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In-vehicle Repair|Oil Pan > < Exhaust Manifold

C-MAX 2003.75 (06.2003-)

Engine - 1.6L Duratorq-TDCi (DV) Diesel - Cylinder Head C-MAX 2003.75 (06/2003-)
In-vehicle Repair

Special Tool(s)

Guide Studs, Cylinder Head

303-034

Gauge, Bolt Angle

303-174
Materials
Name
Specification
Silicone Sealant
WSE-M4G323-A4
  1. Remove the exhaust manifold.
    For additional information, refer to: Exhaust Manifold (303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Remove the intake manifold.
    For additional information, refer to: Intake Manifold (303-01D Engine - 1.6L Duratorq-TDCi (DV) Diesel, In-vehicle Repair).
  1. Remove the fuel injectors. For additional information, refer to: (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel)
    Fuel Injectors - VIN Plate Emission Level Code: S (Removal and Installation),
    Fuel Injectors - VIN Plate Emission Level Code: K (Removal and Installation).
  1. Remove the thermostat.
    For additional information, refer to: Thermostat (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
  1. Remove the brake vacuum pump.
    For additional information, refer to: Brake Vacuum Pump - 1.6L Duratorq-TDCi (DV) Diesel (206-07 Power Brake Actuation, Removal and Installation).

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

 
Item
Part Number
Description
1
-
Camshaft housing retaining studs and bolts
See Removal Detail
See Installation Detail
2
-
Camshaft housing
See Installation Detail

 
Item
Part Number
Description
3
-
Cylinder head retaining bolts
See Removal Detail
See Installation Detail
4
-
Cylinder head
5
-
Cylinder head gasket
See Installation Detail
All vehicles
  1. To install, reverse the removal procedure.
Vehicles with front and rear power windows
  1. Initialise the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Removal Details

Item 1 : Camshaft housing retaining studs and bolts

  1. Remove the camshaft housing retaining bolts and studs in the sequence shown.

Item 3 : Cylinder head retaining bolts
  1. CAUTION:
    CAUTION:Do not remove the cylinder head bolts until the cylinder head has cooled to below 30°C.
    Remove the cylinder head retaining bolts in the sequence shown.
    • Discard the bolts.

Installation Details

Item 5 : Cylinder head gasket
  1. CAUTION:
    CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole/tooth marked).
    CAUTION:
    CAUTION:Make sure that the two locating dowels are installed.
    NOTE:
    NOTE:Install a new cylinder head gasket.
    Install the cylinder head gasket.
    1. Locating dowels.
    1. Cylinder head gasket tooth

Item 3 : Cylinder head retaining bolts
  1. NOTE:
    NOTE:Install new cylinder head retaining bolts.
    Install the cylinder head.
    • Tighten the bolts in the sequence shown in three stages.
    • Stage 1: 20 Nm.
    • Stage 2: 40 Nm.
    • Stage 3: 260 degrees.

Item 2 : Camshaft housing
  1. CAUTION:
    CAUTION:Install the camshaft housing within five minutes of applying the sealant.
    Apply a 2.5 mm diameter bead of sealant to the mating face of the cylinder head.

  1. Using the special tool, align the camshaft housing to the cylinder head.

Item 1 : Camshaft housing retaining studs and bolts

  1. Install the camshaft housing retaining bolts and studs.
    • Tighten the bolts and studs in two stages in the sequence shown.
    • Stage 1: 5 Nm.
    • Stage 2: 10 Nm.

In-vehicle Repair|Oil Pan > < Exhaust Manifold