🏷️ Basic Information Identification Make: Peugeot Model: Boxer Year: 2005 Engine Variant: 2.2 HDi (8S) Codes Engine Code: DW12TED4 (common designation for this family, specific boxer code may vary) 👋 Introduction Market Position Vehicle Segment: Light Commercial Vehicle (LCV) / Panel Van / Chassis Cab Competitive Analysis Key Competitors: Ford Transit, Fiat Ducato, Renault Master, Mercedes-Benz Sprinter, Volkswagen Crafter Key Features Vehicle Type Emphasis: Practicality, load capacity, reliability for commercial use Manual Purpose: Empower owners and technicians with detailed repair and maintenance knowledge 📋 Manual Details Coverage Areas Coverage Scope: Complete vehicle service and repair Page Count Page Count: Not specified (digital manual) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, lubrication, cooling, fuel, emissions, starting, charging Engine Electrical: Ignition system, ECU, sensors, actuators, wiring diagrams Transmission Manual: Clutch, gearbox disassembly and assembly, shift mechanism Transmission Automatic: Not applicable for this specific manual, manual transmission focus Drivetrain: Front-wheel drive, driveshafts, differential Suspension: Front and rear suspension components, shock absorbers, springs, bushings Steering: Steering column, steering rack, power steering system Brakes: Hydraulic system, ABS, brake discs, pads, calipers, parking brake Electrical System: Battery, charging system, lighting, fuses, relays, body electronics, dashboard instruments Body And Chassis: Body panels, doors, windows, interior trim, chassis components HVAC: Heating, ventilation, and air conditioning system (diagnosis and repair) Fuel System: Fuel tank, fuel pump, injectors, common rail system Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes Procedures Included Preventative Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspection points Troubleshooting: Diagnostic charts, symptom analysis, common fault identification Repair Procedures: Step-by-step instructions for component removal, installation, and repair Disassembly Assembly: Complete disassembly and reassembly of major vehicle components Diagnostic Tests: Procedures for testing electrical components, sensors, and actuators Engine Rebuild: Detailed engine overhaul procedures, including torque specifications and clearances Brake System Service: Brake bleeding, pad/disc replacement, caliper service Electrical System Diagnosis: Wiring diagram interpretation, component testing, common electrical faults Technical Depth Depth Level: Comprehensive (from basic maintenance to complete overhaul) Diagrams Quality: Top quality diagrams and illustrations Target Audience: DIY enthusiasts and professional mechanics 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: Full Printable Binding Type Binding Type: Digital Download (no physical binding) Paper Type Paper Type: Not applicable (digital) Zoom Capability Zoom Capability: YES (Zoom IN/OUT) Software Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Compatibility: All Versions of Windows & Mac Delivery Method Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Type: 2.2 litre Inline-4 Turbocharged Diesel (HDi) Fuel Type: Diesel Performance Horsepower Range: Typically around 100-120 PS (varies by specific tune) Torque Range: Typically around 230-250 Nm (varies by specific tune) Fuel System Fuel Injection System: Common Rail Direct Injection (HDi) Emission Control: Euro 3/4 compliant (depending on specific market configuration) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission: None specified for this engine/year combination in the product info Features Drivetrain Layout: Front-Wheel Drive (FWD) 📐 Dimensions Exterior Vehicle Type: Panel Van / Chassis Cab (multiple wheelbase and height options available for the Boxer range) Cargo Cargo Volume: Highly variable based on specific body style and wheelbase Weights Gross Vehicle Weight Rating Gvwr: Typically in the 2.8 to 3.5 tonne range (GVWR) 🛡️ Safety Features Ratings Euro Ncap Rating: Varies by configuration and year; later models generally improved, consult specific crash test data for 2005 Active Features ABS: Standard on most models Esp: Optional or standard on higher trims/later models Passive Features Airbags: Driver airbag typically standard, passenger airbag optional/available 💡 Technology Features Infotainment Infotainment System: Basic radio/cassette/CD player, optional upgraded units Driver Assistance Cruise Control: Optional on many models Connectivity Bluetooth: Rarely standard on 2005 models, optional 🔧 Maintenance Service Intervals Oil Change Interval: Typically 12,500 miles or 1 year (refer to manual for exact schedule) Timing Belt Replacement: Diesel engines of this era generally use timing chains or belts requiring replacement; consult manual for interval (often around 70-100k miles) Fluid Specifications Engine Oil Type: API CF or ACEA B3/B4 specifications, SAE 5W-40 or 10W-40 (confirm viscosity with manual) Coolant Type: Glycol-based antifreeze, OAT (Organic Acid Technology) formulation, typically blue or green Brake Fluid Type: DOT 4 Known Issues Common Problems Engine: DPF (Diesel Particulate Filter) regeneration issues if used for short trips, injector problems, turbocharger wear, glow plug failure Common Problems Transmission: Clutch wear, gearbox synchromesh wear Common Problems Suspension: Front suspension wear (bushings, ball joints), rear leaf spring issues Common Problems Electrical: Wiring loom degradation, ECU issues, intermittent electrical faults 📚 Vehicle History Brand Heritage Manufacturer Origin: France Model Evolution Generation: Second Generation (X244) - Launched 2002 Production Manufacturing Plant: Sevel Sud (Italy) and potentially other Fiat/PSA joint venture plants