Peugeot Boxer - Service Manual - Manual de Taller - Manuel de Reparation - Manuale di Officina - Reparaturanleitung

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PEUGEOT BOXER 1994 MULTILANGUAGE SERVICE MANUAL

Multilanguage (Francais, Deutsch, English, Italiano, Nederlands, Suomi, Español, Svenska, Dansk, Portugês,polish, Hungarian, Czech, Turkish And Russian) Service Manual, to vehicles Peugeot BOXER.

CONTENTS:

CONTENTS
VEHICLE / GENERAL
DATA - IDENTIFICATION
GENERAL REPAIR TIME SCHEDULE PRESENTATION
MODEL CODE BOXER
MODIFICATION BODY COLOURS
NUMBERING OF THE REPAIR TIME SCHEDULE GROUPS AND SUB-GROUPS
PAINT REPAIR TIME SCHEDULE PRESENTATION
VEHICLE / GENERAL
OPERATING INSTRUCTIONS
CATALOGUE OF THE SERVICES DOCUMENTATION - INFO FLASHES
CATALOGUE OF THE SERVICES DOCUMENTATION - INFO FLASHES
CATALOGUE OF THE SERVICES DOCUMENTATION
MECHANICAL / ENGINE / GENERAL
DATA - IDENTIFICATION
IDENTIFICATION ENGINE - DK/DJ ENGINE
IDENTIFICATION ENGINES - XU ENGINE
IDENTIFICATION- DATA ENGINE - DJ5TED ENGINE - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / GENERAL
CHECKS
CHECK : OIL TIGHTNESS OF THE ENGINES AND GEARBOXES
MECHANICAL / ENGINE / GENERAL
DRAINING - FILLING - BLEEDING
ENGINE CAPACITIES
SUCTION DRAINING ENGINE - DK/DJ ENGINE
MECHANICAL / ENGINE / ENGINE ASSEMBLY
DATA - IDENTIFICATION
IDENTIFICATION - DATA - TIGHTENING TORQUES - 2800 ENGINE
MECHANICAL / ENGINE / ENGINE ASSEMBLY
FAULT(S) READING
TIGHTENING TORQUES ENGINE - DJ5 ENGINE - DJ5T ENGINE
TIGHTENING TORQUES XU ENGINES 8 VALVES - XU10J2 ENGINE
MECHANICAL / ENGINE / ENGINE ASSEMBLY
REMOVAL-FITTING
REMOVAL - REFITTING POWER UNIT - 2800 ENGINE
MECHANICAL / ENGINE / ENGINE ASSEMBLY
OVERHAUL
DISMANTLING ENGINE - DJ5 ENGINE - DJ5T ENGINE
DISMANTLING - DISMANTLING ENGINE - XU ENGINE
MECHANICAL / ENGINE / ENGINE BLOCK
DATA - IDENTIFICATION
DATA - IDENTIFICATION CYLINDER BLOCK - XU ENGINE
IDENTIFICATION - DATA : CYLINDER BLOCK - DJ5 ENGINE - DJ5T ENGINE - DJ5TED ENGINE
MECHANICAL / ENGINE / ENGINE BLOCK
OVERHAUL

REASSEMBLY 8 VALVE ENGINE(S) (TIMING) - XU10J2 ENGINE
REASSEMBLY ENGINE (CYLINDER BLOCK) - XU ENGINE
REASSEMBLY ENGINE - DJ5 ENGINE - DJ5T ENGINE
REASSEMBLY - ASSEMBLY ENGINES - XU ENGINE
REASSEMBLY : ENGINE (CYLINDER BLOCK) - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / CRANKSHAFT
DATA - IDENTIFICATION
DATA CRANKSHAFT - DJ5 ENGINE - DJ5T ENGINE
