2021 PEUGEOT BOXER service

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 3
Practical information
7Manual gearbox
The gearbox does not require any maintenance (no oil change).
Brake pads
Brake wear depends on the style of
driving, particularly in the case of vehicles
used in town, over short distances. It may be
necessary to have the condition of the brakes
checked, even between vehicle services.
Unless there is a leak in the circuit, a drop in the
brake fluid level indicates that the brake pads
are worn.
If this warning lamp comes on, have the
brake pads checked by a PEUGEOT
dealer or a qualified workshop.
After washing the vehicle, moisture, or in wintry conditions, ice can form on the
brake discs and pads: braking efficiency may
be reduced. Gently dab the brakes to dry and
defrost them.
Brake disc wear
For information on checking brake disc
wear, contact a PEUGEOT dealer or a
qualified workshop.
Manual parking brake
If you notice excessive brake lever travel
or decreased effectiveness, the parking brake must be adjusted, even between two
services.
This system must be checked by a PEUGEOT
dealer or a qualified workshop.
Diesel fuel filter
The Diesel fuel filter is located in the engine
compartment near the brake fluid reservoir.
If this warning lamp comes on, bleed the
filter.
You can also bleed it regularly at each engine oil
change.
Bleeding the water in the filter

► Couple a clear hose to the bleed screw
1 head.
►

Place the other end of the clear hose in a
container

.
► Loosen bleed screw 2 .
► Switch on the ignition.
►

W
ait for the scavenge pump to stop.
►

Switch off the ignition.
►


T
ighten bleed screw 2.
►

Remove, then drain the clear hose and the
container

.
►

Start the engine.
►


Check that there are no leaks.
HDi engines make use of advanced
technology. Any intervention requires a
special qualification guaranteed by the
PEUGEOT


dealer network or a qualified
workshop .
Wheels and tyres
The inflation pressure of all tyres, including the spare wheel, must be
checked on "cold” tyres.
The pressures indicated on the tyre pressure
label are valid for "cold" tyres. If you have driven
for more than 10 minutes or more than 6 miles
(10 kilometres) at over 31 mph (50
km/h), add
0.3 bar (30 kPa) to the values indicated on the
label.
Under-inflation increases energy
consumption. Non-compliant tyre
pressures cause tyres to wear prematurely
and have an adverse effect on the vehicle's
road holding - risk of accident!

11 5
Practical information
7Freezing of the AdBlue®
AdBlue® freezes at temperatures below
around -11°C.
The SCR system includes a heater for the
AdBlue
® tank, allowing you to continue driving
in very cold conditions.
Supply of AdBlue®
It is recommended that the AdBlue® be topped
up as soon as the first alert is issued indicating
that the reserve level has been reached.
For the correct operation of the SCR
system:
–

Use
only AdBlue
® fluid that meets the ISO
22241 standard.
–

Never

transfer AdBlue
® to another container
as it would lose its purity.
–

Never dilute

AdBlue
® with water.
It is possible to obtain AdBlue
® from a PEUGEOT
dealer or a qualified workshop.
You can also visit a service station equipped with AdBlue® pumps specially
designed for passenger vehicles.
Recommendations on storage
AdBlue® freezes at about -11°C and deteriorates
above +25°C. Containers should be stored in a
cool area and protected from direct sunlight.
Under these conditions, the fluid can be kept for
at least a year.
If the fluid has frozen, it can be used once it has
completely thawed out at room temperature.
Never store AdBlue® containers in your
vehicle.
Precautions for use
AdBlue® is a urea-based solution. This fluid is
non-flammable, colourless and odourless (when
kept in a cool place).
In the event of contact with the skin, wash the
affected area with soap and running water. In the
event of contact with the eyes, immediately rinse
the eyes with large amounts of water or with an
eye wash solution for at least 15 minutes. Seek
medical attention if you feel a persistent burning
sensation or irritation.
If swallowed, immediately wash out the mouth
with clean water and then drink plenty of water.
In certain conditions (high temperature, for
example), the risk of release of ammonia cannot
be excluded: do not inhale the fluid. Ammonia
vapours have an irritant effect on mucous
membranes (eyes, nose and throat).
Store AdBlue® out of the reach of
children, in its original container.
Procedure
Before starting the top-up procedure, ensure that
the vehicle is parked on a flat and level surface.
In wintry conditions, ensure that the temperature
of the vehicle is above -11 °C. Otherwise the
AdBlue
® may be frozen and so cannot be poured
into its tank. Park the vehicle in a warmer area
for a few hours to allow the top-up to be carried
out.
Never put the AdBlue® into the Diesel
fuel tank.
If any AdBlue® is splashed, or if there are
any spillages on the bodywork, rinse
immediately with cold water or wipe with a
damp cloth.
If the fluid has crystallised, clean it off using a
sponge and hot water.
Important: in the event of a top-up after
an AdBlue breakdown, you must wait
about 5
minutes before switching on the
ignition, without opening the driver's door,
unlocking the vehicle or bringing the
electronic key into the passenger
compartment.
Switch on the ignition, then wait for 10
seconds before starting the engine.
►

