2004 Peugeot Boxer 2.2 HDi Service & Repair Manual

VERY IMPORTANT As the booklet is constantly r e-edited, this one only covers vehicles for this particular model year . It is ther efor e necessary to or der a new booklet each year and RET AIN THE OLD ONES. CORRESPONDENCE TABLE FOR PETROL ENGINES TU XU EW 1 3 5 10 Engine families JP JP4 J2U J2U/K J4 1.1i 1.4i 1.6i 16V 2.0i 2.0i 16V Engine families HFX KFW NFU RFL R6G RFN Berlingo X X X Dispatch X Relay X X CORRESPONDENCE TABLE FOR DIESEL ENGINES DV DW SOFIM 6 8 10 12 ATED ATED B TD BTED CTED UTD ATED4 UTED TD BTED+ 1.6 16V 1.9D 2.0HDi 2.0 8S 2.0 16V 2.2 8S 2.8 TD 2.8HDi HDi HDi HDi HDi Engine families 9HZ WJY RHY RHX RHZ RHV RHW 4HY 8140.43 8140.43S C15 X BERLINGO X X X DISPATCH X X X X RELAY X X X X Engine families

UTILITY VEHICLES C15-BERLINGO DISPATCH RELAY 2005 UTILITY VEHICLES CAR 000 021 2005 AC/DTAV/PRME/MMCB/MMEC Méthodes Mécaniques  «The intellectual property rights relating to the technical information contained in this document belong exclusively to the manufacturer. Reproduction, translation or distribution in whole or in part without prior written authorisation from the manufacturer is forbidden». "The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer». «The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITROËN network periodically for further information and to obtain any possible updates".

PRESENTATION THIS HANDBOOK summarises the specifications, adjustments, checks and special features of CITROEN utility vehicles, not including PRIVATE vehicles for which there exist separate handbooks. The handbook is divided into groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - AIR CONDITIONING. In each section, the vehicles are dealt with in the following order: C15 – BERLINGO – DISPATCH - RELAY and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.

IMPORTANT If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : – INSUFFICIENT INFORMATION – SUPERFLUOUS INFORMATION – NEED FOR MORE DETAILS Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

GENERAL C15 1 - 2 Berlingo 3 - 4 Dispatch 5 - 6 Relay 7 - 10 C15 12 Berlingo 13 Dispatch 14 Relay 15 Lubricants 16 - 38 ENGINE Specifications 39 - 40 Tightening torques : engines all types 41 - 75 Cylinder head tightening : all types 76 - 79 Auxiliary drive belt 80 - 81 Checking and setting the valve timing 106 - 107 Checking the oil pressure 172 - 173 Valve clearances 174 Checking the air supply circuit : Berlingo (DV6ATED4) 188 Checking the air supply circuit : Dispatch (DW10TD) 189 Checking the air supply circuit : Relay (DW10UTD) 190 Checking the air supply circuit : Relay (DW12UTED) 191 Checking the air supply circuit : Relay (SOFIM 2.8 HDi) 192 Checking the exhaust gas recycling circuit : Berlingo, Dispatch, Relay 193 Checking the exhaust gas recycling circuit : Relay 194 IGNITION Sparking plugs 195 CLUTCH-GEARBOX-TRANSMISSION Speedometer 196 C15 197 Berlingo 198 CONTENTS Vehicle identification Capacities INJECTION Checking the low pressure fuel supply circuit : C15 (DV6ATED4) 175 Checking the low pressure fuel supply circuit : Berlingo Dispatch (DW10TD) 176 - 177 Checking the low pressure fuel supply circuit : Relay (DW10UTD) 178 - 179 Checking the low pressure fuel supply circuit : Relay (DW12UTED/SOFIM) 180 - 181 Checking the turbo pressure : Berlingo (DW10TD) 182 Checking the turbo pressure : Dispatch (DW10ATED) 183 Checking the turbo pressure : Relay (DW10UTD) 184 Checking the turbo pressure : Relay (DW12UTED) 185 Checking the turbo pressure : Relay (SOFIM 2.8TD) 186 Checking the turbo pressure : Relay (SOFIM 2.8 HDi) 187 Clutch specifications