DATA PISTONS - PISTON RINGS - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / CRANKSHAFT
ADJUSTMENTS CHECK
CHECK CRANKSHAFT PULLEY - XU ENGINE
MECHANICAL / ENGINE / CRANKSHAFT
REMOVAL-FITTING
REMOVAL - REFITTING ANCILLARY DRIVE BELT - 2800 ENGINE
MECHANICAL / ENGINE / CRANKSHAFT
OVERHAUL
ASSEMBLY CONNECTING RODS - PISTONS - XU ENGINE
MECHANICAL / ENGINE / CYLINDER HEAD
DATA - IDENTIFICATION
DATA CYLINDER HEAD - DJ5 ENGINE - DJ5T ENGINE
DATA ROCKER SHAFT LUBRICATION JETS - DJ5 ENGINE - DJ5T ENGINE
DATA SWIRL CHAMBERS - DJ5 ENGINE - DJ5T ENGINE
DATA THRUST WASHER - VALVE SPRING - DJ5 ENGINE - DJ5T ENGINE
DATA VALVE SEATS - DJ5 ENGINE - DJ5T ENGINE
DATA VALVE SPRING - VALVES - DJ5 ENGINE - DJ5T ENGINE
DATA - IDENTIFICATION VALVE GUIDES - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / CYLINDER HEAD
ADJUSTMENTS CHECK
ADJUSTMENTS CHECK VALVE CLEARANCES - 2800 ENGINE
MECHANICAL / ENGINE / CYLINDER HEAD
ADJUSTMENTS
ADJUSTMENT VALVE CLEARANCES (8 VALVE ENGINE(S)) - XU10J2 ENGINE
MECHANICAL / ENGINE / CYLINDER HEAD
REMOVAL-FITTING
REMOVAL - REFITTING CYLINDER HEAD - 2800 ENGINE
REMOVAL - REFITTING CYLINDER HEAD - XUD9TE ENGINE
MECHANICAL / ENGINE / CYLINDER HEAD
OVERHAUL
DISMANTLING - ASSEMBLY 8 VALVE CYLINDER HEAD - XU10J2 ENGINE
OVERHAUL CYLINDER HEAD - DJ5 ENGINE - DJ5T ENGINE - DJ5TED ENGINE
REASSEMBLY ENGINE (CYLINDER HEAD) - DJ5 ENGINE - DJ5T ENGINE - DJ5TED ENGINE
REFITTING CYLINDER HEAD - XU ENGINE
MECHANICAL / ENGINE / TIMING
DATA - IDENTIFICATION
DATA TIMING - 2800 ENGINE
IDENTIFICATION CAMSHAFT - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / TIMING
REMOVAL-FITTING
CHECK VALVE TIMING - 2800 ENGINE
REMOVAL - REFITTING CAMSHAFT SEAL - 2800 ENGINE
REMOVAL - REFITTING CAMSHAFT - 2800 ENGINE
REMOVAL - REFITTING TIMING BELT - 2800 ENGINE
MECHANICAL / ENGINE / TIMING
OVERHAUL
REASSEMBLY 8 VALVE ENGINE(S) (TIMING) - XU10J2 ENGINE
REASSEMBLY ENGINE (TIMING / INJECTION PUMP) - DJ5 ENGINE - DJ5T ENGINE
REASSEMBLY - ASSEMBLY ENGINES - XU ENGINE
MECHANICAL / ENGINE / LUBRICATION
DATA - IDENTIFICATION
CAPACITY OF UNITS
DATA - TIGHTENING TORQUES - LUBRICATION - DJ5TED ENGINE
IDENTIFICATION - ENGINE OIL FILTER CARTRIDGE - XU/XUD ENGINE - DK/DJ ENGINE
REPLACEMENT : ENGINE OIL FILTER CARTRIDGE - XU/XUD ENGINE - DK/DJ ENGINE
MECHANICAL / ENGINE / LUBRICATION
CHECKS
CHECK OIL PRESSURE - 2800 ENGINE
CHECK OIL PRESSURE
MECHANICAL / ENGINE / LUBRICATION
REMOVAL-FITTING
