2006.5 Peugeot Boxer Owner's Manual

98
Opening the bonnet
On the inside
Pull the lever on the side of the fascia panel
towards you. On the outside
Push the lever located above the grille to the
right and raise the bonnet.
Bonnet strut
Unclip the strut and tilt it to insert it in the
first notch, then the second.
Before closing the bonnet, put the strut back
in its housing.To close
Lower the bonnet and release it at the end
of its travel. Check that the bonnet is locked.
If the bonnet is not closed
correctly, this warning light comes
on on the instrument panel.
OPENING THE BONNET

1
23
4
56a7a
8
6c7b
7c
6b
+
-
99
7
CHECKS
Under the bonnet
1 - Windscreen/headlamp wash reservoir.
2 - Fuse box.
3 - Coolant reservoir.
4 - Brake and clutch fluid reservoir.
5 - Air filter. 6 -
Dipstick.
a: 2.2 l 100
b: 2.2 l 120
c: 3.0 l 160
7 - Engine oil filler cap.
a: 2.2 l 100
b: 2.2 l 120
c: 3.0 l 160
8 - Power steering reservoir.
Battery connections: + Positive metal point.
- Negative metal point (earth).
UNDER THE BONNET
DIESEL ENGINES

BA
100
LEVELS
These regular maintenance operations
will keep your vehicle in good running
order. Consult the instructions at PEUGEOT
dealerships, on the Infotec site or in the
servicing booklet enclosed in the handbook
pack.
If you have to remove/refit the engine
style cover, handle it with care to avoid
damaging the fixing clips.
Oil level
Check the level regularly and top up between
changes. The maximum consumption is 0.5 l
per 600 miles (1 000 km).
Check the level with the vehicle level,
engine cold, using the dipstick.
Dipstick
There are two marks on
the dipstick:
A = maximum
If you fill past this mark,
contact a PEUGEOT
dealer.
B = minimum
Never allow the level to fall
below this mark.
Levels
To maintain the reliability of engines and
emission control systems, the use of
additives in engine oil is prohibited.
Oil change
It is imperative that this is carried out at the
intervals specified and the viscosity grade of
the oil selected must fulfil the requirements
in accordance with the manufacturer’s
servicing schedule. Consult the instructions at
PEUGEOT dealerships or on the Infotec site.
Remove the dipstick before filling.
Check the level after filling (never exceed
the maximum mark).
Screw the cap back onto the sump before
closing the bonnet.
Viscosity selection
In all cases, the oil selected must meet the
manufacturer ’s requirements.
Changing the brake fluid
The brake fluid must be changed at
the intervals stated, according to the
manufacturer ’s servicing schedule.
Use fluids recommended by the
manufacturer, which fulfil DOT4 standards.
The level must be between the MIN and
MAX marks on the reservoir.
If fluid has to be added frequently, this
indicates a failure which must be checked by
a PEUGEOT dealer as soon as possible.
Warning lights
Checking by means of the warning
lights on the instrument panel
is described in chapter 2, refer to the
"Instruments and controls" section.

101
7
CHECKS
Levels
Cooling system
Only use the fluid recommended by the
manufacturer.
Otherwise, you risk seriously damaging your engine.
When the engine is warm, the temperature
of the coolant is controlled by the engine
fan. As this fan can operate with the ignition
key removed and because the cooling
system is pressurised, wait for at least one
hour after the engine has stopped before
carrying out any work.
Slacken the cap by 1/4 of a turn to release
the pressure to prevent any risk of scalding.
When the pressure has dropped, remove the
cap and top up the level with coolant.
If fluid has to be added frequently, this
indicates a failure which must be checked by
a PEUGEOT dealer as soon as possible.
Topping up
The level must be between the MIN and
MAX marks on the expansion bottle. If
more than 1 litre of fluid is required to top
up the level, have the system checked by a
PEUGEOT dealer. Power steering fluid level
The vehicle must be parked on level ground
with the engine cold. Unscrew the cap
integrated with the gauge and check the
level which must be between the
MIN and
MAX marks.
Windscreen wash and headlamp
wash level
For best quality cleaning and for your safety,
we would advise that you use products of
the PEUGEOT Universal range.
Capacity of the reservoir: approximately
5.5 litres. Used oil
Avoid prolonged contact of used oil with the
skin.
Brake fluid is harmful to health and very
corrosive.
Do not dispose of used oil, brake fluid or
coolant into drains or into the ground but
into the containers dedicated to this use at
PEUGEOT dealerships.

102
CHECKS
Bleeding the water contained in
the diesel filter
If this warning light comes on,
bleed the filter, otherwise bleed
regularly each time the engine is
drained.
To evacuate the water, unscrew the bleed
screw or the water in diesel sensor, located
at the base of the filter.
Operate until all of the water has been
drained out.
Then tighten the bleed screw or the water sensor.
HDi engines use advanced technology.
All work requires a special qualification
which is guaranteed by a PEUGEOT dealer.
Battery
At the start of winter, have your battery
checked by a PEUGEOT dealer.
Air filter and passenger
compartment filter
A clogged passenger compartment filter may
reduce the performance of the air conditioning
system and generate undesirable odours.
The replacement intervals for these components
are indicated in the servicing booklet.
Depending on the environment (dusty
atmosphere...) and the use of the vehicle
(urban driving...), change them twice as
often if necessary, refer to the "Under the
bonnet" section of chapter 7.
Brake pads
Brake pad wear depends on the style of
driving, in particular for vehicles which are
used in town, over short distances.

