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C-MAX 2003.75 (06.2003-)

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

Special Tool(s)

Lifting Bracket, Engine

303-122

Aligner/Installer, Crankshaft Front Seal

303-318

Alignment Plate, Camshaft

303-376B

Socket, Cylinder Head Bolt

303-392

Locking Tool, Flywheel

303-393

Installer, Crankshaft Oil Seal

303-395

Remover/Installer, Hose Clamp

303-397

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Mounting Plate for 303-435-06

303-435-14A

Socket, Spark Plug

303-499

Locking Tool, Crankshaft

303-748

Locking Tool

303-1054

Locking Tool, Variable Camshaft Timing Oil Control Unit

303-1097
General Equipment
Five M8 x 20 mm studs
Engine hoist
Materials
Name
Specification
Silicone Sealant
WSE-M4G323-A4 
Gasket Eliminator Sealant
WSK-M2G348-A5 
Engine Oil - 5W-30
WSS-M2C913-B 
All vehicles
  1. Using the special tools, mount the engine.

  1. NOTE:
    NOTE:Install a new crankshaft rear seal carrier.
    NOTE:
    NOTE:A new crankshaft rear seal carrier is supplied preassembled with an installation sleeve that will be removed during installation.
    NOTE:
    NOTE:Do not lubricate the crankshaft rear seal lip.
    Install the crankshaft rear seal carrier.

  1. Install the crankshaft position (CKP) sensor bracket.

  1. NOTE:
    NOTE:Install new flywheel retaining bolts.
    NOTE:
    NOTE:Do not tighten the flywheel retaining bolts at this stage.
    Install the flywheel and using the special tool, lock the flywheel in position.

  1. Tighten the flywheel retaining bolts in the sequence shown in two stages.
    • Stage 1: 30 Nm.
    • Stage 2: 80 degrees.
  1. Install the clutch disc and pressure plate.
    For additional information, refer to: Clutch Disc and Pressure Plate (308-01A Clutch - Vehicles With: 5-Speed Manual Transaxle (iB5), Removal and Installation).

  1. Remove the special tool.

  1. Install the CKP sensor.

  1. NOTE:
    NOTE:Install a new oil pump gasket.
    Install the oil pump.

  1. Using the special tool, install the crankshaft front seal.

  1. NOTE:
    NOTE:Install a new oil pump pickup tube gasket.
    Install the oil pump pickup tube.

  1. CAUTION:
    CAUTION:The crankcase may be damaged if sealant enters the blind holes.
    Install 5 M8 x 20 mm studs into the blind holes as shown.

  1. NOTE:
    NOTE:Install the oil pan within 10 minutes of applying the sealer and tighten the retaining bolts within a further 5 minutes.
    Apply a 3 mm to 4 mm diameter thick bead of sealant to the oil pan flange.

  1. NOTE:
    NOTE:Align the oil pan so that the oil pan is flush with the cylinder block at the flywheel end.
    NOTE:
    NOTE:Do not fully tighten the oil pan retaining bolts at this stage.
    Install the oil pan
    • Remove the studs and install the retaining bolts.

  1. Tighten the oil pan retaining bolts in the sequence shown in two stages.
    • Stage 1: 10 Nm.
    • Stage 2: 20 Nm.

  1. NOTE:
    NOTE:Inspect the oil pan drain plug seal for damage. Install a new drain plug and seal if necessary.
    Install the drain plug.

  1. Install the positive crankcase ventilation (PCV) cover.

  1. CAUTION:
    CAUTION:The knock sensor (KS) cables must not touch the cylinder head or the PCV cover.
    Install the knock sensors (KS).

  1. NOTE:
    NOTE:Install a new thermostat housing gasket.
    Install the thermostat and the thermostat housing.

  1. Install the oil pressure switch.

  1. CAUTION:
    CAUTION:Do not damage the coolant pump impeller.
    NOTE:
    NOTE:Install a new coolant pump gasket.
    Install the coolant pump.
  1. Rotate the crankshaft against its normal direction, until piston No. 1 is approximately 25 mm before top dead center (TDC).

  1. NOTE:
    NOTE:Install a new cylinder head gasket.
    NOTE:
    NOTE:Position the cylinder head onto the two guide sleeves.
    Using the special tool, install the cylinder head.
    • Tighten the cylinder head bolts in the sequence shown in three stages.
    • Stage 1: 15 Nm.
    • Stage 2: 30 Nm.
    • Stage 3: 90 degrees.

  1. Using the special tool, connect the thermostat housing to coolant shut off valve coolant hose to the thermostat housing.

  1. Install the intake manifold lower retaining bolts.

  1. Install the oil level indicator tube.

  1. Connect the PCV hose to the PCV cover.
  1. Coat the camshafts with clean engine oil.

  1. CAUTION:
    CAUTION:Position the camshafts in place so that none of the cams are at full lift.
    NOTE:
    NOTE:The intake and exhaust camshafts are marked with two identification rings. The intake camshaft has a larger space between the identification rings.
    Install the camshafts.

  1. Apply sealant to the points indicated on the variable camshaft timing (VCT) bridge.
  1. Coat the VCT bridge camshaft bearing surface and the camshaft bearing caps with clean engine oil.

