Peugeot 208 R2

How to Prepare Your Peugeot 208 R2 for Rallying and Competition?

Developed by Peugeot Sport and introduced in 2012, the Peugeot 208 R2 is a rally car designed for the FIA R2 category. Used in promotional series as well as national and international championships, it features specific modifications tailored for competition.

Homologated based on the Peugeot 208 VTi 125 under FIA number A-5743 as of October 1, 2012, it is equipped with a naturally aspirated 1,598 cm³ EP6C engine, a 5-speed sequential shift mechanism, a mechanical limited slip differential, Alcon brakes, and adjustable Öhlins shock absorbers.

To prepare or maintain a Peugeot 208 R2, it is essential to identify its technical specifications and whether it is configured for asphalt or gravel before selecting parts for the engine, transmission, brakes, suspension, rims, and safety equipment.

Peugeot 208 R2 Technical Specifications

• Manufacturer: Peugeot
• Racing Development: Peugeot Sport
• Model: Peugeot 208 R2
• Release: starting in 2012
• FIA Approval: A-5743
• Approval effective: October 1, 2012
• Category: R2
• Layout: front-mounted transverse engine, front-wheel drive
• Engine: EP6C, naturally aspirated 4-cylinder, 16 valves
• Cubic capacity: 1,598 cm³
• Bore x stroke: 77 x 85.8 mm
• Power: 189 ch at 7,800 rpm according to the Peugeot Sport spec sheet
• Torque: 190 Nm at 6,300 rpm
• Valve train: dual overhead camshafts, chain-driven, with variable valve timing
• Fuelinjection: Magneti Marelli indirect injection, motorized single butterfly throttle body
• Transmission: 5-speed sequential shift mechanism + reverse
• Differential: preloaded mechanical limited slip differential with ramps
• Clutch: Hydraulic-controlled cerametallic single-plate clutch
• Front brakes (asphalt): Ø 310 mm ventilated floating brake disks, Alcon 4-piston brake calipers
• Front off-road brakes: Ø 285 mm ventilated floating brake discs, Alcon 4-piston calipers
• Rear brakes: solid discs, 290 mm
• Handbrake: hydraulic
• Suspension: type McPherson
• Shock absorbers: 3-way adjustable Öhlins
• Rims: 6.5 x 16"
• Off-road rims: 6 x 15"
• Fuel tank: 60 liters
• Wheelbase: 2,538 mm
• Minimum weight: 1,030 kg

Note: Initial 2012 Peugeot Sport specifications listed 185 ch. The subsequent technical specifications list 189 ch. Specifications should be verified based on the year and the car’s evolution.

Peugeot Sport Documentation and A-5743 Approval

The Peugeot 208 R2 comes with Peugeot Sport technical documentation, including mounting manuals, maintenance procedures, technical information, and parts catalogs.

• FIA Approval A-5743: specification for the Peugeot 208 VTi 125 and R2 extensions.
• Peugeot Sport Catalog: Specific part numbers for competition components.
• Technical Manuals: mounting and service procedures.
• InfoTech: updates and technical information.
• Operating documentation: setups and rally use.
• FIA R2 Regulations: requirements applicable to the period of use.

Updates approved in 2013 and 2014 pertain specifically to the engine, fuel, transmission, and suspension systems. The Peugeot Sport part number and the car’s technical specifications must therefore be verified before placing any order.

Preparation of the Peugeot 208 R2’s EP6C engine

The naturally aspirated 1,598 cm³ EP6C engine is tuned by Peugeot Sport, featuring specific pistons, connecting rods, and camshafts.

Its timing chain-driven system, variable valve timing, and Magneti Marelli indirect injection require maintenance in accordance with the manufacturer’s recommendations. Service intervals must be determined based on competition mileage and the vehicle’s maintenance history.

• Lower engine: special pistons, piston rings, connecting rods, bearings, and crankshaft.
• Cylinder head: valves, springs, gaskets, and cylinder head components.
• Timing system: camshafts, chain, tensioners, and associated components.
• Oiling: oil pump, filtration system, and oiling system.
• Cooling system: radiator, water pump, thermostat, fan, and hoses.
• Firing: spark plugs and related components.
• Electronics: sensors and actuators as defined by Peugeot Sport.

Intake, injection, and engine management by Magneti Marelli

The Peugeot 208 R2’s intake system uses a single motorized butterfly valve combined with indirect fuel injection and Magneti Marelli electronic control.

