Get Quick Help -> Puncture repair kit Guide for Peugeot Boxer Van First Generation (1994-2002)

Levels

Cooling system

Power steering fluid level

Used oil

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.

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.

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.

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.

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.

Capacity of the reservoir: approximately

5.5 litres.

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.

Checks

CHECKS

Air filter and passenger compartment

filter

Parking brake

Where the parking brake travel is too great

or there is a reduction in the performance

Bleeding the water contained in the

Diesel filter

A clogged passenger compartment ﬁlter may

reduce the performance of the air conditioning of the system, the parking brake should be

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

system and generate undesirable odours. The

replacement intervals for these components

are indicated in the servicing booklet.

adjusted, even between services.

Have the system checked by a PEUGEOT

dealer.

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.

Oil filter

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.

Change the ﬁlter regularly, in accordance with

the servicing schedule.

Manual gearbox

Have the level checked in accordance with

the manufacturer's servicing schedule.

Brake pads

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.

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.

Battery

At the start of winter, have your battery

checked by a PEUGEOT dealer.

Only use products recommended by

PEUGEOT or products of equivalent quality

and specification.

Unless there is a leak on the system, a drop

in the brake fluid level indicates that the

brake pads are worn.

In order to optimise the operation of units as

important as the braking system, PEUGEOT

selects and offers specific products.

Brake disc/drum wear status

For any information relating to checking

the brake disc/drum wear status, contact a

PEUGEOT dealer.

In order to avoid damaging the electrical

units, high pressure washing to clean the

engine compartment is strictly prohibited.

The presence of this label, in particular with

the Stop & Start system, indicates the use of

a speciﬁc 12 V lead-acid battery with special

technology and speciﬁcation. The involvement

of a PEUGEOT dealer or a qualiﬁed workshop

is essential when replacing or disconnecting

the battery.

7

Checks

After prolonged idling or driving at very low

speeds, you may occasionally notice water

vapour being emitted from the exhaust when

accelerating. This is of no consequence

to the running of the vehicle or to the

environment.

Saturation / Regeneration

If there is risk of blockage of the

Particle filter system (Diesel)

An addition to the catalytic converter, this

filter makes an active contribution to the

preservation of air quality by the retaining

of the unburnt pollutant particles. Black

exhaust fumes are thus no longer emitted.

filter, this warning lamp comes on

in the instrument panel.

This alert tells you that the particle filter

is starting to fill up (in conditions of urban

driving of exceptionally long duration: low

speeds, traffic jams etc.)

Because of the higher exhaust gas

temperature resulting from the normal

operation of the particle filter, it is

recommended that you do not park the

vehicle over inflammable materials (grass,

dry leaves, pine needles, ...) so as to avoid

any risk of fire.

This filter, fitted to the exhaust system,

accumulates particles of soot. The engine

control unit manages the automatic

periodic elimination of the soot particles

(regeneration).

To regenerate the filter, it is advised to drive

as soon as possible, when traffic conditions

and the law permit, at a speed of at least

40 mph (around 60 km/h), with an engine

speed above 2 000 rpm for about fifteen

minutes (until the warning lamp and/or the

message disappears).

The regeneration procedure is invoked

according to the quantity of particles

accumulated and the driving conditions

of the vehicle. During this phase, you

may notice some unusual phenomena -

increased idling speed, cooling fan running,

increase in smoke and higher exhaust gas

temperature - which does not affect the

operation of the vehicle or the environment.

If possible, avoid switching off the engine

before the end of regeneration of the

filter; repeated interruptions could cause

premature deterioration of the engine oil. It

is not recommended to end regeneration of

the filter with the vehicle stationary.

Operating fault

If this alert persists, do not ignore the

warning; it indicates that a fault has occurred

in the exhaust / particle filter system.

Have it checked by a PEUGEOT dealer.

