Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Confort
- Current generation
- Dashboard
- Electrical harnesses
- Engine
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Gearbox assembly
- General points
- General points about the vehicle
- Instruments and controls
- Lighting - signalling
- Mechanical
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear section
- Rear shock absorbers
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot Boxer I
Step-by-step instructions on "Engine" for Peugeot Boxer I (1994–2006). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Timing gear
- Data: camshaft (DW12UTED)
- Identification camshaft (DJ5, DJ5TED, DJ5T)
- Removing - refitting: Camshaft (SOFIM, SOFIM EURO5)
- Data timing gear (SOFIM)
- Identification - data - tightening torques timing gear (SOFIM)
- Checking: setting the valve timing (SOFIM, SOFIM EURO5)
- Removing - refitting camshaft (DJ5TED)
- Partial removal/refitting timing belt (DJ5T, DJ5)
- Check setting the valve timing (DW12UTED, DW10TD)
- Removing - refitting: timing belt (SOFIM, SOFIM EURO5)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (part number 9776.X9)
- Removing - refitting timing belt (SOFIM)
- Removing - refitting: camshaft seal (DW10TD, DW12UTED)
- Presentation - use: D-TEK de LEYBOLD refrigerant leak detector (Part No. 9776.X9)
- Removing - refitting: camshaft (DW10TD, DW12UTED)
- Removing - refitting: timing belt (DW10TD, DW12UTED)
- Modification: removal of the crankshaft pulley bolt (DW12UTED, DW10TD)
Lubrication
- Capacity of units
- General: lubrication
- Capacity: engine oil
- Recommendations lubricants
- Recommendations: oils for petrol engines
- Recommendations: lubricants — variant 2
- Recommended engine oils (DIESEL)
- Data - tightening torques: lubrication
- Checks: oil pressure (SOFIM EURO5, SOFIM)
- Check oil pressure (DW12UTED, DW10TD)
- Check: oil pressure (With oil pressure switch)
- Check: oil pressure (Without oil pressure switch)
- Recommendations: lubricants — variant 3
- Removing - refitting: oil pump (SOFIM, SOFIM EURO5)
- Suction draining (engine)
- Removing - refitting oil pump (DJ5T, DJ5)
- Overhaul oil pump assembly (SOFIM)
- Maintenance: recommended ingredients, year 2006
- Replace: engine oil filter cartridge (DJ5TED, DJ5T, DJ5)
- Replace: engine oil filter cartridge
- Replacement: engine oil filter cartridge (DJ5, DJ5T, DJ5TED)
Ignition
- Pressurising the fuel system
- Pressurising the fuel system — variant 2
- Injection-ignition: BOSCH MP7.0
- Injection-ignition: BOSCH MP7.0 — variant 2
- Help in diagnosis
- Help in diagnosis — variant 2
- Check: ignition advance
- Check: ignition advance — variant 2
- Check high voltage present
- Check high voltage present — variant 2
- Check high voltage present — variant 3
- Check high voltage present — variant 4
- Check high voltage present — variant 5
- Check high voltage present — variant 6
- Foot Off/Foot Down recognition
- Foot Off/Foot Down recognition — variant 2
- Injection-ignition wiring diagram: injection ignition
- Injection-ignition wiring diagram: injection ignition — variant 2
Engine block
Crankshaft
- Identification - data: pistons - little ends - piston rings (DW12UTED)
- Removing - refitting ancillary drive belt (DJ5)
- Identification - data: crankshaft - connecting rod bearing shells - balance shafts (DW12UTED)
- Data liners - pistons - piston rings - little ends (SOFIM)
- Data crankshaft (DJ5T, DJ5)
- Data: conrods (DW12UTED)
- Modification: reciprocating gear
- Data pistons - piston rings (DJ5, DJ5TED, DJ5T)
- Removing - refitting: auxiliary equipment drive belt (SOFIM, SOFIM EURO5)
- Removing - refitting: engine ring seals (SOFIM EURO5, SOFIM)
- Removing - refitting ancillary drive belt(s) (SOFIM)
- Data - tightening torques: crankshaft (SOFIM)
- Check crankshaft pulley
- Piston replacement (DJ5TED, DJ5T, DJ5)
- Data - tightening torques conrods - connecting shells (SOFIM)
- Removing - refitting ancillary drive belt (DW12UTED, DW10TD)
- Assembly connecting rods - pistons
- Tooling: dismantling - refitting (DJ5TED, DJ5, DJ5T)
- Tooling: dismantling - re-assembly (DJ5, DJ5T, DJ5TED)