The ECU, sensors, injection valves, and wiring harness must comply with the homologated configuration. A part compatible with a street-legal EP6 engine is not necessarily suitable for the 208 R2.

• Intake: manifold, ducts, sleeves, and air filter.
• Injection: injection valves, fuel delivery components, and controllers.
• Engine management: Magneti Marelli engine control module, motorized butterfly throttle body, and sensors.
• Electrics system: wiring harness, connectors, and actuators.

Exhaust System of the Peugeot 208 R2

The exhaust system of the Peugeot 208 R2 is part of its technical competition specifications. The exhaust manifold, exhaust line, and muffler must comply with Peugeot Sport specifications and regulatory requirements.

• Exhaust manifold: specific exhaust manifold.
• Pipes: pipes and replacement parts.
• Muffler: muffler adapted for rally configuration.
• Mounting: gaskets, flanges, clamps, and brackets.
• Protection: heat shields and heat protection.

Sequential shift mechanism, clutch, and limited slip differential

The Peugeot 208 R2 uses a 5-speed sequential shift mechanism with reverse and manual shift control. It is paired with a preloaded mechanical limited slip differential with ramps.

This specialized drivetrain requires monitoring of mileage and scheduled maintenance. Component selection must take into account the homologated final drive ratios and the transmission’s evolution.

• Sequential shift mechanism: pinions, dog clutches, shafts, bearings, and gaskets.
• Final drive ratio: torque values corresponding to approved configurations.
• Differential: ramps, discs, and service components.
• Shift mechanism: handle, linkage, and joints.
• Clutch: single-plate cerametalic clutch and hydraulic control.
• Drivetrain: drive shafts, joints, and cardan shaft bellows.
• Oiling: transmission fluid compliant with technical specifications.

Alcon Braking: asphalt and dirt

The Peugeot 208 R2’s braking system features two specific front configurations.

On asphalt, the ventilated floating discs measure 310 x 30 mm. On dirt, they measure 285 x 26 mm. Both configurations use Alcon 4-piston calipers.

At the rear, the car is equipped with 290 x 8 mm solid brake discs and a hydraulic handbrake.

• Front (asphalt): Ø 310 mm front disks, Alcon calipers, disc bells, and brake pad components.
• Front (dirt): Ø 285 mmfront disks, Alcon calipers, brake pads, and brake pad components.
• Rear: Ø 290 mm rear discs, brake pads, and caliper components.
• Repair: pistons, gaskets, and repair kits.
• Hydraulics: master cylinders, flexible aviation hoses, and fittings.
• Handbrake: handle and hydraulic components.
• Fluid: high-temperature brake fluid.

Öhlins Suspension and Chassis

The Peugeot 208 R2 is equipped withthree-way adjustable Öhlins shock absorbers, allowing for adjustment of low-speed compression, high-speed compression, and rebound. Adjustable hydraulic stops complete the system.

The front axle uses a McPherson-type design with specialized control arms mounted on rod ends. At the rear, the H-beam axle is trussed for competition.

Suspension settings, ride height, and alignment must be adjusted for asphalt or dirt track conditions.

• Shock absorbers: Öhlins front and rear, including adjustment and service components.
• Front axle: control arms, rod ends, pivots, and linkages.
• Rear axle: axle and Peugeot Sport components.
• Anti-roll bar: bar, bushings, and mounting.
• Hubs: wheel bearings, hubs, and mounting hardware.
• Alignment: adjustment components and joints.

Rims and tires: asphalt or dirt

The Peugeot 208 R2 uses two rim mountings specified by Peugeot Sport.

• Pavement: 6.5 x 16" rims with 19/60-16 tires.
• Dirt: 6 x 15" rims with appropriate dirt rally tires.
• Mounting: studs, nuts, and mounting accessories.
• Accessories: valves and components suitable for competition.

The choice of rims must be consistent with the front disk diameter and the clearance of the Alcon calipers. The 16" asphalt mounting should not be confused with the 15" gravel configuration.

Cockpit, seats, and rally equipment

The cockpit of the Peugeot 208 R2 is designed around the driver and co-driver. It includes controls for the sequential shift mechanism, the hydraulic handbrake, and the equipment necessary for rally navigation.

• Driver: seat, brackets, harness, and mounting points.
• Co-driver: seat, harnesses, and footrests.
• Steering: racing steering wheel and hub.
• Controls: sequential gearshift handle and hydraulic handbrake.
• Communication: driver/co-driver intercom.
• Navigation: co-driver lighting and accessories for pace notes.

