Manual sections
Wiring diagrams- Battery
- Body
- Bodywork
- Braking
- Comfort and convenience
- Confort
- Connector pinouts
- Current generation
- Dashboard
- Driver information
- Driving assistance
- Electrical harnesses
- Engine
- Equipment
- Front anti -roll bar
- Front axle
- Front doors
- Front seats
- Front section
- Front shock absorbers
- Gearbox assembly
- General points
- General points about the vehicle
- Instrument panel
- Instruments and controls
- Lighting - signalling
- Mechanical
- Other
- Power unit
- Pre-heating
- Protections and doors
- Re-assembling
- Rear axle
- Rear door windows
- Rear seats
- Rear section
- Rear shock absorbers
- Roof panel
- Side structure
- Starting
- Steering
- Suspension
- Transmission
- Washing and wiping
Repair manual
Engine Peugeot Boxer II
Step-by-step instructions on "Engine" for Peugeot Boxer II (2006–2014). Pick an article — removal, installation, adjustment and diagnostics with illustrations.
Crankshaft
- Data: pistons - little ends - piston rings (3.0 HDI 160, 3.0 HDI 160 FAP)
- Data: conrods - connecting rod half shells (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: crankshaft and bearing half-shells (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: pistons - little ends - piston rings (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: conrods andhalf shells (3.0 HDI 160, 3.0 HDI 160 FAP, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Data: crankshaft and bearing half-shells (3.0 HDI 160, 3.0 HDI 160 FAP, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Dismantling - refitting: conrods - pistons (3.0 HDI 160 FAP, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Removing - refitting: ancillary drive belt (2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
- Removing - refitting: accessories drive belts (p22dte+ engine) (2.2 HDI 120 PUMA)
- Dismantling - refitting: conrods - pistons (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: accessories drive belts (p22dte engine) (2.2 HDI 100 PUMA)
- Removing - refitting: engine ring seals (3.0 HDI 160 FAP, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Removing - refitting: accessories drive belts (3.0 HDI 175 FAP EURO 5, 3.0 HDI 160 FAP, 3.0 HDI 160, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Aid to mechanical diagnosis: double damped engine flywheel
Lubrication
- Check: oil pressure (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA, 2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C)
- Check: oil pressure (3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 160 FAP, 3.0 HDI 160)
- Removing - refitting: oil pressure sensor (2.2 HDI 130 PUMA, 2.2 HDI 120 PUMA, 2.2 HDI 100 PUMA)
- Removing - refitting: oil level sensor / the oil temperature (2.2 HDI 130 PUMA, 2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: engine oil temperature and level sensor (3.0 HDI 160 FAP, 3.0 HDI 160)
- Removing - refitting: oil pressure sensor (3.0 HDI 160, 3.0 HDI 160 FAP)
- Removing - refitting: oil pump (3.0 HDI 145 FAP EURO 5)
- Removing - refitting: oil level/temperature sensor (3.0 HDI 160 FAP, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5)
- Removing - refitting: engine oil temperature and level sensor (2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: oil pressure sensor (2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: oil pump (2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C)
- Maintenance: recommended ingredients, year 2006
Timing gear
- Data: camshaft (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: camshafts (3.0 HDI 145 FAP EURO 5, 3.0 HDI 160 FAP, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5)
- Removing - refitting: camshafts (2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C)
- Removing - refitting: camshafts (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: camshafts (3.0 HDI 155 FAP EURO 5, 3.0 HDI 160 FAP, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Check: setting the valve timing (2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C)
- Check: setting the valve timing (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Check: setting the valve timing (3.0 HDI 175 FAP EURO 5, 3.0 HDI 160 FAP, 3.0 HDI 160, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Removing - refitting: timing chain (2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
- Removing - refitting: timing chain (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: timing chain (3.0 HDI 145 FAP EURO 5, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 160 FAP)
Exhaust
- Tightening torques: exhaust system (3.0 HDI 145 FAP EURO 5)
- Tightening torques: exhaust system (2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C)
- Tightening torques: exhaust system (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- General specifications: exhaust system (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- General specifications: exhaust system (3.0 HDI 175 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: pre-catalyst (3.0 HDI 155 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: exhaust manifold (3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Removing - refitting: exhaust system (3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Removing - refitting: exhaust manifold (2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C)
- Removing - refitting: exhaust system (2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: pre-catalyser (2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: fuel injection vaporiser at the exhaust (2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: pre-catalyst (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: exhaust system (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: exhaust manifold (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: pre-catalyst (3.0 HDI 160)
- Removing - refitting: exhaust system (3.0 HDI 160)
- Removing - refitting: exhaust gas pressure sensor pressure take-off (3.0 HDI 160 FAP)
- Removing - refitting: particle filter (3.0 HDI 160 FAP)
- Removal - refitting: catalytic converter/particle filter assembly (2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C)
- Removal - refitting: exhaust gas pressure sensor pressure take-off (2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
