Peugeot Boxer Dag (2010 year). Manual — part 9

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.

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.

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 (France) or to an
authorised waste disposal site.

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.

Windscreen wash and headlamp
wash level

For best quality cleaning and to prevent
freezing, this fluid must not be topped up or
replaced with plain water.

Capacity of the reservoir: approximately
5.5 litres.

Checks

CHECKS

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.

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 specification.

In order to optimise the operation of units as
important as the braking system, 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.

Parking brake

Where the parking brake travel is too great
or there is a reduction in the performance
of the system, the parking brake should be
adjusted, even between services.

Have the system checked by a PEUGEOT
dealer.

Bleeding the water contained in
the Diesel filter

If this warning lamp comes on,
bleed the filter, otherwise bleed
regularly each time the engine oil
is changed.

To drain the water out, unscrew the bleed
screw or the water in Diesel sensor, located
at the base of the filter. Leave open 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.

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 system, 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.

Oil filter

Change the filter regularly, in accordance
with the servicing schedule.

Fuel

Low fuel level

When the fuel tank level E
(Empty) is reached, this warning
lamp 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.

Support the cap with one hand.

With the other hand, insert the key, then
turn it anticlockwise.

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 3rd 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, may be fitted.

FUEL SYSTEM
CUT-OFF

In the event of a serious collision, a device
automatically cuts off the fuel supply to the
engine and the vehicle's electrical supply.

FILLING WITH FUEL

Check that there is no smell or leak of fuel
outside the vehicle.

Restore the supply by pressing:

the first button, located under the glove
box.

the second button, located in the battery
compartment under the driver's floor.

In low temperatures

In mountainous and/or cold areas, it is
advisable to use a "winter" type fuel suited
to low or minus temperatures.

A. Positive metal point on your vehicle

B. Slave battery

C. Earth on your vehicle

Charging the battery using
a charger

disconnect the battery located in the
front left 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.

BATTERY

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

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.

It is advisable to disconnect the negative
(-) terminal of the battery if the vehicle is
not to be used for a period of more than
one month.

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 contact a
PEUGEOT dealer.

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, consult a PEUGEOT.

If your vehicle is fitted with a tachograph or
an alarm, disconnection of the negative (-)
terminal of the battery (located under the
floor on the left-hand side, in the cab) is
recommended if the vehicle is not to be used
for a period of more than 5 days.

Battery

Changing a wheel

1. PARKING THE VEHICLE

As far as possible, park the vehicle on level,
stable and non-slippery ground.

Apply the parking brake, switch off the
ignition and engage first gear.

Put on a high visibility jacket and position
the warning triangle.

If possible, place a chock under the
wheel diagonally opposite the wheel to be
changed.

2. TOOLS

These are located under the front passenger
seat cushion.

Turn the button a quarter of a turn then
pull the box.

After use, press the button then turn it a
quarter of a turn to secure the box.

A. Extended socket.

B. Ratchet wrench.

C. Jack.

D. Towing hook.

E. Wheelbrace.

F. Screwdriver.

CHANGING A WHEEL

You must ensure that the occupants get out
of the vehicle and wait in a safe location.

Changing a wheel

4. OPERATING PROCEDURE

Remove the trim using the screwdriver F
as a lever.

Release the bolts using the wheelbrace E .

Position the jack C at one of the four
locations provided on the underbody
near the wheels.

3. SPARE WHEEL

The spare wheel retaining bolt is located on
the rear right side.

Turn the bolt using the socket A and the
ratchet wrench B to release the wheel.

Turn to the locking point, indicated by
an increase in the force required for the
manoeuvre.

Take out the spare wheel using the
wrench.

Unscrew the handle G and remove the
support H .

Release the spare wheel and place it
near the wheel to be changed.

If you have a retractable foor board, the jack
must be positioned at 45°.

Extend the jack using the ratchet
wrench B until the wheel is a few
centimetres off the ground.

Unscrew the bolts fully and change the
wheel.

Changing a wheel

6. REFITTING THE REPAIRED

WHEEL

Refitting of the wheel is identical to step 5,
do not forget to refit the wheel trim.

Refer to the "Identification markings"
section of chapter 9 to locate the tyre
label.

The spare wheel is not designed to be used
over long distances. Have the tightening of
the bolts and pressure of the spare wheel
checked by a PEUGEOT dealer without
delay.

Also, have the original wheel repaired and
refitted by a PEUGEOT dealer as soon as
possible.

5. FITTING THE SPARE WHEEL

Put the wheel in place on the hub and
start screwing in the bolts by hand.

Carry out an initial tightening of the bolts
using the wheelbrace E .

Lower the vehicle completely by folding
the jack, then remove the jack.

Tighten the bolts again using the
wheelbrace E , tighten them fully without
forcing them.

Stow the wheel to be repaired at the
rear of the vehicle.

