🏷️ Basic Information Identification Make: Peugeot Model: Boxer Year: 2005 Engine: 2.2 HDi (8S) Codes Engine Code Prefix: 4HV Chassis Code Family: X244 👋 Introduction Market Position Market Segment: Light commercial vehicle (LCV), panel van, chassis cab, minibus. Competitive Analysis Key Competitors: Ford Transit, Renault Master, Fiat Ducato, Mercedes-Benz Sprinter, Volkswagen Crafter. Key Features Manual Value Proposition: Official, factory-level repair information enabling DIY maintenance and repair, saving costs and downtime. Accessibility: Instant download, portable on PC, printable sections for workshop use. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Page Count Estimate: Comprehensive (Specific page count not provided, but described as complete and detailed) Manual Type Manual Type: Official Full Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, lubrication system, cooling system, exhaust system, ignition system (where applicable to diesel), turbocharger system. Transmission: Manual transmission (gearbox), clutch system, driveshafts, differentials. Chassis: Suspension (front and rear), steering system, braking system (including ABS if equipped). Electrical: Wiring schematics, lighting system, starting and charging system, instrument cluster, body control modules, diagnostic procedures. Bodywork: Body panels, doors, windows, interior trim, seats, body seals, anti-corrosion measures. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, lubrication, brake pad replacement, spark plug/glow plug replacement. Repair: Engine overhaul, cylinder head removal/installation, piston and connecting rod replacement, transmission overhaul, clutch replacement, brake caliper and disc replacement, suspension component replacement, electrical component diagnosis and repair. Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs), electrical system diagnosis, fuel system diagnostics. Technical Depth Depth: Complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications for diagnosis, maintenance, servicing, and repair. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full printable, zoom in/out capability for detailed viewing. Binding Type Binding Type: Digital (No physical binding) Paper Type Paper Type: N/A (Digital format) Software Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Type: Turbocharged Direct Injection Diesel Displacement: 2179 cc (2.2 Liters) Bore X Stroke: 85.0 mm x 96.0 mm Compression Ratio: 18.0:1 (Typical for HDi engines of this era) Performance Horsepower: 100 PS (99 bhp; 74 kW) @ 3500 rpm (Typical for 2.2 HDi 100 variant) Torque: 240 Nm (177 lb-ft) @ 1750 rpm (Typical for 2.2 HDi 100 variant) Fuel System Fuel Injection: Common Rail Direct Injection (CRDi) with Turbocharger Emission Control: Euro 3 compliant (likely for 2005 model) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type Optional: 6-speed Manual Transmission (potentially available on higher output variants or later models within the generation) Features Clutch Type: Hydraulically operated, single dry plate 📐 Dimensions Exterior Length: Varies by body style (e.g., L1H1, L2H2, L3H3 configurations) Width: Varies by body style (excluding mirrors) Height: Varies by body style Cargo Cargo Volume: Varies by wheelbase and roof height configurations Weights Gross Vehicle Weight Rating Gvw: Typically ranges from 2.8 to 3.5 tonnes depending on variant Curb Weight: Varies by configuration 🛡️ Safety Features Ratings Crash Test Ratings: Euro NCAP ratings for this generation are generally not as comprehensive for LCVs as passenger cars, but structural integrity is a focus. Active Features ABS: Anti-lock Braking System (Standard on many variants, optional on some base models) Esp: Electronic Stability Program (Optional or standard on higher trims/later models within the generation) Passive Features Airbags: Driver airbag standard, passenger airbag often optional. Seatbelts: Three-point seatbelts with pretensioners 💡 Technology Features Infotainment Infotainment System: Basic radio/CD player, often with aftermarket upgrade options. Limited integrated technology compared to modern vehicles. Driver Assistance Driver Assistance Features: Basic features like power steering, potentially cruise control on higher trims. Advanced driver-assistance systems (ADAS) are not typically featured. Connectivity Connectivity Options: Limited, primarily focused on vehicle operation rather than external connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 15,000 miles or 12 months, whichever comes first (consult specific manual for exact interval). Air Filter Replacement: Recommended every 15,000 - 30,000 miles or as per manual recommendations. Fuel Filter Replacement: Recommended every 20,000 - 40,000 miles for diesel vehicles (critical for fuel system health). Fluid Specifications Engine Oil Type: Refer to manual, typically ACEA B3/B4 or C3 specification, SAE 5W-40 or 5W-30 (low SAPS for DPF equipped models, though unlikely on 2005). Coolant Type: Antifreeze/coolant, typically OAT (Organic Acid Technology) type, purple or pink colour. Brake Fluid Type: DOT 4 Transmission Fluid Type: Refer to manual, typically API GL-4 or GL-5, SAE 75W-80 or 75W-90. Known Issues Common Problems: DPF clogging (if fitted, though less common on 2005), EGR valve issues, turbocharger problems, injector seal leaks, clutch wear, suspension component wear, electrical gremlins. Maintenance Focus: Regular oil changes with correct specification oil, timely fuel filter replacement, and monitoring of exhaust system...