Switch off the ignition and remove the key
from the switch to switch off the engine.

11 6
Practical information

► Turn the blue cap of the AdBlue® tank a 6th of
a turn anti-clockwise and remove it.
Filling up
► With a container of AdBlue®: after checking
the expiry date, read the instructions on the
label carefully before pouring the contents of the
container

into the vehicle's AdBlue tank.
►

With an


AdBlue® pump: introduce the nozzle
and fill the tank until the nozzle automatically
cuts out.
In order not to overfill the AdBlue® tank:
–
Add between 10 and 13 litres using
AdBlue® containers.
–
Stop after the nozzle’ s first automatic cut-
out, if you are refilling at a service station.
The system only registers AdBlue
® top-ups of
5

litres or more.
If the AdBlue® tank is completely empty
– which is confirmed by the message
"Top up

AdBlue: Starting impossible" – it is
essential to add at least 5 litres.
After refilling
► Refit the blue cap to the tank filler and turn it
clockwise as far as it will go (one sixth of a turn).
►

Close the fuel filler flap.
Do not dispose of AdBlue® containers in
the household waste.
Place them in a container reserved for this
purpose or take them back to where you
bought them.
Advice on care and maintenance
General recommendations
Observe the following recommendations to avoid
damaging the vehicle.
Exterior
Never use a high-pressure jet wash in
the engine compartment - risk of
damaging the electrical components!
Do not wash the vehicle in bright sunshine or
extremely cold conditions.
When washing the vehicle in an
automatic roller-brush car wash, be sure
to lock the doors and, depending on version,
move the electronic key away and deactivate
the "hands-free" function (Hands-Free
Tailgate Access).
When using a pressure washer, keep the jet
nozzle at a minimum distance of 30 cm from
the vehicle (particularly when cleaning areas
containing chipped paint, sensors or seals).
Promptly clean up any stains containing
chemicals liable to damage the vehicle's
paintwork (including tree resin, bird
droppings, insect secretions, pollen and tar).
Depending on the environment, clean the
vehicle frequently to remove salty deposits
(in coastal areas), soot (in industrial areas)
and mud/salts (in wet or cold areas). These
substances can be highly corrosive.
Contact a PEUGEOT dealer or a qualified
workshop for advice on removing stubborn
stains requiring special products (such as tar
or insect removers).
Preferably, have paint touch-ups performed
by a PEUGEOT dealer or a qualified
workshop.

133
In the event of a breakdown
8Ensure that the weight of the towing vehicle is
higher than that of the towed vehicle.
The driver must remain at the wheel of the
towed vehicle and must have a valid driving
licence.
When towing a vehicle with all four wheels on
the ground, always use an approved towing
arm; rope and straps are prohibited.
The towing vehicle must move off gently.
When the vehicle is towed with its engine
off, there is no longer braking and steering
assistance.A professional towing service must be
called if:
–

Broken down on a motorway or main road.
–


Not possible to put
the gearbox into neutral,
unlock the steering, or release the parking
brake.
–

Not possible to tow a vehicle with an
automatic gearbox, with the engine running.
–


T

owing with only two wheels on the ground.
–

Four-wheel drive vehicle.
–


No approved towbar available.
Before towing the vehicle, it is essential
to put the vehicle in free-wheeling mode.
Electric motor
An electric vehicle cannot under any
circumstances be used to tow another
vehicle.
However, it may be used, for example, to exit
a rut.
Towing constraints
Type of vehicle
(engine/gearbox) Front wheels on the
ground Rear wheels on the
ground Flatbed
4 wheels on the ground
with towbar
Internal combustion/Manual


