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PEUGEOT BOXER III - Repair of the AdBlue tank PEUGEOT BOXER III, CITROEN JUMPER

mako122 173742 230
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  • #211 21484681
    mako122
    Level 12  
    >>21461118 .

    Colleague mlody300 is right. You need to disconnect this faulty thermistor on the "yellow-yellow" and attach a resistor in its place, because when you get to the complete failure of this thermistor it can make an open circuit (break in the circuit) and the error will return. You cannot have this faulty thermistor in the circuit now.
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  • #212 21519648
    patrikskrizovsky
    Level 2  
    >>21426633 Good afternoon, may I ask where you purchased the 2x2 mm orings mentioned? Thank you.
  • #213 21519656
    Pablo_Pablo
    Level 3  
    I bought all the orings on Allegro from one seller - he has a very large selection. I don't know if I can give you the contact details here. Get back to me on priv and I'll send you the link.
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  • #214 21519657
    patrikskrizovsky
    Level 2  
    @Pablo_Pablo Good day, may I ask where you purchased the 2x2 mm orings mentioned? Thank you.
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  • #215 21519661
    Pablo_Pablo
    Level 3  
    @patrikskrizovsky I sent a pw. with a link.
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  • #216 21528309
    danio123411
    Level 4  
    Good morning to start with really a piece of work for this material is very useful !!! my problem boxer 2017 2.0 bluehdi no errors just counting down the kilometres tank full to full and kilometres falling as if there was no urea light adblue light was on all the time and still is unfortunately I can not say what was before because I bought the van six months ago and always some problems until I changed the ecu bsi and meter and as far as I know in my old ecu was knocked out adblue and I do not know for what reason .... probably just because of what is now.... has anyone had this problem ? And is it possible to work around this without replacing the tank or should I just order a second hand one and change it? And is it necessary to adapt the tank after changing it ? Thank you for any answer Greetings
  • #217 21528773
    mlody300
    Level 12  
    Maybe a filling procedure needs to be carried out,or a tank reset? Or maybe the float in the tank is not working , after replacement no adaptation needed.
  • #218 21529526
    danio123411
    Level 4  
    I just have a problem with this because I get some kind of error when I try to do a computer procedure I bought a Launch x431 a few weeks ago and I don't know what's wrong with this connection , but the tank I bought used from a younger boxer 2022 today is supposed to arrive tomorrow I'll move it and let you know thank you for your answer
  • #219 21542744
    staszek75
    Level 12  
    I'm also having trouble with low adbue pressure, peugeot 508 2.0bluehdi, I'm betting on a thermistor failure on the yellow wires because in the diagbox the urea temperature is 0 all the time and doesn't change, despite the much higher ambient temperature. I'm going to cut the wires and solder a new thermistor and then run it inside the tank through the hole under the motherboard. Will a 3.3kOhm NTC thermistor be correct?
  • #220 21542794
    melas
    Level 31  
    Hi Danio12344 what engine controller do you have. I have a Ducato 21r at my place with ecu MD1CS069 and I can't do the Adblue system reset. I have the Launch original with the current update and lime so far. It has already counted down my kilometres to zero and the car will not start. I managed to do some reset firing after that it fired up but jumped 50 km to the end. Someone reset the adblue in this ecu and with what tool.
    Texa doesn't get it going either.
    I warn the SGW gate I have bypassed the errors normally clears.
  • #221 21542824
    mlody300
    Level 12  
    staszek75
    The thermistor on the yellow wires measures the temperature of the heater.
    Unplug the yellow plug and measure the resistance and you will know if it is faulty, usually when faulty it has a low resistance around 300 ohms.
    If it is working properly the resistance will be around 10k.
    If it is faulty, cut the wires, solder the thermistor and push it as far as you can through the hole and it will be ok.
  • #222 21542836
    danio123411
    Level 4  
    >>21542794 At my place the controller sits Delphi, I don't have the number unfortunately.... I managed to acquire a used, but from a fairly new van, AdBlue tank and everything settled down by itself. I suspect that the original AdBlue tank had a banged up fluid level sensor that was impossible to get to. I recommend buying a second-hand one and replacing it - peace of mind.
  • #223 21551557
    staszek75
    Level 12  
    Helped. Thermistor 10k soldered, has the previous one was 285ohm. Everything has been working for a few days now. Thanks mlody300, mako122 and others for creating and continuing this thread.
  • #224 21559295
    mati4161
    Level 2  
    I did according to the advice, had 300 ohm on the circuit, soldered a new thermistor and since 1500 km there is no trace of the error. A big thank you to the author of the tutorial!!! I bought the gaskets as a spare, I can resell, jbc prv.
  • #225 21571219
    justingiaffreda422
    Level 1  
    Hello, I have a problem with the AdBlue pump on a 2018 Citroën C4 Pixasso. I completely disassembled the pump unit and resealed it. We checked the circuit board and found that D341 has a short circuit. What type of diode is this? And what effect does this have on my system? The error code is P20E8: Urea pressure too low.
    Section of a green printed circuit board with electronic components and a QR code sticker.
  • #226 21601263
    rs57770917
    Level 1  
    The vehicle is a Berlingo, and thanks to this article, I was able to get the pressure working again.
    The issue was with the yellow wire sensor, so I reconnected a 10k thermistor as described in the article.
    However, even though the pressure has been restored, the distance restriction warning still remains.
    Is clearing the OBD code with an app alone not enough?
    Will the warning disappear on its own after driving for a while?