Hook the support H and screw in the
handle G .

Insert the socket A in the hole then
screw in the bolt, using the ratchet
wrench B , to raise the wheel.

Stow the tools and the trim.

Never go underneath a vehicle
supported only by a jack (use an axle
stand).

The jack and the tool kit are specific to
your vehicle. Do not use them for other
purposes.

Changing a wheel

PUNCTURE REPAIR KIT

This temporary puncture repair kit is located
at the front of the passenger compartment.

It consists of:

a cartridge A , containing the sealant
fluid, equipped with:

a filling hose B ,
a sticker C indicating "max. 80 km/h",

which the driver must affix in full view
(on the dashboard) after repairing the
tyre,

a quick guide to use of the repair kit,

a compressor D equipped with a
pressure gauge and unions,

adaptors, for the inflation of various
items.

Procedure

Apply the parking brake. Unscrew the
tyre valve cap, remove the filling hose B
and screw the ring E onto the tyre valve,

start the engine,

insert the connector G into the nearest
power socket on the vehicle,

switch on the compressor by placing the
switch F in position I (on),

inflate the tyre to a pressure of 4 bars.

To obtain a more accurate reading, you are
advised to check the pressure value on the
pressure gauge H , with the compressor off.

check that the switch F on the
compressor is in position 0 (off),

Changing a wheel

If a pressure of at least 3 bars is not
reached within 5 minutes, disconnect
the compressor from the valve and the
power socket, then move the vehicle
forward by approximately 10 metres to
distribute the sealant fluid inside the
tyre.

Then repeat the inflating operation:

if a pressure of at least 3 bars is not

reached within 10 minutes, switch off
your vehicle: the tyre has suffered
too much damage and repair has not
been possible. Consult a PEUGEOT
dealer.

if the tyre has been inflated to a

pressure of 4 bars , set off again
immediately.

After driving for approximately 10 minutes,
stop and check the pressure of the tyre
again.

Adjust the pressure if necessary and contact
a PEUGEOT dealer as soon as possible.

Checking and adjusting the
pressure

The compressor can only be used to check
and adjust the pressure.

Disconnect the hose I and connect it to
the tyre valve directly; the cartridge will
then be connected to the compressor
and the filling fluid will not be injected.

If it is necessary to deflate the tyre, connect
the hose I to the tyre valve and press the
yellow button, placed in the centre of the
switch on the compressor.

Replacing the sealant fluid
cartridge

To replace the cartridge, carry out the
following operations:

disconnect the hose I ,

turn the cartridge to be replaced
anticlockwise and lift it,

insert the new cartridge and turn it
clockwise,

reconnect the hose I and connect the
hose B in its location.

The cartridge contains ethylene-glycol,
a product which is harmful if swallowed
and which causes irritation to the eyes.

Keep out of reach of children.
After use, do not discard the cartridge in the
environment, take it to a PEUGEOT dealer
or to an organisation responsible for its
collection.
This replacement kit is available from
PEUGEOT dealers.

Changing a bulb

TYPES OF BULB

Various types of bulb are installed on your
vehicle. To remove them:

CHANGING A BULB

Type A Entirely glass bulb: pull gently

as it is fitted by pressure.

Type B Bayonet bulb: press on the bulb

then turn it anticlockwise.

Type C Cylindrical bulb: move aside the

contacts.

Type D - E

Halogen bulb: release the
retaining spring from its
housing.

FRONT LAMPS

Open the bonnet. To access the bulbs, reach
behind the headlamp unit.

Carry out the operations in reverse order to
refit each bulb.

Changing a bulb

1 - Dipped beam headlamp

Type D , H7 - 55 W

Remove the cover by turning it
anticlockwise.

Disconnect the electrical connector.

Release the retaining spring by pressing
on the two clips.

Change the bulb taking care to align the
metal part with the grooves on the lamp.

3 - Main beam headlamp

Type E , H1 - 55 W

Remove the cover by turning it
anticlockwise.

Disconnect the electrical connector.

Release the retaining spring by pressing
on the two clips.

Change the bulb taking care to align the
metal part with the groove on the lamp.

2 - Sidelamp

Type A , W 5 W - 5 W

Remove the cover by turning it
anticlockwise.

Remove the bulb holder fitted by
pressure.

Change the bulb.

4 - Direction indicators

Type B , PY 21 W - 21 W

Turn the bulb holder a quarter turn
anticlockwise.

Remove the bulb by pressing it lightly
while turning it anticlockwise.

Change the bulb.

5 - Foglamps

Type D , H1 - 55 W

Turn the steering fully to the left.

Unscrew the screw located in the wheel
arch then open the flap.

Remove the cover.

Disconnect the electrical connector.

Release the retaining spring by pressing
on the two clips.

Change the bulb taking care to align the
metal part with the grooves on the lamp.

