206 GTi engine change...
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Thread: 206 GTi engine change...

  1. #1
    Fellow Frogger! racing405's Avatar
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    Default 206 GTi engine change...

    OK all you 206 gurus out there, what is the right way to swap engines in a 206 GTi? gearbox and motor out together, or leave the gearbox behind, out the top or out the bottom???

    Best tips appreciated - I'm doing an engine change for a friend who has struggled with it for a while now.

    Hope to get the low down over ready to start work on Saturday.

    Cheers.

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    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  2. #2
    Fellow Frogger!
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    Engine and gearbox together. From underneath.
    Remove steering rack and subframe, put the car up as high as you can get it on stands, drop the engine amd gearbox out.
    206 GTi 180 - Cat Cams, Remapped Group N ECU, AST Camber Tops & Coilovers, -2deg fixed camber hubs by Frogstomp Racing, 24mm Torsion Bars, AP Racing brakes, Yokohama A050, PeugeotSport Baffled Sump, Powerflex Engine Mounts & Bushings, Setrab Oil cooler, Quaife diff, Velo seats.

    Sandown - 1:31.5
    Winton - 1:45.6
    Phillip Island - 1:58.4
    Nürburgring - 10:23.ish (Fiesta ST)

    Previously, 2x 504 Wagon, 505 Wagon, 505 STi, 405.

  3. #3
    Fellow Frogger!
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    A flat trolley is handy to drop it onto, then roll it out the left wheel arch.

    forgot to mentiom, remove hubs. You can leave suspension in, but by that point it's only held by 3 nuts so it might as well come out.
    206 GTi 180 - Cat Cams, Remapped Group N ECU, AST Camber Tops & Coilovers, -2deg fixed camber hubs by Frogstomp Racing, 24mm Torsion Bars, AP Racing brakes, Yokohama A050, PeugeotSport Baffled Sump, Powerflex Engine Mounts & Bushings, Setrab Oil cooler, Quaife diff, Velo seats.

    Sandown - 1:31.5
    Winton - 1:45.6
    Phillip Island - 1:58.4
    Nürburgring - 10:23.ish (Fiesta ST)

    Previously, 2x 504 Wagon, 505 Wagon, 505 STi, 405.

  4. #4
    Fellow Frogger! racing405's Avatar
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    Thanks heaps. Will tell you how I go on Sunday.
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  5. #5
    the famous 18E pug206gti's Avatar
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    Quote Originally Posted by racing405 View Post
    Thanks heaps. Will tell you how I go on Sunday.
    G'day,
    remember, safety first, what could possibly go wrong ?
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    regards,
    Les W.


    206 GTi 180
    the stealth Pug
    Did I do anything last night that suggested I was sane?
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  6. #6
    Fellow Frogger! racing405's Avatar
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    Looked at all the options and came up with:

    Both lower front control arms out - the only way I could see to disconnect the lower ball joint - just couldn't get it to clear the hub otherwise.
    DS headlight out.
    Tucked the PS pump in where the light was.
    Tied the AC pump under the front bar.
    Engine out the top- no problems.

    Just about the hardest part was the stupid exhaust down pipe bolts!!! Knuckle busting, skin donating stupid piece of design.

    How much wear is reasonable on the clutch fork??

    Now to put the new one back in.
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  7. #7
    Fellow Frogger! racing405's Avatar
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    Engine went back in a treat. Connecting the down pipe and exhaust clamp while the engine is still on the hook made it a lot easier.

    Now I have sorted through all the boxes of bits that the car (and two others) was in, I have put everything together with the replacement engine, and the last problems were the lower radiator hose seal and the coolant header tank o-ring. Both destroyed by the oil they were sitting in.

    I can finally see the appeal of these 206s. I've been running this one around for the weekend to make sure everything was sorted. It has some electronic issues with displays and accessories, both it is a rocket. What a hoot to drive.

    Handed back to owner now and I'm pretty sure he would not have got it back together without at least a little help.

    One less broken pug in the yard! Now onto the 406C
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  8. #8
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    Yeah, I've been pleasantly surprised by my 206. It wasn't my first choice, but I really enjoy it and am happy I grabbed it.

    Question; did you remove the bonnet?
    1991 PEUGEOT 405 Mi16

    2003 PEUGEOT 206 GTi

  9. #9
    Fellow Frogger! racing405's Avatar
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    Yes. Takes but a moment and makes access easier.
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  10. #10
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    ...just in case I pop the engine out one day...
    1991 PEUGEOT 405 Mi16

    2003 PEUGEOT 206 GTi

  11. #11
    Fellow Frogger! racing405's Avatar
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    If you leave the K frame in place and take the engine out the top, take the lower control arm out early - it makes suspension removal to get the axles out much easier.
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  12. #12
    1000+ Posts cav91's Avatar
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    That's the reason i drop the k frame on 206s every time. Just so I can get the driveshafts out.

    Sent from my SM-G930F using aussiefrogs mobile app
    406 D8 V6 manual

  13. #13
    Fellow Frogger! racing405's Avatar
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    I was told that was the way to do it, but stupidly I thought I might know better. On 306 and 405 you can get the suspension out far enough to release the axles pretty easily, but on the 206 I could not. Drop the K beam and then out the top or bottom would be achievable. Once the axles were clear you can lower the engine far enough to get the exhaust disconnected then it comes out the top pretty easily.
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  14. #14
    Member Anzactuck's Avatar
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    Quote Originally Posted by racing405 View Post
    Yes. Takes but a moment and makes access easier.
    Out of interest mate, do you think it would be easy to change the clutch without much effort? As in could the gearbox be dropped or slid out of the way with the engine still mounted in?

    I have a 206gti that is basically a spare car, Im thinking of stripping it down to a rally/track car

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    ....Peugeot 206 GTi 180....

  15. #15
    Fellow Frogger! racing405's Avatar
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    Yes, I think it would be easy enough to remove the gearbox without removing the engine. No harder than the 405 - and I've done that once.

    Cheers
    Anzactuck likes this.
    racing 405
    1:59:09 last time at Phillip Island - less than standard Mi16.

  16. #16
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    You can get the gearbox by itself out the top on a 205 pretty easily, bonnet does not have to come off for that as it sits vertically on the second catch position. For a 405 would be best out the bottom with k-frame out, the only slightly hard thing about that is to reconnect the steering column. K-frame out on 405 helps for other jobs as well.
    Don't know about 206 sorry.

  17. #17
    Member Anzactuck's Avatar
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    Its in these moments I remember how nice it is to work on simple rear wheel drive cars.

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    .....................___............
    ..............___/_] [\ ..........
    .............(O)===(O)..........
    ....Peugeot 206 GTi 180....

  18. #18
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    Much easier to change a gearbox in a 205 than a 404, which I did the other day.

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