🏷️ Basic Information Identification Make: Peugeot Model: Boxer Year: 2004 Engine: 2.0 HDi Vehicle Type: Light Commercial Vehicle (LCV) / Van 👋 Introduction Market Position Vehicle Segment: Light Commercial Vehicle (LCV) - Panel Van, Chassis Cab, Combi variants. Competitive Analysis Key Competitors: Ford Transit, Renault Master, Fiat Ducato, Opel/Vauxhall Vivaro, Mercedes-Benz Sprinter (depending on specific configuration and market). Key Features Manual Advantage: Official factory data ensures accuracy and completeness for all repair and maintenance procedures, empowering both professional and DIY users. Ease Of Use: Features easy-to-read text, high-quality diagrams, and step-by-step instructions with detailed exploded views. Content Format: Digital PDF allows for instant access, printing of specific sections, and zooming for clarity. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Page Count Estimated Page Count: Hundreds (Specific number not provided, but implies extensive detail) Manual Type Type: Official Full Factory Service Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, troubleshooting, and component testing. Engine Management: Fuel injection system (HDi), ignition system (if applicable), emissions control systems. Transmission: Repair, maintenance, and troubleshooting for the gearbox. Drivetrain: Front-wheel drive system, axles, and related components. Brakes: Hydraulic system, ABS (if equipped), brake pad/disc replacement, caliper service. Suspension: Front and rear suspension components, shock absorbers, springs, and geometry. Steering: Power steering system, steering rack, column, and linkages. Electrical System: Battery, charging system, starting system, lighting, instrumentation, and auxiliary circuits. HVAC: Heating, ventilation, and air conditioning system service and repair. Bodywork: Exterior panel repair, door mechanisms, latches, hinges, and interior trim. Chassis: Frame and structural components, mounting points. Exhaust System: Diagnosis, repair, and replacement of exhaust components, including catalytic converter and silencers. Cooling System: Radiator, coolant hoses, water pump, thermostat, and fan operation. Fuel Tank And Lines: Inspection and service of the fuel delivery system. Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, fluid checks, lubrication. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides. Repair: Step-by-step instructions for component removal, repair, and installation. Disassembly Assembly: Detailed guides for taking apart and reassembling major vehicle systems and components. Cleaning: Procedures for cleaning specific components during maintenance or repair. Reinstallation: Correct procedures for refitting components to ensure proper function and safety. Technical Specifications: Torque values, clearances, fluid capacities, and other critical data. Wiring Diagrams: Electrical system wiring diagrams for troubleshooting and repairs. Timing Belt Replacement: Detailed procedure for timing belt replacement and tensioner adjustment, critical for diesel engines. Turbocharger Service: Inspection, testing, and replacement of the turbocharger unit. Diagnostic Troubleshooting: Procedures for using diagnostic tools (OBD-II) to read fault codes and diagnose issues. Technical Depth Depth: Comprehensive; covers everything from routine maintenance to complete vehicle rebuilds. Target Audience Primary Audience: Professional Technicians Secondary Audience: Do-it-yourself (DIY) mechanics and owners performing repairs/maintenance. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable (User can print entire manual or specific pages). Binding Type Binding: N/A (Digital Download - Print yourself) Paper Type Paper Type: N/A (Digital Download - Print yourself) Interactivity Searchability: Implied (PDF format allows text searching). Zoom: YES (Allows zooming in/out of diagrams and text). Delivery Method Delivery: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: Likely DW10TD or similar variant (common for 2.0 HDi in this era). Engine Type: 4-cylinder, In-line, Turbocharged Direct Injection Diesel (HDi). Displacement: 1997 cc (2.0 Liters) Bore X Stroke: Typically 85.0 mm x 88.0 mm (for DW10TD, consult manual for exact spec). Compression Ratio: Typically around 18:1 to 19:1 (consult manual for exact spec). Performance Horsepower: Approx. 94 PS (93 bhp / 69 kW) at specified RPM (consult manual for exact spec). Torque: Approx. 215 Nm (159 lb-ft) at specified RPM (consult manual for exact spec). Fuel System Injection Type: Common Rail Direct Injection (HDi). Fuel Type: Diesel Cooling System Cooling Type: Water-cooled, pressurized system with radiator and fan. Emission Control Emissions Standard: Likely Euro 3 compliant for 2004 model year. 🔧 Transmission Standard Type: 5-speed Manual Transmission. Optional Type: Automatic Transmission (less common for this engine variant, consult manual for availability). Features Clutch Type: Hydraulically operated single dry plate clutch. 📐 Dimensions Exterior Body Styles: Panel Van, Crew Cab, Chassis Cab, Passenger variants. Weights Gvwr: Varies by configuration, typically ranging from 2.7 to 3.0 tonnes (consult manual or vehicle plate for specific GVWR). Curb Weight: Varies significantly by body style and equipment, typically starting from around 1700 kg. 🛡️ Safety Features Ratings Crash Test Ratings: Euro NCAP ratings for similar models from this generation vary; consult specific vehicle compliance for official figures. Active Features ABS: Anti-lock Braking System (often optional or standard on higher trims). Ebv: Electronic Brake-force Distribution (often paired with ABS). Passive Features Airbags: Driver airbag (standard), passenger airbag (often...