CLUTCH-GEARBOX-TRANSMISSION Dispatch 199 Relay 200 Specifications : Manual / automatic gearbox : all types 201 - 203 Tightening torques : Manual gearboxes 204 - 217 Manual gearbox controls: all types 218 - 227 Recommendations/precautions : AL4 automatic gearbox 228 - 231 Tightening torques : AL4 gearbox 232 - 234 AL4 automatic gearbox controls 235 - 237 Recommendations/precautions : 4 HP 20 automatic gearbox 238 Tightening torques : 4 HP 20 gearbox 239 - 240 Shift lock : 4 HP 20 gearbox 241 - 244 Filling / topping-up : 4 HP 20 gearbox 245 - 246 Driveshafts 247 BRAKES Brake specifications : C15 278 Tightening torques : brakes 279 Adjusting the brake limiter 280 Adjusting parking brakes 281 Bleeding the brakes 282 Brake specifications : Berlingo 283 - 288 Tightening torques : brakes 289 Checking/adjusting the compensator 290 - 291 Adjusting parking brakes 292 Bleeding the brakes 293 Brake specifications : Dispatch 294 - 297 Manual adjustment of the compensator 298 Checking/adjusting the compensator 299 Adjusting parking brakes 300 Brake specifications : Relay 301 - 302 Adjusting parking brakes 303 - 306 Draining, filling and bleeding the braking circuit 307 - 310 AIR CONDITIONING R134.a : quantities 311 CONTENTS AXLES - SUSPENSION – STEERING Axle geometry : C15 248 - 250 Tightening torques : front axle : C15 251 Tightening torques : rear axle : C15 252 Tightening torques : power steering : C15 253 - 254 Axle geometry : Berlingo 255 - 258 Tightening torques : front axle : Berlingo 259 Tightening torques : rear axle : Berlingo 260 Suspension : Berlingo 261 - 262 Tightening torques : power steering : Berlingo 263 - 264 Axle geometry : Dispatch 265 - 266 Tightening torques : front axle : Dispatch 267 - 268 Tightening torques : rear axle : Dispatch 269 Manual steering : Dispatch 270 Tightening torques: power steering: Dispatch 271 Axle geometry : Relay 272 Tightening torques : front axle : Relay 273 - 274 Tightening torques : rear axle : Relay 275 Tightening torques : power steering : Relay 276 - 277 Clutch specifications

AIR CONDITIONING Compressor lubricant 314 - 315 Checking the efficiency of the circuit 316 - 325 Air conditioning circuit : Berlingo 326 - 327 Air conditioning circuit : Dispatch 328 - 330 Air conditioning circuit : Relay 331 - 332 CONTENTS

1 IDENTIFICATION OF VEHICLES E1AP079D (1) RP organisation no. (2) Chassis no. (3) Paint code (4) Manufacturer’s plate (5) 01/02/99  Label - Tyre pressures. - RP organisation no. - Paint code (6) Model year (7) Gearbox identification reference (8) Engine plate GENERAL C15

2 GENERAL Structure Family (1) Version (2) Variant (3) VD Family (1) VD C 15 VV Van 600 Kg Familiale Spain B VD WT/B VV Version (2) VW Van 765 Kg /B Variant (3) VY Deepened cab WT Familiale N1 Engine Depollution WJY 1.9 D DW8B W4 IDENTIFICATION OF VEHICLES Type approval C15

GENERAL 3 IDENTIFICATION OF VEHICLES BERLINGO E1AP0AMD A – Chassis stamp, cold stamp B - Manufacturer’s vehicle plate C - Label RPO No. Paint colour code Tyre pressures D – Gearbox identification reference – factory serial no. E – Engine legislation type – factory serial no.

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2004 Peugeot Boxer 2.2 HDi Service & Repair Manual

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