Removing/Replacing a 2010 Peugeot Boxer Engine. Possible on a Driveway?

[Wissel]

Hey all. Does anyone know if it's possible to remove the front end of a 2010 Peugeot Boxer to remove the engine? Or does it need to be removed from underneath?

I want to know if I could do this on the driveway it's currently blown up on (with help from someone who knows what they are doing and a hoist etc).

I could then send the engine to a specialist to be re-built, whilst still having the van to live in.

 

[DBK]

There are mobile vehicle hoists but whether they can lift 3.5t I don't know.

 

[Wissel]

There are mobile vehicle hoists but whether they can lift 3.5t I don't know.

It's if the engine can be removed from above (with front removed) I'm after finding out. If it can be, then I should be able to remove it, leaving the gearbox in place, with a normal 2t winch on wheels. I hope.

 

[dave newell]

Yes the whole front end can be removed in around 40minutes then the engine and box can be pulled straight out of the front. It is a big job and you need a substantial engine crane but it is easily acchievable on axle stands.

D.

 

[Wissel]

Yes the whole front end can be removed in around 40minutes then the engine and box can be pulled straight out of the front. It is a big job and you need a substantial engine crane but it is easily acchievable on axle stands.

D.

Thanks Dave - was hoping you'd see this and reply.

Can the gearbox be left in situ, or do the two need to be removed together?

Be great to take just the engine out and send off to be repaired/rebuilt.

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[Silver-Fox]

Thanks Dave - was hoping you'd see this and reply.

Can the gearbox be left in situ, or do the two need to be removed together?

Be great to take just the engine out and send off to be repaired/rebuilt.

No reason to remove the engine from the box.
Lot easier and possible to take out as a unit.

I’d change the clutch as well ?

 

[Wissel]

No reason to remove the engine from the box.
Lot easier and possible to take out as a unit.

I’d change the clutch as well ?

That's one of the reasons I'm thinking of doing (most of it) myself. I can swap others parts out that might look a bit worse for wear and hopefully save down the line. Clutch makes a lot of sense.

Got to do a lot more research yet as I know nothing (well not much) about van engines. I know a little about bike engines though, and have done some things on this van before. Plus my step Dad was a mechanic and I have a few mates that are - not near here but if I was in a pinch they'd help out. Tool wise I'm fairly well set, but I'd need an engine hoist, impact sockets and a few specialist tools (like for the clutch). Not a great deal of money tbh - all probably no more than the cost of having my van towed to a garage. I have most things, plus built a workshop at my Dad's a few months ago which will be useful.

First stage - Haynes manual

Not available for my van, but the Peugeot has the Ford engine so I've ordered the Transit manual to at least give me some fairly relevant knowledge. I would imagine the order of tasks in taking the engine out isn't much different, for instance. Then there's YouTube and asking advice. Plus I have the Peugeot garage software.

It's about time I learn't to do all this anyway. Wish me luck

 

[fifthwheel]

That's one of the reasons I'm thinking of doing (most of it) myself. I can swap others parts out that might look a bit worse for wear and hopefully save down the line. Clutch makes a lot of sense.

Got to do a lot more research yet as I know nothing (well not much) about van engines. I know a little about bike engines though, and have done some things on this van before. Plus my step Dad was a mechanic and I have a few mates that are - not near here but if I was in a pinch they'd help out. Tool wise I'm fairly well set, but I'd need an engine hoist, impact sockets and a few specialist tools (like for the clutch). Not a great deal of money tbh - all probably no more than the cost of having my van towed to a garage. I have most things, plus built a workshop at my Dad's a few months ago which will be useful.

First stage - Haynes manual

Not available for my van, but the Peugeot has the Ford engine so I've ordered the Transit manual to at least give me some fairly relevant knowledge. I would imagine the order of tasks in taking the engine out isn't much different, for instance. Then there's YouTube and asking advice. Plus I have the Peugeot garage software.

It's about time I learn't to do all this anyway. Wish me luck

Edited as my 2p worth was not needed after re reading your post again. DOH
Take plenty of pics and write notes for refitting. I did when I took out a Peugeot Expert engine a few months ago, it was well worth it as it was out for months and I had forgotten where what went where. I also had boxes for different fittings. A box for panel fittings a box for suspension bits and another for engine bits etc etc. Dot be tempted to throw all your bits into one container you will forget where they all go. john.

 

[mitzimad]

doing an engine swop doesn't really require a manual unless your taking bits of the engine but as youll have two engines just take lots off photos for reference almost all the electrical plugs will only fit in the relevant socket,most pipework is push fit i find that you tube is a great source of info as to how various plugs are released usually easiest to take the whole unit out and split it on the floor
ac can be a problem but you can often leave the compressor in the van after removing it from the block same with power steering pumps i've not done a relay so don't take that as gospel it depends where pipework is run
drive shafts will have to be removed so once the van is on stands it will be imobile

 

[dave newell]

Much easier to remove the complete power plant assembly and split them when out. Removal order of the front end is roughly:
Front grille.
Lower grille.
Slam panel.
Quarter bumpers.
Drain coolant.
If you have aircon you would ideally need to have it evacuated so you can remove the condenser, otherwise you need to swing it out of the way and secure and protect it. If no aircon then you can ignore this bit.
Remove radiator and intercooler.
You should now be able to see the power plant.
Remove air filter assembly.
Drain engine oil.
Drain gearbox oil.
Disconnect electrics. (Obviously battery first).
Disconnect fuel lines.
Disconnect exhaust.
Disconnect hubs from struts.
Remove offside shaft intermediate support.
Disconnect drive shafts from gearbox.
Disconnect gearchange linkage.
Disconnect all coolant and heater hoses from engine.
Connect engine hoist securely, I prefer to use a chain of welded link construction with shackles.
Unbolt engine and gearbox mounts.
Remove power plant.

D.

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[Wissel]

dave newell lvs

I owe you a beer. Thank you so much

 

[Bartyfixedit]

Don't forget to replace the clutch slave cylinder while you're at it

 

[TheBig1]

before you spend money, what killed the engine originally? was it the overfuelling issue