    To restore the pressure, I used the CarScanner app with the Citroen 1.5 BlueHDI ECU MD1CS003 connection profile.
  • #227 21612514
    AB2025
    Level 1  
    >>21426633

    Can anyone tell me please where I can find Shaft seal 2mm O-ring - I believe Original is 2x8 mm
    PEUGEOT BOXER III - Repair of the AdBlue tank PEUGEOT BOXER III, CITROEN JUMPER
  • #228 21620069
    baldy77
    Level 2  
    Well, nearly 5 months later after my first adblue trouble the engine management light comes on and a minute after that UREA lights up. Diagbox says it's the dreaded P20E8 low pressure. Of course I immediately pulled tank out and suspected the failure is my previous fix, 10k resistor on yellow-yellow wires. But no! That fix is still working, showing about 9,8kOhms. But I fixed that anyway with a proper thermistor and dropped it deep in the hole. Also measuring the other heating elements and they are within "specs".

    I ran several test with diagbox, like the denox bleed and flow status etc but they fail with incorrect pressurisation. On onne test I pulled the hose off from the injector and when running the test it sprayed nicely adblue into a clear bottle. Could it be the pressure sensor of the pump that has failed? If that's the problem I guess there is no pressure sensor to be found anywhere to buy?

    [edit]I found this https://frenchcarforum.co.uk/forum/viewtopic.php?t=81429 where they replace the pressure sensor with a replacement[/edit]
  • #229 21712462
    cfm101
    Level 1  
    >>19585986 Hi Maco
    What a great "article"
    I don't know if someone already replied about the pump directions.
    When you stop the engine, you can hear the pump running for a few seconds, it is to empty the tube to the injector for urea, if you are parked in sub zero temp. the hose full of urea, will not freeze.
    I am curious to read further in this forum.. Hopefully there will be some discussion about the €6.3 modules, they look the same, but they can not be used in €6.2 and below.
  • #230 21723913
    goss85
    Level 1  
    Hi Guys!

    I have got the 10k thermistor problem too. I have "repaired" it last year with a 12V pulse successfully, but the problem appeared again this year. Now I was not able to repair with this method reliably, so I was looking for a new tank without the pump module.

    I was lucky to see a brand new one and I got a surprise: there are no yellow wires going to the gray connector.

    Close-up of a wiring harness with three connectors in an AdBlue tank

    What do you know about this upgrade? The tank was manufactured around 2023.