Roll cage, safety features, and FIA equipment

The 208 R2’s structure is based on a monocoque with a truss reinforced by a welded multi-point roll cage. During repairs or reconstruction, it is essential to adhere to Peugeot Sport’s structural specifications.

• Protection: roll cage and regulation roll cage guards.
• Restraint: homologated seat seats, harnesses, and mountings.
• Fire: fire suppression system and accessories.
• Electrics system: cut-out device and controls.
• Crew: helmets, FHR/hans system when required, racing suits, flame-retardant clothing, gloves, and boots.

FIA standards and equipment expiration dates must always be verified in accordance with applicable regulations.

Bodywork and Underbody Protection

The Peugeot 208 R2 rally car must protect its mechanical components from impacts and flying debris. Peugeot Sport provides, in particular, a specific steel underbody protection.

• Underbody: protection for the engine and armor.
• Bodywork: bumpers, fenders, hood, and specific components.
• Mountings: quick-release fasteners and approved accessories.
• Towing: regulation towing hooks and straps.
• Ground clearance: splash guards and protection against flying debris.

Electrics System, Wiring Harness, and Fuel System

The Magneti Marelli electronics management system plays a key role in the operation of the 208 R2. Sensors, actuators, and wiring harnesses must comply with Peugeot Sport specifications.

The car also uses a 60-liter fuel tank. The fuel system must be inspected regularly, particularly the pumps, filters, hoses, and fittings.

• Electronics: ECU, sensors, actuators, and wiring harness.
• Electrical system: battery, starter motor, relays, and fuses.
• Fuel: tank, pump, filter, hoses, and fittings.
• Safety: cut-out device and regulation-compliant components.

Maintenance and Rally Support: What Parts Should You Have On Hand?

Maintenance of a Peugeot 208 R2 must be organized according to Peugeot Sport’s recommendations and the competition mileage of the main components.

Monitoring the EP6C engine, sequential shift mechanism, differential, driveshafts, Öhlins shock absorbers, and Alcon brakes allows you to anticipate maintenance needs and assistance requirements.

• Engine: engine oil, filters, spark plugs, fluids, and hoses.
• Transmission: transmission fluid, driveshafts, and maintenance components.
• Brakes: brake pads, brake discs, and brake fluid.
• Suspension: rod ends, hubs, bearings, and joints.
• Rims: spare rims, studs, lug nuts, and valves.
• Electrical system: sensors, fuses, relays, and connectors.

How do you choose parts for a Peugeot 208 R2?

A part compatible with a standard Peugeot 208 is not necessarily suitable for a 208 R2. Many components are specific to Peugeot Sport and homologated upgrades.

Before ordering, check the Peugeot Sport part number, the car’s year and variant, as well as the engine, transmission, braking, and suspension configurations.

In particular, you must distinguish between the 310 mm diameter front brakes for asphalt and the 285 mm diameter front brakes for dirt, the 16" and 15" rims, as well as the Öhlins shock absorber part numbers and components of the sequential shift mechanism.

This method allows you to select the correct Peugeot 208 R2 parts for a service, repair, rally preparation, or asphalt/dirt conversion.

Frequently Asked Questions About the Peugeot 208 R2

What is the Peugeot 208 R2’s approval?

The Peugeot 208 VTi 125, which serves as the basis for the 208 R2, bears FIA homologation number A-5743, with approval effective as of October 1, 2012.

What engine does the Peugeot 208 R2 have?

It uses an atmospheric 1,598 cm³ EP6C engine. The Peugeot Sport spec sheet lists 189 ch at 7,800 rpm and 190 Nm at 6,300 rpm.

What type of transmission does the Peugeot 208 R2 use?

The car is equipped with a 5-speed sequential shift mechanism plus reverse, paired with a preloaded mechanical limited slip differential with ramps.

What brakes are fitted to the Peugeot 208 R2?

Up front, it uses 310-mm discs on asphalt or 285-mm discs on dirt, with Alcon 4-piston calipers. The rear discs measure 290 mm.

What rims should be fitted to a Peugeot 208 R2?

Peugeot Sport specifies 6.5 x 16" rims for asphalt and 6 x 15" rims for dirt, depending on the brake mounting.

What shock absorbers does the Peugeot 208 R2 use?

It is equipped withthree-way adjustable Öhlins shock absorbers, featuring adjustable hydraulic stops.

How do you maintain a Peugeot 208 R2?

Maintenance involves tracking competition mileage and following Peugeot Sport’s recommendations for the engine, sequential shift mechanism, differential, brakes, shock absorbers, and suspension components.