Halogen bulbs must be changed after
the headlamp has been off for several

minutes (risk of serious burns). Do not
touch the bulb directly with your fingers,
use lint-free cloths.

When each operation has been completed,
check the operation of the lamps.

When using a high pressure washer
on stubborn dirt, do not persist on the
headlamps, the lamps and their edges to
avoid damaging their varnish and seals.

Changing a bulb

DIRECTION INDICATOR SIDE
REPEATER

Type A , W 16 W F - 16 W

Move the mirror glass to access the
screws.

Unscrew the two screws using the
screwdriver supplied.

Pull the bulb holder to release it from the
dog points.

Pull the bulb then change it.

Front/Rear

COURTESY LAMPS

Type C , 12 V 10 W - 10 W

Press the points, indicated by the
arrows, then remove the courtesy lamp.

Open the protective flap.

Change the bulb moving aside the
two contacts.

Ensure that the new bulbs are secured
correctly between the two contacts.

Close the protective flap.

Fix the courtesy lamp in its housing and
ensure that it is secured correctly.

SIDE MARKER LAMPS

Type A , W 5 W - 5 W

If your vehicle is fitted with these lamps
(van type L4), unscrew the two screws
using the screwdriver supplied.

Pull the bulb holder to release it from
the lugs.

Pull the bulb then change it.

Changing a bulb

REAR LAMPS

For more information on the bulbs, refer to
the table "Types of bulb".

Remove the two fixing nuts.

Pull the lens block from the outside.

Unscrew the three screws using the
screwdriver supplied (under the front
passenger seat) and extract the bulb
holder.

Remove the faulty bulb by pressing it
lightly while turning it anticlockwise.

Change the bulb.

1. Brake/ sidelamps

Type B, P 21/5 W - 5 W

THIRD BRAKE LAMP

Type B , P21 W - 21 W

Unscrew the two screws.

Remove the lamp.

Remove the bulb holder moving aside
the two tabs.

Remove the faulty bulb by pressing it
lightly while turning it anticlockwise.

Change the bulb.

2. Direction indicators

Type B, PY 21 W - 21 W

3. Reversing lamps

Type B, P 21 W - 21 W

4. Foglamps

Type B, P 21 W - 21 W

Identify the faulty bulb then open the
rear doors.

Disconnect the electrical connector.

Type A , C 5 W - 5 W

Press the point, indicated by the arrow,
then remove the plastic lens.

Change the bulb by moving aside the
two contacts.

Ensure that the new bulbs are secured
correctly between the two contacts.

Replace the plastic lens and press on it.

Changing a fuse

The three fuseboxes are located in
the dashboard on the driver's side, in
the passenger pillar and in the engine
compartment.

The pliers are secured to the fusebox on the
driver's side.

Removing and fitting a fuse

Before changing a fuse, the cause of the
fault must be found and rectified. The fuse
numbers are indicated on the fuse box.

- Use the pliers.

Always replace a faulty fuse with a fuse
of the same rating.

CHANGING A FUSE

PEUGEOT does not accept any
responsibility for expenses incurred

by repairs to your vehicle or for any
malfunctions resulting from the installation
of additional accessories which are not
supplied or recommended by PEUGEOT
and which are not installed in accordance
with its instructions, in particular when
the combined consumption of all of the
additional equipment connected exceeds
10 milliamperes.

Correct

Incorrect

Changing a fuse

DRIVER'S SIDE DASHBOARD FUSES

Remove the bolts and tilt the box to access the fuses.

Fuses

A (amps)

Allocation

7.5

Right-hand dipped headlamp

7.5

Left-hand dipped headlamp - Headlamp height adjuster

7.5

Relay supply

Minibus interior lighting - Hazard warning lamps

Rear 12 V socket

Not used

7.5

Reversing lamps - Water in Diesel sensor

Door locking/unlocking unit

7.5

Brake lamps switch - Third brake lamp - Instrument panel

Interior relays

Audio equipment - Diagnostic socket - Alarm siren - Programmable additional heating controls -

Air conditioning controls - Tachograph

Defrosting: rear screen (left-hand side), mirror (driver's side)

Defrosting: rear screen (right-hand side), mirror (passenger side)

7.5

ABS control unit and sensor - ESP sensor - Brake lamps switch

Windscreen wiper motor

Cigar lighter - Front 12 V socket

7.5

Electric window and mirror switches (driver's side) - Passenger's electric window

Not used

Driver's electric window motor

Passenger's electric window motor

7.5

Rain/sunshine sensor - Audio equipment - Driver's electric window motor - Alarm - Instrument panel controls

7.5

Airbags and pre-tensioners unit

7.5

Tachograph - Cruise control - Air conditioning controls

7.5

Passenger compartment relays

7.5

Instrument panel - Rear foglamps

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Peugeot Boxer Dag (2010 year). Manual — part 9

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