    If I want to buy a new pump module for this tank, the dealer asks for the old one.

    Is it possible that the current tank+pump with disconnected yellow cables would work with a firmware upgrade? Are there other modifications too?

    Will the adblue system reliable enough to use the car for longer trips? In the last 5 years it had problems with the tank (replaced in warranty), NOX sensor, now the tank again. It shows a "1100km" warning, typically before planned longer trips, which is annoying.

    I know there are ways to get rid of adblue errors forever, but I would also prefer to use this system if it was reliable.

    I'm not brave enough to replace the 10k resistor with an other one, as maybe the urea heater board has a PID regulator, which uses this resistor as a reference input.

    If I use new firmware with the old module: is the new version of the tank uses some safety heat switch on board instead of the resistor?

    I have heard about the extended warranty of Stellantis, also read the TBS about that. Is it covering my problem for a Peugeot 5008 2.0blueHdi, 2015 155000km which tank was replaced at about 70000kms in 2020?

    Thank you for your help!
  • #231 21741158
    aberto74
    Level 1  
    Hi @mako122,
    I’m currently dealing with the P20E8 – Low pressure in the AdBlue system error on a PSA group vehicle. I’ve seen that several companies offer repair services for the electronic module with the pump, without replacing the entire AdBlue tank. These repairs usually cost around €400–€500, and they focus only on the electronic part.
    I’m attaching a screenshot from one of the providers offering this kind of repair.


    Table with details on fault code P20E8 00 related to emission fluid pressure

    From what I understand, if the fault is related to the SMD resistor of the 10K thermistor or the 3.3K thermistor, Do you think it might be possible to fix the issue by repairing or replacing the electronic control board???. This board seems to manage the heating elements (wires B, C, D, E, F – green, yellow, blue, white), and if the failure is in one of these heating circuits, it could be resolved by repairing just the electronic part.
    Maybe these companies install a new thermistor or resistor directly on the board to bypass or correct the error caused by a faulty sensor. That would explain how they manage to fix the issue without replacing the whole tank.

    So my question is: if the fault is in one of the heating elements or the thermistors (10K or 3.3K), how do they manage to repair it just by working on the electronic module? Is it a matter of replacing components on the PCB, or do they reprogram something?

    Thanks in advance for your help and insights!
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Topic summary

The discussion focuses on the repair and diagnostics of the AdBlue tank system in PEUGEOT BOXER III and CITROEN JUMPER vehicles, addressing common errors such as P20E8 (low urea pressure) and communication faults with the SCR (Selective Catalytic Reduction) system. Key issues include sensor failures (urea level sensor, temperature sensors on the heating plate and heater circuits), pump and solenoid valve malfunctions, and electronic board damage due to urea corrosion. The tank electronics include a microcontroller (R5F21368WKFP), pump driver circuits with an H-bridge allowing bidirectional pump control, and multiple heating circuits to prevent AdBlue freezing. Repair strategies involve visual inspection for leaks and corrosion, testing and bypassing faulty sensors (e.g., using resistor voltage dividers to simulate full tank level), replacing damaged temperature sensors with 10 kΩ thermistors, and verifying heating circuit resistances. The system requires clearing ECU errors via diagnostic tools (DiagBox) after repairs, as error messages do not always clear automatically. Some users report that the system self-bleeds air over driving distance, negating the need for manual bleeding. The pressure sensor model HM8500J is identified as critical for monitoring AdBlue pressure, with detailed testing performed. The discussion also covers the challenges of tank disassembly and repair, recommending plastic welding over gluing due to ABS plastic construction. Some users mention software or ECU programming to disable or neutralize the AdBlue system as a last resort. The importance of proper electrical connections and CAN bus communication is emphasized, as loss of communication leads to power cutoff to the tank electronics after about 30 seconds. Overall, the thread provides detailed technical insights, component specifications, diagnostic procedures, and practical repair tips for maintaining and restoring AdBlue tank functionality in PSA group diesel vehicles.
Summary generated by the language model.
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