REMOVAL - REFITTING OIL PUMP - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / LUBRICATION
DRAINING - FILLING - BLEEDING
ENGINE CAPACITIES
SUCTION DRAINING ENGINE - DK/DJ ENGINE
MECHANICAL / ENGINE / LUBRICATION
PRECAUTIONS TO BE TAKEN
RECOMMENDATIONS LUBRICANTS
MECHANICAL / ENGINE / COOLING SYSTEM
DATA - IDENTIFICATION
DATA COOLING SYSTEM - 2800 ENGINE
MECHANICAL / ENGINE / COOLING SYSTEM
DRAINING - FILLING - BLEEDING
DRAINING - FILLING - BLEEDING COOLING SYSTEM - 2800 ENGINE
MECHANICAL / ENGINE / SUPPLY
DATA - IDENTIFICATION
DATA HDI (HIGH PRESSURE DIRECT INJECTION) SYSTEM - 2800 ENGINE
IDENTIFICATION - DATA INJECTION PUMP DIESEL BOSCH - DJ5TED ENGINE - DJ5 ENGINE
MECHANICAL / ENGINE / SUPPLY
ADJUSTMENTS CHECK
CHECKS - ADJUSTMENTS {{N11694}} COMMANDES POMPE D'INJECTION - BOSCH EQUIPMENT - DJ5 ENGINE
MECHANICAL / ENGINE / SUPPLY
REMOVAL-FITTING
REMOVAL - REFITTING DIESEL INJECTORS - 2800 ENGINE
REMOVAL - REFITTING HIGH PRESSURE FUEL INJECTION COMMON RAIL - 2800 ENGINE
REMOVAL - REFITTING HIGH PRESSURE FUEL PUMP - 2800 ENGINE
REMOVAL - REFITTING HIGH PRESSURE FUEL SENSOR - 2800 ENGINE
MECHANICAL / ENGINE / SUPPLY
PRECAUTIONS TO BE TAKEN
CONDITIONS FOR WORKING ON THE DIESEL CIRCUIT - 2800 ENGINE
REPAIR PROCEDURE FUEL UNIONS ON THE HIGH PRESSURE DIRECT INJECTION RAIL - 2800 ENGINE
MECHANICAL / ENGINE / EXHAUST
DATA - IDENTIFICATION
DATA EXHAUST SYSTEM - 2800 ENGINE
IDENTIFICATION, DATA, TIGHTENING TORQUE(S) EXHAUST SYSTEM - DJ5TED ENGINE - DJ5 ENGINE - DJ5T ENGINE
MECHANICAL / ENGINE / EXHAUST
MODIFICATIONS
MODIFICATION SUB-FRAME AND FRONT EXHAUST PIPE - PETROL - DIESEL
MECHANICAL / ENGINE / EMISSION CONTROL
DATA - IDENTIFICATION
EMISSION CONTROL EURO 3 - EOBD
MECHANICAL / ENGINE / TURBO-CHARGING
CHECKS
CHECK TURBOCHARGER PRESSURE - 2800 ENGINE
MECHANICAL / ENGINE / TURBO-CHARGING
REMOVAL-FITTING
REMOVAL - REFITTING TURBOCHARGER - 2800 ENGINE
MECHANICAL / TRANSMISSION / GEARBOX
DATA - IDENTIFICATION
CAPACITY OF UNITS
IDENTIFICATION BREATHER ASSEMBLIES - ML5T GEARBOX
IDENTIFICATION FORK : 5TH - ML5T GEARBOX
IDENTIFICATION, DATA, TIGHTENING TORQUE(S) ML5T GEARBOX - ML5T GEARBOX
PRESENTATION TOOLING GEARBOX - ML5T GEARBOX
MECHANICAL / TRANSMISSION / GEARBOX
CHECKS
CHECK : OIL TIGHTNESS OF THE ENGINES AND GEARBOXES
MECHANICAL / TRANSMISSION / GEARBOX
ADJUSTMENTS CHECK
CHECK - ADJUSTMENT INPUT SHAFT BEARINGS - ML5T GEARBOX
MECHANICAL / TRANSMISSION / GEARBOX
REMOVAL-FITTING
