: brake fluid is harmful to
health and very corrosive. Avoid allcontact with the skin. Cooling system Use the fluid approved by the manu-
facturer. When the engine is warm, the tem- perature of the coolant is controlled
by the engine fan. As this fan canoperate with the ignition key remo-ved and because the cooling systemis pressurised, wait for at least onehour after the engine has stoppedbefore carrying out any work. Slacken the cap to the first notch torelease the pressure to prevent anyrisk of scalding. When the pressurehas dropped, remove the cap andtop up the level. Note:
the coolant does not need to
be changed. Used oil Do not dispose of used oil, brake fluid or coolant into drains or into theground. Power steering reservoir ☞ Open the reservoir, with the engi-
ne at ambient temperature. Thelevel should always be above theMIN. mark and close to the MAX.mark.
W indscreen and headlamp
wash reservoir For best quality cleaning and for your
safety, we recommend that you useproducts approved by PEUGEOT(7.5 litres with headlamp wash).

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Only use products
approved by Automobiles
PEUGEOT.
To ensure best perfor-
mance from components
as important as the power steering and the braking system,PEUGEOT selects and offersquite specific products.
CHECKS Battery
At the start of winter, have your bat-
tery checked by a PEUGEOT dealer. Air filter and pollen filter Have the filter elements replaced
regularly. If you drive in dusty
conditions, change them twice asoften. Brake pads Brake pad wear depends on the style of driving, in particular forvehicles which are used in town,over short distances. It may benecessary to check the thickness ofthe pads, even between services. Handbrake Where the handbrake travel is too great or there is a reduction in theperformance of the system, thehandbrake should be adjusted, evenbetween services. Have the system checked by a
PEUGEOT dealer. Manual gearbox This does not need an oil change. Check the level, according to themanufacturer's servicing schedule. Automatic gearbox This does not need an oil change. Have the level checked by a
PEUGEOT dealer, according to themanufacturer's servicing schedule. Oil filter
Change the filter regularly, in accor- dance with the servicing schedule.
Fuel supply cut-off In a serious collision, a system pre- vents fuel from reaching the engine.
To
re-establish the fuel supply, press
the switch on the angle of the front
left-hand suspension assembly,under the bonnet.
PRACTICAL INFORMATION
144