- Forced regeneration: particle filter (technical note)
Engine block
Cylinder head
- Data: cylinder head gasket (2.2 HDI 120 PUMA, 2.2 HDI 100 PUMA)
- Data: cylinder head bolts - cylinder head tightening (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: valves and valve springs (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: valve seats and guides (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: cylinder head (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Data: cylinder head, cylinder head gasket and cylinder head bolts (3.0 HDI 145 FAP EURO 5, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 160 FAP)
- Data: valves - valve springs - tappets (3.0 HDI 160, 3.0 HDI 160 FAP, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5)
- Data: valve seats and guides (3.0 HDI 160 FAP, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Stripping-assembling: cylinder head - cylinder head cover (3.0 HDI 160, 3.0 HDI 160 FAP, 3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 175 FAP EURO 5)
- Stripping - re-assembling: cylinder head (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: cylinder head (on vehicle) (2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: cylinder head (on vehicle) (2.2 HDI 120 PUMA, 2.2 HDI 130 PUMA, 2.2 HDI 100 PUMA)
- Removing - refitting: cylinder head (3.0 HDI 155 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 160 FAP, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: air inlet manifold (3.0 HDI 155 FAP EURO 5, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: air inlet manifold (2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C)
- Removing - refitting: air metering unit (2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
Cooling system
- General specifications: engine cooling system type puma 2.2 (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Identification - data: engine cooling system - type SOFIM F30DT (3.0 HDI 160, 3.0 HDI 175 FAP EURO 5)
- Removing - refitting: coolant level sensor (3.0 HDI 160 FAP, 2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA, 2.2 HDI 130 PUMA, 3.0 HDI 160)
- Removing - refitting: coolant temperature sensor (2.2 HDI 120 PUMA, 2.2 HDI 100 PUMA, 2.2 HDI 130 PUMA)
- Removing - refitting: Coolant pump (3.0 HDI 145 FAP EURO 5)
- Removing - refitting: coolant outlet housing (3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: engine cooling radiator (2.2 HDI 110 PUMA C, 2.2 HDI 100 PUMA, 2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 120 PUMA, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: coolant pump (2.2 HDI 120 PUMA, 2.2 HDI 100 PUMA, 2.2 HDI 150 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: coolant outlet housing temperature sensor (3.0 HDI 160 FAP, 3.0 HDI 160)
- Drain and refill - refilling - bleeding: cooling system
Air and fuel supply
- Removing - refitting: inlet air pressure sensor (3.0 HDI 160 FAP, 3.0 HDI 160)
- Removing - refitting: Fuel tank (3.0 HDI 145 FAP EURO 5)
- Removing - refitting: air inlet manifold (2.2 HDI 100 PUMA, 2.2 HDI 130 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: fuel pump and gauge assembly (2.2 HDI 150 PUMA C, 2.2 HDI 120 PUMA, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 2.2 HDI 110 PUMA C, 3.0 HDI 160 FAP, 3.0 HDI 155 FAP EURO 5, 2.2 HDI 130 PUMA C, 2.2 HDI 100 PUMA, 3.0 HDI 145 FAP EURO 5)
- Removing - refitting: fuel tank
- Removing - refitting: fuel filter (3.0 HDI 145 FAP EURO 5, 2.2 HDI 110 PUMA C, 3.0 HDI 160, 3.0 HDI 160 FAP, 2.2 HDI 130 PUMA C, 3.0 HDI 155 FAP EURO 5, 2.2 HDI 120 PUMA, 2.2 HDI 150 PUMA C, 3.0 HDI 175 FAP EURO 5, 2.2 HDI 100 PUMA)
- Removing - refitting: air inlet manifold (3.0 HDI 160, 3.0 HDI 160 FAP)
- Drain - refill: fuel tank (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: accelerator pedal sensor (3.0 HDI 160 FAP, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
Emission control
- Removing - refitting: EGR (exhaust gas recycling) electrovalve (3.0 HDI 160 FAP, 3.0 HDI 160)
- Removing - refitting: oxygen sensor (2.2 HDI 110 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 150 PUMA C)
- Checking: exhaust gas recirculation circuit (3.0 HDI 155 FAP EURO 5, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 145 FAP EURO 5)
- Check: exhaust gas recirculation circuit (3.0 HDI 160)
- Removing - refitting: exhaust gas temperature sensor (3.0 HDI 160)
- Removing - refitting: oxygen sensor (3.0 HDI 160)
- Removing - refitting: exhaust gas pressure sensor (3.0 HDI 160)
- Removing - refitting: exhaust gas recirculation heat exchanger (3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 175 FAP EURO 5)
- Removing - refitting: exhaust gas recycling solenoid valve (2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: exhaust gas recirculation heat exchanger (2.2 HDI 110 PUMA C)
- Removing - refitting: exhaust gas temperature sensors (2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
- Removing - refitting: exhaust gas pressure sensor (2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C)
- Removing - refitting: exhaust gas recycling solenoid valve (2.2 HDI 120 PUMA, 2.2 HDI 130 PUMA, 2.2 HDI 100 PUMA)
- Removing - refitting: exhaust gas recycling solenoid valve (3.0 HDI 160, 3.0 HDI 160 FAP)
- Modification: oxygen sensor
Turbocharging
- Check: turbocharge pressure (3.0 HDI 175 FAP EURO 5)
- Check: turbocharger pressure (2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
- Check: turbocharger pressure (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Check: turbocharger pressure (3.0 HDI 145 FAP EURO 5, 3.0 HDI 160)
- Removing - refitting: turbocharger (3.0 HDI 145 FAP EURO 5, 3.0 HDI 155 FAP EURO 5, 3.0 HDI 175 FAP EURO 5)
- Removing - refitting: Turbocharger (2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C, 2.2 HDI 150 PUMA C)
- Removing - refitting: turbocharger air cooler (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA)
- Removing - refitting: turbocharger (2.2 HDI 100 PUMA, 2.2 HDI 120 PUMA, 2.2 HDI 130 PUMA)
- Removing - refitting: turbocharger air cooler (3.0 HDI 145 FAP EURO 5, 3.0 HDI 175 FAP EURO 5, 3.0 HDI 160, 3.0 HDI 160 FAP, 3.0 HDI 155 FAP EURO 5, 2.2 HDI 150 PUMA C, 2.2 HDI 130 PUMA C, 2.2 HDI 110 PUMA C)
- Removing - refitting: turbocharger (3.0 HDI 160)