How to replace the clutch on a Peugeot 208 1.2 VTi PureTech

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  • OVERALL DIFFICULTY INDEX: 3/10
  • IF YOU HAVE NO TOOLS YOU SPEND $25 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 1 HOUR TO CARRY OUT THIS JOB
  • RISK OF IRRITATION FROM DUST INHALATION
BEFORE YOU START
  • Make sure to wear gloves at all time when working on an open engine.
  • Work in a well ventilated area and wear masks when cleaning mechanical parts
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.

Context of this clutch replacement pictorial

The below clutch replacement was performed on a dismantled power unit as part of a complete engine rebuild intervention.
In order to access the clutch on a vehicle, you need first to remove the driveshafts and separate the gearbox from the engine.
Click on the below button to see how to split a manual gearbox from a transverse engine on any FWD vehicle, although this intervention occurred on a Peugeot 208 1.2 VTi PureTech. 
See also our specific pictorial for clutch removal.

Cleaning and refitting the flywheel on the Peugeot 1.2VTi PureTech

Use a metallic brush to clean well the flywheel disc. 
The clutch kit does not contain a new flywheel, it only includes a clutch disc, a clutch plate and a clutch bearing.
For this reason, you need to clean well the flywheel surface from any dust or grease.
Use a degreaser like white spirit after the brush in order to make sure no grease or oil is left on the flywheel.
Finish the job by using a grit 400 sandpaper to on the flywheel clutch surface.
Refit the flywheel to the crankshaft wheel by hand first.
Fix well the engine to the bench to be able to tighten the flywheel bolts.
In the case of the Peugeot 208 1.2 (EB2 engine), the flywheel bolts are to be locked with a thread-lock compound and tightened as follows:
  1. All bolts are tightened to contact first.
  2. Then to 3 mKg and in opposite sequence.
  3. Then to 90 degrees in opposite sequence

Use a permanent marker to mark well the bolts which tightening has been completed not to forget them.​​

Refitting a new clutch disc and plate kit on the Peugeot 208 1.2

Make sure to wear new gloves when handling the new clutch disc and plate since you don't want to take the risk of contaminating these with any oil or grease.
Hold the disc with your hand in a manner it is centered to the flywheel and insert the clutch centering tool.
You can try managing without a centering tool but it is much easier with the tool for later re-assembling the gearbox to the engine.
Refit the clutch plate bolts and tighten them first by hand until contact.
Make sure the clutch spring plates are well centered around the centering tool, then tighten the clutch bolts in opposite sequence to 2 mKg and make sure again the clutch remains well centered or else repeat the procedure.

See also...

Buy your clutch alignment tool here: