​How to refit the power train of a Peugeot 208 1.2 VTi without workshop equipment

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  • OVERALL DIFFICULTY INDEX: 7/10
  • IF YOU HAVE NO TOOLS YOU SPEND $250 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 3 HOURS TO CARRY OUT THIS JOB
  • RISK OF INJURIES FROM FALLING OBJECTS
BEFORE YOU START
  • This tutorial is intended for DIYers who do not own an engine winch and no particular workshop equipment except hydraulic jacks and jack stands.
  • NEVER go beneath the engine during this intervention.
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.

Preparatory works for the refitting of Peugeot 208 engine

Bring the engine and gearbox on any trolley beneath the vehicle.
Make sure the exhaust pipe fits within the arch that is intended for its passage.
Use a crowbar to lift the gearbox little by little while inserting a wood block each time in order to lift it higher and higher,
Repeat the same on the engine side of the powertrain.
​Prepare several wood blocks.

Refitting the powertrain (power train) on a front-wheel drive car

Once the powertrain is lifted enough, insert the hydraulic jacks and continue lifting it up a bit higher making sure to use wood blocks between the jack and the oil sump or gearbox body to avoid any damage to the power train.
Attach the power train to wood planks as shown in the middle picture in a manner to be able to remove the hydraulic jacks with the engine staying high enough for the next step.
A mechanic plastic creeper (trolley) as shown in the right picture from which both wheels and head cushion have been removed will be used in the next steps.
The lower engine link support it removed in order to make the bottom of the EB2 engine as flat as possible.
The mechanic creeper is now inserted under the powertrain with the hydraulic jacks underneath.
You can now lift the engine and gearbox safely until the trolley hits parts of the chassis or the bumper.
Do not remove yet the wood planks and the ropes.
Use a permanent marking pen to mark the areas of the trolley that are hitting on the vehicle chassis.
Lower the power train again and let it hang on the ropes.
Take out the mechanic trolley (creeper) and cut out the parts you had marked with a jig saw.
The result is a customized engine tray that goes underneath the vehicle and can be lifted as high as needed so the engine and gearbox reach their supports.  
Lift again the powertrain and move the hydraulic jacks right or left along with the engine until the part of the engine mount on the gearbox matches the other part on the car chassis.
Fit the engine mount bolts and tighten them to contact.
Do not tighten them yet to torque since you need first to refit all mounts and make sure the powertrain is well centered.
Use jack stands and wood blocks beneath the fabricated engine tray to hold the engine in place until you finish reassembling whatever needs to be refitted on the top of engine and all engine mounts and links are fitted ad secured.

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