Maintenance with TOTAL

Innovation at the service of performance

The TOTAL Research and Development teams

develop lubricants for PEUGEOT which satisfy the

requirements of the latest technical innovations

incorporated in PEUGEOT vehicles.

This ensures that you obtain the best performance

and the maximum engine life.

Reduced exhaust emissions

TOTAL lubricants are formulated to optimise the

efficiency of engines and the protection of the

emissions post-treatment systems. It is crucial to

observe the servicing recommendations made by

PEUGEOT to ensure correct operation.

RECOMMENDS

7

Fuel

The fuel tank must be filled with the

FUEL SYSTEM CUT-OFF

engine off.

In the event of a serious collision, a device

automatically cuts off the fuel supply

-

Open the fuel filler flap.

to the engine and the vehicle's electrical

supply.

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.

Check that there is no smell or leak of fuel

outside the vehicle.

A label affixed to the inside of the flap

reminds you of the type of fuel to be used.

Restore the supply by pressing:

When filling the fuel tank, do not continue

after the 3rd cut-off of the nozzle. This could

cause malfunctions.

-

the first button, located below the

steering wheel.

The capacity of the fuel tank is

approximately 90 litres.

FILLING WITH FUEL

-

After filling the fuel tank, lock the cap

and close the flap.

With Stop & Start, never refuel with

the system in STOP mode; you must

switch off the ignition with the key.

Fuel tanks of different capacities,

60 and 125 litres, may be fitted.

-

the second button, located in the

battery compartment, under the front

passenger's floor.

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

In low temperatures

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.

In mountainous and/or cold areas, it is

advisable to use a "winter" type fuel suited

to low or minus temperatures.

Battery

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.

Proceed with a slow charge charge at low

current for a maximum pf about 24 hours to

avoid damaging the battery.

Starting from another battery

-

connect the red cable to the metal

point A then to the positive (+) terminal

of the slave battery B,

BATTERY

Charging the battery using a charger

-

disconnect the battery located in the

front left floor,

connect one end of the green or black

cable to the negative (-) terminal of the

slave battery B,

A. Positive metal point on your vehicle

B. Slave battery

follow the instructions for use given by

the battery charger manufacturer,

C. Earth on your vehicle

connect the other end of the green or

black cable to the earth point C on your

vehicle,

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.

-

operate the starter, let the engine run,

wait for the engine to return to idle, then

disconnect the cables.

8

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.

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.

The description of the battery charging

procedure is given as an indication only.

Take used batteries to a special collection

point.

Before disconnecting the battery, you must

wait for 2 minutes after switching off the

ignition.

If the battery has been disconnected

for some time, it may be necessary to

reinitialise the following functions:

Never disconnect a terminal when the

engine is running.

-

the display parameters (date, time,

language, distance unit and temperature

unit),

Never charge a battery without first

disconnecting the terminals.

Access to the negative terminal

-

the radio stations,

the central locking.

Close the windows and doors before

disconnecting the battery.

For access to the negative (-) terminal:

press button 2 then pull on connector 1.

Some settings are cleared and must be

reprogrammed, consult a PEUGEOT.

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 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

The presence of this label, in particular

with the Stop & Start system, indicates

the use of a 12 V lead-acid battery with

special technology and specification; the

involvement of a PEUGEOT dealer or

a qualified workshop is essential when

replacing or disconnecting the battery.

Failure to observe this recommendation may

cause premature wear of the battery.

After refitting the battery by a

PEUGEOT dealer or a qualified

workshop, the Stop & Start system will

only be active after a continuous period of

immobilisation of the vehicle, a period which

depends on the climatic conditions and the

state of charge of the battery (up to about

8 hours).

Do not disconnect the battery to

charge it.

8

Changing a wheel

You must ensure that the occupants get out

of the vehicle and wait in a safe location.

A. Long socket.

B. Ratchet wrench.

C. Jack.

CHANGING A WHEEL

1. PARKING THE VEHICLE

D. Towing hook.

E. Wheelbrace.

F. Screwdriver.

As far as possible, park the vehicle on level,

stable and non-slippery ground.

