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In-vehicle Repair|Disassembly > < Crankshaft Rear Seal

C-MAX 2003.75 (06.2003-)

Engine - 1.6L Duratec-16V Ti-VCT (Sigma) - Engine C-MAX 2003.75 (06/2003-)
Removal

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397

Disconnect Tool, Fuel Line (5/16")

310-040
General Equipment
Retaining straps
Workshop table
Workshop hoist
WARNING:
WARNING:Do not smoke or use any kind of naked flame when working on or near any fuel-related components. Highly flammable vapors are always present and may ignite. Failure to observe this instruction can lead to injury.
All vehicles
  1. Release the fuel system pressure.
    For additional information, refer to: Fuel System Pressure Release (310-00 Fuel System - General Information, General Procedures).
  1. Disconnect the battery.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Drain the cooling system.
    For additional information, refer to: Kühlsystem entleeren, mit Kühlmittel auffüllen und entlüften (303-03 Kühlsystem - 1.6L Duratec-16V (Sigma), General Procedures).

  1. Detach the battery positive lead from the battery terminal.
  1. Remove the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratec-16V (Sigma)/1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4) (414-01 Battery, Mounting and Cables, Removal and Installation).

  1. Remove the central junction box (CJB) cover.

  1. Detach the connector from the CJB.

  1. Detach the ground cable from the wheelhouse.

  1. Detach the heated oxygen sensor (HO2S) and the catalyst monitor sensor connectors.

  1. Disconnect the HO2S and the right-hand catalyst monitor sensor connectors.

  1. Detach the coolant hose from the coolant expansion tank using the special tool.

  1. Detach the coolant expansion tank from the wheelhouse and lay it to one side.

  1. Remove the power steering fluid reservoir from the bracket.

  1. Remove the crash box.

  1. Remove the cross brace.
  1. Remove the left-hand front driveshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Remove the right-hand front driveshaft together with the intermediate shaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
Vehicles without air conditioning
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.6L Duratec-16V (Sigma), Vehicles Without: Air Conditioning (303-05 Accessory Drive, Removal and Installation).

  1. Detach the lower radiator hose from the radiator using the special tool
Vehicles with air conditioning
  1. Remove the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt - 1.6L Duratec-16V (Sigma), Vehicles With: Air Conditioning (303-05 Accessory Drive, Removal and Installation).
  1. Remove the radiator.
    For additional information, refer to: Radiator (303-03A Engine Cooling - 1.6L Duratec-16V (Sigma), Removal and Installation).

  1. NOTE:
    NOTE:Secure the A/C compressor to one side.
    Remove the A/C compressor.
    • Detach the A/C clutch connector.
All vehicles
  1. Detach the ground cable from the cylinder block.

24. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Exhaust heat shield bolts
2
-
Exhaust heat shield
3
-
Exhaust manifold bolt and nuts
4
-
Flexible exhaust pipe nuts
See Removal Detail
5
-
Exhaust pipe rubber insulators
6
-
Catalytic converter bracket bolts
See Removal Detail

 
Item
Part Number
Description
7
-
Fuel evaporation system (EVAP) vacuum hose
8
-
Fuel supply line
See Removal Detail
9
-
Heater core coolant hose
See Removal Detail
10
-
Coolant outlet connection hose
See Removal Detail
11
-
Heater core coolant hose
See Removal Detail
12
-
Coolant distribution connection hose
See Removal Detail
13
-
Brake servo vacuum hose
14
-
Clutch slave cylinder pressure line
See Removal Detail

 
Item
Part Number
Description
15
-
Power steering pump
See Removal Detail
16
-
Engine roll restrictor rubber mountings
See Removal Detail
17
-
Gearshift cable cover
See Removal Detail
18
-
Gearshift cables
See Removal Detail

 
Item
Part Number
Description
19
-
Engine rear mounting retaining bolt
See Removal Detail
20
-
Front engine mounting
See Removal Detail

 
Item
Part Number
Description
21
-
Starter motor
See Removal Detail
22
-
Transmission left-hand retaining bolt
See Removal Detail

Removal Details

Item 4 : Flexible exhaust pipe nuts
  1. CAUTION:
    CAUTION:Excessive bending of the flexible exhaust pipe can cause damage that may lead to component failure.
    Protect flexible exhaust pipes with a suitable support sleeve or reinforcement.

Item 6 : Catalytic converter bracket bolts

NOTE:
NOTE:The catalytic converter remains in the vehicle.

Item 8 : Fuel supply line
  1. Remove the fuel supply line with the special tool.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

Item 9 : Heater core coolant hose
  1. NOTE:
    NOTE:Release the catch by turning counter-clockwise.
    Disconnect the heater core coolant hose.

Item 10 : Coolant outlet connection hose
  1. Remove the coolant hose from the coolant outlet connection using the special tool.

Item 11 : Heater core coolant hose
  1. Detach the coolant hose from the coolant distribution connection using the special tool.

Item 12 : Coolant distribution connection hose
  1. Detach the coolant hose from the coolant distribution connection using the special tool.

Item 14 : Clutch slave cylinder pressure line
  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    CAUTION:
    CAUTION:Close off the clutch slave cylinder pressure line to prevent fluid loss or dirt ingress.
    Detach the clutch slave cylinder pressure line from the clutch slave cylinder.
    • Detach the clutch slave cylinder pressure line from the bracket.
    • Remove the spring clip.

Item 15 : Power steering pump
  1. Detach the power steering pump from the bracket and secure it to one side.

Item 16 : Engine roll restrictor rubber mountings
  1. Remove the engine roll restrictor rubber mountings.

Item 17 : Gearshift cable cover
  1. Remove the gearshift cable cover.

Item 18 : Gearshift cables
  1. Detach the gearshift cables from the transmission.
    1. Detach the gearshift cables from the gear selector levers.
    1. Turn the abutment sleeves clockwise and detach the gearshift cables from the bracket.

Item 19 : Engine rear mounting retaining bolt
  1. NOTE:
    NOTE:Support the engine and transmission with suitable wooden blocks.
    Secure the engine and transmission on the workshop table using suitable retaining straps.

  1. Unclip the transmission breather.

Item 20 : Front engine mounting
  1. Remove the front engine mounting.
  1. Raise the vehicle.
    For additional information, refer to: Anheben mit Hebebühne (100-02 Fahrzeug anheben, Description and Operation).
  1. Remove the engine / transmission assembly.

  1. Attach the engine / transmission assembly to the engine lifting bracket using the special tool.

Item 21 : Starter motor
  1. Detach the battery positive lead and the ignition switch cable from the starter motor.

  1. Remove the starter motor.

Item 22 : Transmission left-hand retaining bolt
  1. Remove the transmission right-hand retaining bolts.

  1. Remove the transmission lower retaining bolts.

  1. Remove the transmission upper retaining bolts.
  1. Separate the transmission from the engine.

In-vehicle Repair|Disassembly > < Crankshaft Rear Seal