REMOVAL - REFITTING POWER UNIT - 2800 ENGINE
MECHANICAL / TRANSMISSION / GEARBOX
OVERHAUL
ASSEMBLY DIFFERENTIAL - ML5T GEARBOX
ASSEMBLY GEARBOX CONTROL PLATE - ML5T GEARBOX
DISMANTLING DIFFERENTIAL BOX - ML5T GEARBOX
DISMANTLING GEARBOX CONTROL PLATE - ML5T GEARBOX
DISMANTLING - ASSEMBLY CLUTCH HOUSING (SECOND ASSEMBLY) - ML5T GEARBOX
DISMANTLING - ASSEMBLY CLUTCH HOUSING (SECOND ASSEMBLY) - ML5T GEARBOX
DISMANTLING - ASSEMBLY CLUTCH HOUSING - ML5T GEARBOX
DISMANTLING - ASSEMBLY INPUT SHAFT - ML5T GEARBOX
DISMANTLING - ASSEMBLY OUTPUT SHAFT - ML5T GEARBOX
DISMANTLING - ASSEMBLY SYNCHRONISER - ML5T GEARBOX
IDENTIFICATION SYNCHRONISERS - ML5T GEARBOX
REFITTING 5TH SPEED GEAR - ML5T GEARBOX
REFITTING GEARBOX CASING - ML5T GEARBOX
REFITTING INPUT AND OUTPUT SHAFTS - GEARBOX CONTROL PLATE - ML5T GEARBOX
REMOVAL 5TH SPEED GEAR - ML5T GEARBOX
REMOVAL DIFFERENTIAL BOX - ML5T GEARBOX
REMOVAL GEARBOX CASING - ML5T GEARBOX
REMOVAL GEARBOX CONTROL AND INPUT AND OUTPUT SHAFTS PLATE - ML5T GEARBOX
REMOVAL - REFITTING FORK GUIDE BALL RACES - ML5T GEARBOX
MECHANICAL / TRANSMISSION / GEARBOX
MODIFICATIONS
MODIFICATION 5TH GEAR COVER - ML5T GEARBOX
MODIFICATION BEARING SUPPORT PLATE - ML5T GEARBOX
MODIFICATION REVERSE SLIDING GEAR SHAFT - ML5T GEARBOX
MECHANICAL / TRANSMISSION / TRANSFER BOX
DATA - IDENTIFICATION
CAPACITY OF UNITS
MECHANICAL / TRANSMISSION / REAR FINAL DRIVE
DATA - IDENTIFICATION
CAPACITY OF UNITS
MECHANICAL / TRANSMISSION / DRIVE SHAFTS
PRINCIPLES OF OPERATION
PRESENTATION DRIVE SHAFTS
MECHANICAL / TRANSMISSION / DRIVE SHAFTS
REPLACEMENT
REPLACEMENT DRIVE SHAFT BEARING ALL TYPES
REPLACEMENT DRIVE SHAFT GAITERS TYPE GLAENZER SPICER (GKN)
REPLACEMENT DRIVE SHAFT GAITERS TYPE PSA
REPLACEMENT GAITER BEARING AT GEARBOX END (MB3 DRIVE SHAFT)
MECHANICAL / TRANSMISSION / DRIVE SHAFTS
REPAIR PROCEDURE
USE LIGAREX CLIPS
MECHANICAL / SUSPENSION / FRONT SHOCK ABSORBER
DATA - IDENTIFICATION
CAPACITY OF UNITS
MECHANICAL / STEERING / GENERAL
DATA - IDENTIFICATION
CAPACITY OF UNITS
DATA - TIGHTENING TORQUES POWER STEERING
MECHANICAL / STEERING / GENERAL
REMOVAL-FITTING
REMOVAL - REFITTING POWER STEERING
MECHANICAL / STEERING / GENERAL
MODIFICATIONS
NEW STEERING RACK ROTATION PREVENTION TOOL
MECHANICAL / STEERING / STEERING RACK
REMOVAL-FITTING
REMOVAL - REFITTING : STEERING ASSEMBLY TRACK RODS - POWER STEERING
MECHANICAL / STEERING / STEERING RACK
MODIFICATIONS
