Peugeot 205 Manual

Engine/transmission removal - preparation and precautions
Engine removal and overhaul procedures / Engine/transmission removal - preparation and precautions


If you have decided that an engine must be removed for overhaul or major repair work, several preliminary steps should be taken.

Locating a suitable place to work is extremely important. Adequate work space, along with storage space for the car, will be needed. If a workshop or garage is not available, at the very least, a flat, level, clean work surface is required.

If possible, clear some shelving close to the work area and use it to store the engine components and ancillaries as they are removed and dismantled. In this manner the components stand a better chance of staying clean and undamaged during the overhaul.

Laying out components in groups together with their fixing bolts, screws etc will save time and avoid confusion when the engine is refitted.

Clean the engine compartment and engine/transmission before beginning the removal procedure; this will help visibility and help to keep tools clean.

The help of an assistant should be available; there are certain instances when one person cannot safely perform all of the operations required to remove the engine from the vehicle. Safety is of primary importance, considering the potential hazards involved in this kind of operation. A second person should always be in attendance to offer help in an emergency. If this is the first time you have removed an engine, advice and aid from someone more experienced would also be beneficial.

Plan the operation ahead of time. Before starting work, obtain (or arrange for the hire of) all of the tools and equipment you will need.

Access to the following items will allow the task of removing and refitting the engine/transmission to be completed safely and with relative ease: an engine hoist - rated in excess of the combined weight of the engine/transmission, a heavy-duty trolley jack, complete sets of spanners and sockets as described at the rear this manual, wooden blocks, and plenty of rags and cleaning solvent for mopping up spilled oil, coolant and fuel. A selection of different sized plastic storage bins will also prove useful for keeping dismantled components grouped together. If any of the equipment must be hired, make sure that you arrange for it in advance, and perform all of the operations possible without it beforehand; this may save you time and money.

Plan on the vehicle being out of use for quite a while, especially if you intend to carry out an engine overhaul. Read through the whole of this Section and work out a strategy based on your own experience and the tools, time and workspace available to you. Some of the overhaul processes may have to be carried out by a Peugeot dealer or an engineering works - these establishments often have busy schedules, so it would be prudent to consult them before removing or dismantling the engine, to get an idea of the amount of time required to carry out the work.

When removing the engine from the vehicle, be methodical about the disconnection of external components. Labelling cables and hoses as they removed will greatly assist the refitting process.

Always be extremely careful when lifting the engine/transmission assembly from the engine bay. Serious injury can result from careless actions. If help is required, it is better to wait until it is available rather than risk personal injury and/or damage to components by continuing alone. By planning ahead and taking your time, a job of this nature, although major, can be accomplished successfully and without incident.

On all models covered by this manual, the engine and transmission are removed as a complete assembly, upwards and out of the engine bay. The engine and transmission are then separated with the assembly on the bench.


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