2. TOOLS

Apply the parking brake, switch off the

ignition and engage first gear.

These are located under the front passenger

seat cushion.

Put on a high visibility vest and position the

warning triangle.

-

Turn the button a quarter of a turn then

pull the box.

If possible, place a chock under the

wheel diagonally opposite the wheel to be

changed.

-

After use, press the button then turn it a

quarter of a turn to secure the box.

Changing a wheel

-

Take out the spare wheel using the

wrench.

-

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

below the bumper on the right.

Unscrew the handle G and remove the

support H.

-

Turn the bolt using the socket A and the

ratchet wrench B to release the wheel.

If you have a retractable foot board, the jack

must be positioned at 45°.

Release the spare wheel and place it

near the wheel to be changed.

-

Turn to the locking point, indicated by

an increase in the force required for the

manoeuvre.

-

Extend the jack using the ratchet

wrench B until the wheel is a few

centimetres off the ground.

4. OPERATING PROCEDURE

-

Unscrew the bolts fully and change the

wheel.

-

Remove the trim using the screwdriver F

as a lever.

Release the bolts using the

wheelbrace E.

8

Changing a wheel

-

Hook the support H and screw in the

handle G.

6. REFITTING THE REPAIRED WHEEL

Refitting of the wheel is identical to step 5,

do not forget to refit the wheel trim.

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).

Refer to the "Identification markings"

section of chapter 9 to locate the tyre

label.

The jack and the tool kit are specific to your

vehicle. Do not use them for other purposes.

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.

Changing a wheel

-

start the engine,

PUNCTURE REPAIR KIT

Procedure

insert the connector G into the nearest

power socket on the vehicle,

-

Apply the parking brake. Unscrew the

This temporary puncture repair kit is located

at the front of the passenger compartment.

tyre valve cap, remove the filling hose B

and screw the ring E onto the tyre valve,

-

switch on the compressor by placing the

switch F in position I (on),

It consists of:

-

a cartridge A, containing the sealant

fluid, equipped with:

-

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.

● 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.

-

check that the switch F on the

compressor is in position 0 (off),

8

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.

Checking and adjusting the pressure

Replacing the sealant fluid cartridge

To replace the cartridge, carry out the

following operations:

The compressor can only be used to check

and adjust the pressure.

● if the tyre has been inflated to a

pressure of 4 bars, set off again

immediately.

-

disconnect the hose I,

turn the cartridge to be replaced

anticlockwise and lift it,

-

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.

After driving for approximately 10 minutes,

stop and check the pressure of the tyre again.

-

insert the new cartridge and turn it

clockwise,

reconnect the hose I and connect the

hose B in its location.

Adjust the pressure if necessary and contact

a PEUGEOT dealer as soon as possible.

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.

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

CHANGING A BULB

TYPES OF BULB

Various types of bulb are installed on your

vehicle. To remove them:

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.

FRONT LAMPS

Type C Cylindrical bulb: move aside the

contacts.

Open the bonnet. To access the bulbs, reach

behind the headlamp unit.

Carry out the operations in reverse order to

refit each bulb.

Type D - E Halogen bulb: release the

retaining spring from its

housing.

8

Changing a bulb

-

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.

1 - Dipped beam headlamp

3 - Main beam headlamp

-

Change the bulb taking care to align the

metal part with the grooves on the lamp.

Type D, H7 - 55 W

Type E, H1 - 55 W

-

Remove the cover by turning it

anticlockwise.

-

Remove the cover by turning it

anticlockwise.

-

Disconnect the electrical connector.

-

Disconnect the electrical connector.

Halogen bulbs must be changed after

the headlamp has been off for several

Release the retaining spring by pressing

on the two clips.