MODIFICATION : STEERING GEAR HOUSING MOUNTING BOLTS - POWER STEERING SERIE FROM 15688640
MECHANICAL / POWER STEERING / GENERAL
DATA - IDENTIFICATION
RECOMMENDATIONS POWER STEERING FLUID (SERVICE)
MECHANICAL / POWER STEERING / GENERAL
REMOVAL-FITTING
REMOVAL - REFITTING POWER STEERING - POWER STEERING
MECHANICAL / BRAKES / PEDAL BRACKET
MODIFICATIONS
MODIFICATION REVERSING LIGHT SWITCH - ML5T GEARBOX - MG5T GEARBOX
MECHANICAL / ABS/TRACTION CONTROL /
DATA - IDENTIFICATION
CAPACITY OF UNITS
MECHANICAL / ABS/TRACTION CONTROL /
DRAINING - FILLING - BLEEDING
CAPACITY BRAKE SYSTEM
BODYWORK / GENERAL
DATA - IDENTIFICATION
RECOMMENDED PRODUCTS MECHANICAL
BODYWORK / FRONT SECTION / WINDSCREEN
DATA - IDENTIFICATION
IDENTIFICATION BONDING KIT GLASS
IDENTIFICATION TOOLS FOR GLASS
BODYWORK / FRONT SECTION / FRONT SUB-FRAME
MODIFICATIONS
MODIFICATION SUB-FRAME AND FRONT EXHAUST PIPE - PETROL - DIESEL
BODYWORK / REAR SECTION / REAR SCREEN
DATA - IDENTIFICATION
IDENTIFICATION BONDING KIT GLASS
IDENTIFICATION TOOLS FOR GLASS
BODYWORK / SIDE STRUCTURE / FRONT DOOR GLASS
DATA - IDENTIFICATION
IDENTIFICATION BONDING KIT GLASS
IDENTIFICATION TOOLS FOR GLASS
EQUIPMENT / FRONT SEATS / SIDE AIRBAG
REPLACEMENT
REPLACEMENT OF THE PRE-TENSIONING COMPONENTS AFTER TRIGGERING OF THE AIRBAG AND THE BELTS - INSTRUCTION FOR REPLACEMENT OF FAULTY PARTS AND REPAIRABILITY OF THE HARNESS
EQUIPMENT / INTERIOR TRIM / SEAT BELTS
REPLACEMENT
REPLACEMENT OF THE PRE-TENSIONING COMPONENTS AFTER TRIGGERING OF THE AIRBAG AND THE BELTS - INSTRUCTION FOR REPLACEMENT OF FAULTY PARTS AND REPAIRABILITY OF THE HARNESS
EQUIPMENT / HEATING/VENTILATION / AIR CONDITIONING COMPRESSOR
REMOVAL-FITTING
REMOVAL - REFITTING ANCILLARY DRIVE BELT - 2800 ENGINE
EQUIPMENT / SUN ROOF /
DATA - IDENTIFICATION
IDENTIFICATION BONDING KIT GLASS
IDENTIFICATION TOOLS FOR GLASS
ELECTRICAL / GENERAL
DATA - IDENTIFICATION
RECOMMENDED PRODUCTS ELECTRICAL
ELECTRICAL / ELECTRICAL / CURRENT GENERATION
REMOVAL-FITTING
REMOVAL - REFITTING ANCILLARY DRIVE BELT - 2800 ENGINE
DEALER FIT / GENERAL
DATA - IDENTIFICATION
RECOMMENDED PRODUCTS ELECTRICAL
SPECIAL TOOLS USED FOR REPAIRS / GENERAL
DATA - IDENTIFICATION
IDENTIFICATION TOOLS FOR GLASS
PRESENTATION TOOLING GEARBOX - ML5T GEARBOX
SPECIAL TOOLS USED FOR REPAIRS / GENERAL
SPECIAL TOOLS USED FOR REPAIRS
NEW SPECIAL TOOLS
SPECIAL TOOLS USED FOR REPAIRS / GENERAL
MODIFICATIONS
NEW STEERING RACK ROTATION PREVENTION TOOL