It may be necessary to check the thickness
of the pads, even between services.
Unless there is a leak on the circuit, a drop
in the brake fluid level indicates that the
brake pads are worn.
Brake disc/drum wear status
For any information relating to checking
the brake disc/drum wear status, contact a
PEUGEOT dealer.
Handbrake
Where the handbrake travel is too great
Checks
Manual gearbox
Have the level checked in accordance with
the manufacturer ’s servicing schedule.
To check the main levels and certain
components, in accordance with the
manufacturer ’s servicing schedule, refer
to the pages of the servicing booklet which
correspond to your vehicle’s engine.
Only use products recommended by
PEUGEOT or products of equivalent quality
and characteristics.
In order to optimise the operation of units as
important as the braking circuit, PEUGEOT
selects and offers specific products.
In order to avoid damaging the electrical
units, high pressure washing to clean the
engine compartment is strictly prohibited.
or there is a reduction in the performance
of the system, the handbrake should be
adjusted, even between services.
Have the system checked by a PEUGEOT
dealer.
Oil filter
Change the filter regularly, in accordance
with the servicing schedule.

104
Fuel
Low fuel level
When the fuel tank level E
(Empty) is reached, this warning
light comes on.
At this moment, you have
enough fuel left to drive approximately
30 miles (50 km) , depending on the driving
conditions, the engine and the profile of the
road. Fill up without delay to avoid running
out of fuel. The fuel tank must be filled
with the engine
off .
- Open the fuel filler flap.
- Insert the key, then turn it a quarter turn.
- Remove the cap and hook it onto the clip located on the inside of the flap.
A label affixed to the inside of the flap
reminds you of the type of fuel to be used.
When filling the fuel tank, do not continue
after the 3
rd cut-off of the nozzle. This could
cause malfunctions.
The capacity of the fuel tank is
approximately 90 litres.
- After filling the fuel tank, lock the cap and
close the flap.
Fuel tanks of different capacities, 60
and 125 litres, are sold.
FUEL CIRCUIT DEACTIVATED
In the event of a serious collision, a device
automatically cuts off the fuel supply to the
engine and the vehicle’s electrical supply.
Check that there is no smell or leak of fuel
outside the vehicle.
Restore the supply by pressing:
- the first button, located below the steering wheel.
- the second button, located in the battery compartment under the front passenger ’s
floor.
FILLING WITH FUEL

C
B
A
105
TROUBLESHOOTING
8
A.
Positive metal point on your vehicle
B. Slave battery
C. Negative metal point (earth) on your
vehicle
It is imperative that the negative point
(earth) located above the grille is used.
Battery
CHARGING THE BATTERY USING
A CHARGER
- disconnect the battery located under the cab floor,
- follow the instructions for use given by the
battery charger manufacturer,
- reconnect starting with the negative (-) terminal,
- check that the terminals and connectors are clean. If they are covered with sulphate
(white or greenish deposit), disconnect
them and clean them. The charging operation must be carried
out in a ventilated area away from naked
flames or any possible sources of sparks to
eliminate the risk of explosion and fire.
Do not attempt to charge a frozen battery: it
must first be thawed to eliminate the risks of
explosion. If the battery has frozen, before
charging it have it checked by a specialist
who will check that the internal components
have not been damaged and that the
container is not cracked, which could mean
that there is a risk of a leak of toxic and
corrosive acid.
STARTING FROM ANOTHER
BATTERY
- connect the red cable to the metal point
A
then to the positive (+) terminal of the slave
battery B,
- connect one end of the green or black cable to the negative (-) terminal of the
slave battery B,
- connect the other end of the green or black
cable to the earth point C on your vehicle,
- operate the starter, let the engine run,
- wait for the engine to return to idle, then disconnect the cables.
BATTERY

106
Battery
The batteries contain harmful
substances such as sulphuric acid and
lead. They must be discarded in accordance
with the provisions of the law and must not,
in any circumstances, be discarded with
household waste.
Take used batteries to a special collection
point.
Before disconnecting the battery, you must
wait for 2 minutes after switching off the
ignition.
Never disconnect a terminal when the
engine is running.
Never charge a battery without first
disconnecting the terminals.
Close the windows and doors before
disconnecting the battery.
After every reconnection of the battery,
switch on the ignition and wait 1 minute
before starting to allow the electronic
systems to be initialised. If slight difficulties
are experienced after this, please consult 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.
If the battery has been disconnected
for some time, it may be necessary to
reinitialise the following functions:
- the display parameters (date, time, language, distance unit and temperature
unit),
- the radio stations,
- the central locking.
Some settings are cleared and must be
reprogrammed, contact a PEUGEOT dealer.