Release the retaining spring by pressing

on the two clips.

minutes (risk of serious burns). Do not touch

the bulb directly with your fingers, use lint-

free cloths.

-

Change the bulb taking care to align the

metal part with the grooves on the lamp.

-

Change the bulb taking care to align the

metal part with the groove on the lamp.

When each operation has been completed,

check the operation of the lamps.

2 - Sidelamp

4 - Direction indicators

Type A, W 5 W - 5 W

Type B, PY 21 W - 21 W

When using a high pressure washer

on stubborn dirt, do not persist on the

headlamps, the lamps and their edges to

avoid damaging their lacquer finish and

seals.

-

Remove the cover by turning it

anticlockwise.

-

Turn the bulb holder a quarter turn

anticlockwise.

Remove the bulb holder fitted by

pressure.

Change the bulb.

Changing a bulb

Front/Rear

DIRECTION INDICATOR SIDE

REPEATER

SIDE MARKER LAMPS

COURTESY LAMPS

Type A, W5W - 5W

Type A, W 16 W F - 16 W

-

If your vehicle is fitted with these lamps

(van type L4), unscrew the two screws

using the screwdriver supplied.

Type C, 12 V 10 W - 10 W

-

Move the mirror glass to access the

screws.

-

Press the points, indicated by the

arrows, then remove the courtesy lamp.

Open the protective flap.

Unscrew the two screws using the

screwdriver supplied.

-

Pull the bulb holder to release it from the

lugs.

-

Change the bulb moving aside the two

contacts.

Pull the bulb holder to release it from the

dog points.

Pull the bulb then change it.

-

Ensure that the new bulbs are secured

correctly between the two contacts.

Pull the bulb then change it.

-

Close the protective flap.

Fix the courtesy lamp in its housing and

ensure that it is secured correctly.

8

Changing a bulb

-

Remove the two fixing nuts.

-

Ensure that the new bulbs are secured

correctly between the two contacts.

REAR LAMPS

For more information on the bulbs, refer to

the table "Types of bulb".

Pull the lens block from the outside.

Replace the plastic lens and press on it.

Unscrew the three screws using the

screwdriver supplied (under the front

passenger seat) and extract the bulb

holder.

1. Brake/sidelamps

Type B, P 21/5 W - 5 W

-

Remove the faulty bulb by pressing it

lightly while turning it anticlockwise.

2. Direction indicators

Type B, P21W - 21W

Change the bulb.

Type B, PY 21 W - 21 W

-

Unscrew the two screws.

Remove the lamp.

3. Reversing lamps

NUMBER PLATE LAMPS

Type A, C 5 W - 5 W

Remove the bulb holder moving aside

the two tabs.

Type B, P 21 W - 21 W

4. Foglamps

-

Press the point, indicated by the arrow,

then remove the plastic lens.

-

Remove the faulty bulb by pressing it

lightly while turning it anticlockwise.

Type B, P 21 W - 21 W

-

Identify the faulty bulb then open the

rear doors.

Change the bulb by moving aside the

two contacts.

Change the bulb.

-

Disconnect the electrical connector.

Changing a fuse

Good

Failed

CHANGING A FUSE

The three fuseboxes are placed in the

dashboard on the passenger's side, in

the driver's door pillar and in the engine

compartment.

Always replace a failed fuse with a fuse

of the same rating.

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 fusebox.

Descriptions are given only for fuses that

can be changed by the user. For all other

work on the fuses, go to a PEUGEOT dealer

or a qualified workshop.

PEUGEOT declines to accept any

responsibility for expenses incurred for

repairs to your vehicle or for any malfunctions

resulting from the installation of additional

accessories which are not supplied or

Motor trade professionals : for compete

information on the fuses and relays,

refer to the diagrams in the workshop

procedure documents available at dealers.

recommended by PEUGEOT the manufacturer

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.

8

Quick Help -> Puncture repair kit for Your Peugeot Boxer Van First Generation (1994-2002)

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