Cylinder head
- Data: valves and valve springs (DW12UTED)
- Modification: cylinder head
- Identification - data: valve guides and seats (DW12UTED)
- Identification - data: cylinder head (DW12UTED)
- Refitting: cylinder head
- Data: cylinder head bolts - cylinder head tightening (DW12UTED)
- Data: cylinder head gasket (DW10TD)
- Data swirl chambers (DJ5T, DJ5)
- Data valve spring - valves (DJ5T, DJ5)
- Stripping - re-assembling: cylinder head (DW12UTED)
- Identification - data cylinder head (SOFIM)
- Data rocker shaft lubrication jets (DJ5T, DJ5)
- Removing - refitting: cylinder head (on vehicle) (SOFIM, SOFIM EURO5)
- Data abutment washer - valve spring (DJ5T, DJ5)
- Data - identification valve guides (DJ5T, DJ5)
- Removing - refitting cylinder head (on the vehicle) (DW12UTED, DW10TD)
- Checking-adjusting: valve clearances (SOFIM)
- Data cylinder head (DJ5T, DJ5)
- Data valve seats (DJ5T, DJ5)
- Identification: cylinder head bolts
- Identification: cylinder head bolts — variant 2
- Identification: cylinder head bolts — variant 3
- Removing - refitting cylinder head (1.9 TD)
- Overhaul cylinder head (DJ5, DJ5TED, DJ5T)
- Stripping - re-assembling: cylinder head (XU10J2)
- Adjustment: valve clearances (8 valve engine(s)) (XU10J2)
Air and fuel supply
- Check air supply circuit (SOFIM)
- Checks: idling - emission control
- Checks: idling - emission control — variant 2
- Removing - refitting: Fuel filter (SOFIM, SOFIM EURO5)
- Removing - refitting fuel filter (SOFIM)
- Checks: idling - emission control — variant 3
- Checks: idling - emission control — variant 4
- Removing - refitting fuel filter (DW12UTED, DW10TD)
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump BOSCH)
- Removing - refitting: fuel tank
- Removing - refitting: fuel pump and gauge assembly (SOFIM EURO5)
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump BOSCH)
- Removing - refitting Natural gas reservoirs (XU10J2)
- Replacement: stop electrovalve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Replacement: stop solenoid valve - coded anti-start module (mechanical or semi-electronic pump BOSCH - metal screening)
- Removing - refitting: LPG tank
- Replacement: stop electrovalve - transponder module (mechanical or semi-electronic pump LUCAS)
- Removing - refitting: Natural gas reservoirs (XU10J2) — variant 2
- Replacement: stop solenoid valve - transponder module (mechanical or semi-electronic pump LUCAS)
- Charging procedure: starting batteries
- Presentation: set of gas circuit protection plugs (LPG - gnv)
- Check: ignition advance
- Check: ignition advance — variant 2
Exhaust
Emission control
- Check exhaust gas recirculation circuit (SOFIM)
- Name: emission control standards
- Reference: emission control standards
- Check exhaust gas recirculation circuit (DW12UTED, DW10TD)
- Removing - refitting exhaust gas recycling valve (EGR) (DJ5TED)
- Removing - refitting exhaust gas recycling valve (SOFIM)
- Removing - refitting: exhaust gas recycling valve (EGR) (DW12UTED, DW10TD)
- Modification: oxygen sensor
Turbocharging
- Checks: turbocharge pressure (SOFIM EURO5, SOFIM)
- Removing - refitting turbocharger (DJ5TED)
- Removing - refitting turbocharger (DJ5T, DJ5)
- Check: turbocharge pressure (SOFIM)
- Check turbocharger pressure (DW12UTED, DW10TD)
- Check - adjustment: turbocharging pressure regulation valve (SOFIM)
- Removing - refitting: turbocharger (SOFIM, SOFIM EURO5)
- Removing - refitting turbocharger (DW12UTED, DW10TD)
- Removing - refitting: turbocharging pressure regulation valve (SOFIM)
Cooling system
- Maintenance: fluids recommendation
- Identification - data cooling system (DW12UTED, DW10TD)
- Identification - data: cooling system (DJ5TED, DJ5T, DJ5)
- Removing - refitting coolant pump drive belt (DJ5, DJ5T)
- Removing - refitting: Coolant pump (SOFIM EURO5, SOFIM)
- Draining - refilling - draining: cooling system (SOFIM EURO5, SOFIM)
- Check: purge canister solenoid valve function
- Drain and refill - refilling - bleeding: cooling system
- Data: air conditioning systems
- Check: purge canister solenoid valve function — variant 2
- Drain and refill - refilling: refrigerant circuit