  1. CAUTION:
    CAUTION:The VCT bridge inner bolts are M7 x 51 mm, the outer bolts are M7 x 38 mm.
    Install the VCT bridge and camshaft bearing caps.
    • Tighten the camshaft bearing cap and the VCT bridge retaining bolts in the sequence.
    • Tighten the bolts one half turn until all of the camshaft bearing caps are in contact with the cylinder head.
    • Bolt 1-16: 7 Nm.
    • Bolt 17-20: 10 Nm.
    • Bolt 1-16: 45 degrees.
    • Bolt 17+19: 70 degrees.
    • Bolt 18+20: 53 degrees.
  1. NOTE:
    NOTE:Use an open-ended wrench to rotate the camshafts by the hexagon.
    Adjust the valve clearences.
    For additional information, refer to: Valve Clearance Adjustment (303-01B Engine - 1.6L Duratec-16V Ti-VCT (Sigma), General Procedures).

  1. NOTE:
    NOTE:Install new camshaft seals.
    Using the special tool, install the camshaft seals (intake camshaft shown for clarity).

  1. Install the timing belt rear cover.

  1. Rotate the camshafts and install the special tool.

  1. NOTE:
    NOTE:Do not tighten the VCT element retaining bolts at this stage.
    Install the VCT elements.

  1. NOTE:
    NOTE:Make sure that the timing mark on each VCT element is at the 12 o´clock position.
    Using the special tool, tighten the VCT element retaining bolts.

  1. Remove the special tool.

  1. Remove the special tool.

  1. WARNING:
    WARNING:With the aid of another technician, make sure that the camshafts are held in position.
    WARNING:
    WARNING:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
    Tighten the VCT element retaining bolts.

  1. Install the special tool.

  1. Install the crankshaft pulley.
Vehicles built up to 04/2005
  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the automatic timing belt tensioner.
    Install the automatic timing belt tensioner.
  1. NOTE:
    NOTE:Install a new timing belt.
    NOTE:
    NOTE:Install the timing belt, beginning with the crankshaft timing belt pulley working counterclockwise.
    Install the timing belt.

  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the automatic timing belt tensioner.
    Tension the timing belt.
    • Remove the special tool.
Vehicles built 04/2005 onwards
  1. WARNING:
    WARNING:Do not remove the special tool, until the timing belt is correctly positioned. Failure to follow this instruction may result in personal injury, or may damage the automatic timing belt tensioner.
    Install the timing belt tensioner.
  1. NOTE:
    NOTE:Install a new timing belt.
    NOTE:
    NOTE:Install the timing belt, beginning with the crankshaft timing belt pulley working counterclockwise.
    Install the timing belt.

  1. Tension the timing belt.
    • Remove the special tool.
All vehicles
  1. NOTE:
    NOTE:Only rotate the crankshaft in its normal direction of rotation.
    Remove the blanking plug and install the special tool.
    • Carefully rotate the crankshaft against the special tool.

  1. Measuring the depth of the threaded hole in the crankshaft.
    • Depth of the threaded = 42 mm: Use an M12x29 mm crankshaft pulley center bolt.
    • Depth of the threaded = 52 mm: Use an M12x44,5 mm crankshaft pulley center bolt.

  1. Install the timing belt lower cover.

  1. CAUTION:
    CAUTION:Make sure that the crankshaft is held in position.
    NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Install the crankshaft pulley.
    • Using the special tool, hold the crankshaft in position and tighten the crankshaft pulley retaining bolt in two stages.
    • Stage 1: 45 Nm.
    • Stage 2: 90 degrees.

  1. Remove the special tool.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft approximately two revolutions until the marks on the VCT elements are in a 11 o´clock position.

  1. Install the special tool.
    • Carefully rotate the crankshaft against the special tool.

  1. Install the special tool and check the valve timing.
    • If necessary loosen the VCT elements and correct the valve timing following the previous steps.

  1. WARNING:
    WARNING:With the aid of another technician, make sure that the camshafts are held in position.
    WARNING:
    WARNING:Use an open-ended wrench to hold the camshafts by the hexagon to prevent the camshafts from turning.
    NOTE:
    NOTE:Inspect the blanking plug gasket. Install a new blanking plug if necessary.
    Install the blanking plugs.

  1. Remove the special tool.

  1. Install the blanking plug.

  1. Remove the special tool.

  1. Using the special tool, install the spark plugs.

  1. Install the valve cover.
    • Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Tighten bolt 1 by three to four turns.
    • Stage 2: Tighten bolts 1 through 13 to 3 Nm.
    • Stage 3: Tighten bolts 1 through 13 to 9 Nm.

  1. CAUTION:
    CAUTION:Coat the inside of the spark plug connectors with silicone grease to prevent damage to the spark plug connector gasket.
    Connect the spark plug electrical connectors.
    • Attach the spark plug wires to the valve cover.

  1. Install the timing belt upper cover.

  1. Install the engine front mount bracket.

  1. Install the coolant pump pulley.

  1. Install the generator.

  1. Install the oil cooler.

  1. NOTE:
    NOTE:Install a new oil filter.
    Install the oil filter.
  1. Fill the engine with clean engine oil.
    For additional information, refer to: Specifications (303-01A Engine - 1.6L Duratec-16V (Sigma), Specifications).
  1. Install the engine wiring harness.

  1. Using the special tool, attach the engine to the engine hoist.

  1. Remove the special tools.

Assembly|Installation > < Cylinder Head