Electric

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

161
Special features
10SymptomsVerification/Check
The hydraulic
unit does not
work. Power harness and unit
relay.
Control harness (control
unit).
Circuit-breaker.
The ram does
not lower. No, check the coil and the
electrical connections of
the valve.
The control unit
does not work. Check the connection and
contacts.
The fuse blows
while lowering. Replace the lowering coil.
Hydraulic faults
Symptoms Verification/Check
Very noisy unit,
rises slowly. Suction strainer clogged
or crushed at the bottom
of the tank.
Very noisy
new unit, rises
quickly. Pump alignment, change
the unit.
The ram lowers
by itself. Lowering valve crushed or
blocked.
Symptoms
Verification/Check
The ram does
not lower. Yes, check the slide valve
and bleed.
Refer to the
"Maintenance" section.
No, replace the solenoid
valve.
No, check the alignment
of the ram.
The unit works
but its pressure
does not
increase. Slide valve jammed if no
solenoid valve on the unit.
Refer to the
"Maintenance" section.
Pressure relief device,
setting, dirt.
Pump seal out of service.
Motor/pump coupling.
Pump loose from its
support.
The hydraulic
unit does not
work. Solenoid valve stuck,
replace it or retighten the
nut behind the strainer.
Emulsion in the
tank. Incorrectly positioned
return pipe.
Insufficient oil level.Symptoms
Verification/Check
The oil flows
back through
the oil breather
pipe. Oil level too high.
Tolerance of the oil
breather pipe membrane
too high, to be replaced.
Valid only for UD2386
units.

167
Audio system
11It is possible to replace the "Mobile
phone" tag with three other available
tags: "Home"; "Office"; "Other".
Call* > Henri Dupont
Dial the telephone number associated with the
contact Henri Dupont.
Call* > Henri Dupont > Mobile phone
Dial the telephone number with the mobile phone
tag associated with the contact Henri Dupont.
Call number > 0123456789
Call number 0123456789.
Redial
Call the number or contact of the last call made.
Call back
Call the number or contact of the last call
received.
Recent calls*
View the complete list of recent calls: outgoing,
missed and incoming.
Outgoing calls *
View the list of outgoing calls.
Missed calls*
View the list of missed calls.
Incoming calls *
View the list of incoming calls.
Directory *
View the directory of the connected telephone.
* This function is av ailable only if the telephone connected to the system supports downloading of contacts and recent calls and if the corresponding
download has been performed.
**

This function is a
vailable only if the telephone connected to the system supports the text message reading function.
***

It
is possible to replace "Magic" with any other FM station name received by the radio. Not all radio stations provide this service.
Search* > Henri Dupont
View Henri Dupont's contact information in the
directory with all of the numbers saved.
Search* > Henri Dupont > Mobile phone
View the telephone number with the mobile
phone tag associated with the contact Henri
Dupont.
View messages**
View the list of text messages received by the
connected telephone.
If the telephone allows the recording of
the "First Name" (Henri) and the
"Surname" (Dupont) in two separate fields,
perform the following voice commands:
–

"Call" > "Henri" > "Dupont" or "Call" >
"Dupont" > "Henri".
–


"Search" > "Henri" > "Dupont" or "Search"
> "Dupont" > "Henri".
"AM/FM radio” voice
commands
The following commands can be made from any main screen page after pressing
the voice recognition button located on the
steering wheel, as long as there is no telephone
call in progress. Tune to
> 105.5 > FM
Tune the radio to the 105.5 frequency of the FM
band.
Tune to > 940 > AM
Tune the radio to the 940 frequency of the AM
band.
Tune to *** > Magic > FM
Tune the radio to the station Magic.
"Media" voice commands
The following commands can be made from any main screen page after pressing
the voice recognition button located on the
steering wheel, as long as there is no telephone
call in progress.
Listen to track > "Track 1"
Play the track
“Track 1”.
Listen to album > "Album 1"
Play the songs of the album “Album 1”.
Listen to artist > "Artist 1"
Play the songs of the artist
“Artist 1”.
Listen to music style > "Jazz"
Play the songs of the music style “Jazz”.
Listen to playlist > "Playlist 1"
Play the songs of the playlist “Playlist1”.
Listen to podcast > "Radio 1"
Play the podcast
“Podcast 1”.
Listen to audio book > "Book 1"