2008 S Max 2.0 TDCI

Hi, I am the owner of a 2008 2.0 tdci smax, this is the Peugeot engine type. Since I have had it I have had it serviced by a local garage and more recently a very cheap local one. As I am a marine engineer in the navy I decided to self service to save on costs and upon inspection of the sump I found that the plug was rounded off on the internal Allen key port. After many attempts of trying to remove the drain plug I noticed that the sump had hairline cracks appearing on it. I ordered a new sump from GSF and changed the sump. The Haynes manual mentions to remove the air conditioner compressor and push aside without breaching the hose connectors. After looking at this I found this was not necessary. Below is what I did to remove it.

• remove under trays

• suck oil out via dipstick or upper expansion plug (3/8 square socket drive)

• remove air conditioner compressor lower bolt (13mm)

• remove charge pipe (jubilee clips on inter cooler and turbo suction and 8mm bolt on sump and loosen 10mm nut on pipe) pipe will now be removed.

• remove bell housing dust caps and then access 4x Allen bolts and 2x 13mm sump bolts that bolt onto bell housing.

• remove all Allen bolts on sump flange, carefully prise sump off and support whilst doing it. 
• once removed clean mating faces and remove old sealant.

• using sealant supplied with the sump apply a 3mm bead of sealant and then offer to bottom of block and re-bolt finger tight. 
•evenly tighten up all bolts, replace charge pipe, replace air conditioner compressor bolt and leave overnight. 
•refill with new oil, run up engine and check for leaks. If all is well remove charge pipe replace dust caps refit charge pipe and then re assemble under trays. 

This job saved me £200 garage labour and the sump kit was £91.

My car has a slight oil weep from about 2/3 up the engine on the off side so I’m thinking camshaft seal or can cover gasket. Which I will be investigating shortly and I will update on my findings.

 Feel free to comment