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In-vehicle Repair|Disassembly > < Engine - Vehicles With: Manual Transaxle

C-MAX 2003.75 (06.2003-)

Engine - 1.6L Duratorq-TDCi (DV) Diesel - Engine—Vehicles With: Automatic Transaxle C-MAX 2003.75 (06/2003-)
Removal

Special Tool(s)

Lifting Bracket, Engine

303-122

Remover/Installer, Hose Clamp

303-397
General Equipment
Engine hoist
Securing straps
Workshop table
Worldwide Diagnostic System (WDS)
Drill
Drill bit, 2mm
Drill bit, 5mm
WARNING:
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable vapors are always present and may ignite. Failure to follow these instructions may result in personal injury.
  1. Using datalogger in WDS, check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C.

  1. Remove the engine undershield.
  1. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. Remove the cowl panel grille.
    For additional information, refer to: Cowl Panel Grille - Vehicles Built Up To: 03/2007 (501-02 Front End Body Panels, Removal and Installation).
  1. Remove the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Lynx) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the cooling fan motor and shroud.
    For additional information, refer to: Cooling Fan Motor and Shroud (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).

  1. Remove the crashbox (if equipped).
  1. Remove the right-hand halfshaft.
    For additional information, refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).
  1. Remove the left-hand halfshaft.
    For additional information, refer to: Front Halfshaft LH (205-04 Front Drive Halfshafts, Removal and Installation).

  1. Remove the left-hand fender splash shield.

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

 
Item
Part Number
Description
1
-
Coolant expansion tank to heat exchanger coolant hose
See Removal Detail
2
-
Fuel supply line
See Removal Detail
3
-
Battery junction box (BJB) electrical connector
See Removal Detail
4
-
Engine ground cables
5
-
Heater core coolant hose
6
-
Charge air cooler outlet pipe
7
-
Turbocharger outlet pipe
See Removal Detail

 
Item
Part Number
Description
8
-
Exhaust flexible pipe
See Removal Detail
9
-
Engine support insulator
See Removal Detail
10
-
Powertrain control module (PCM) electrical connectors
See Removal Detail
11
-
Air conditioning (A/C) compressor
See Removal Detail

 
Item
Part Number
Description
12
-
Brake booster vacuum hose
13
-
Selector lever cable
See Removal Detail
14
-
Radiator to thermostat housing coolant hose
See Removal Detail
15
-
Thermostat housing degas hose
See Removal Detail
16
-
Transmission fluid cooler feed and return lines
See Removal Detail
17
-
Engine rear mount
See Removal Detail
18
-
Engine front mount
See Removal Detail

 
Item
Part Number
Description
19
-
Starter motor
See Removal Detail
20
-
Torque converter retaining nuts
See Removal Detail
21
-
Transaxle retaining bolts
See Removal Detail

Removal Details

Item 1 : Coolant expansion tank to heat exchanger coolant hose
  1. Using the special tool, remove the coolant expansion tank to heat exchanger coolant hose and detach the coolant expansion tank from the wheelhouse panel and position it to one side.

Item 2 : Fuel supply line

  1. Disconnect the fuel supply lines quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

Item 3 : Battery junction box (BJB) electrical connector

  1. CAUTION:
    CAUTION:Do not bend the BJB electrical connector.
    Unlock and disconnect the BJB electrical connector.

Item 7 : Turbocharger outlet pipe
  1. Disconnect the turbocharger outlet hose and detach the turbocharger outlet pipe from the transaxle.

  1. Disconnect the charge air cooler intake hose and detach the charge air cooler intake pipe from the transaxle and remove downwards.

Item 8 : Exhaust flexible pipe
  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may cause damage resulting in failure.
    Support the exhaust flexible pipe with a suitable support wrap or suitable splint.

  1. Remove the floor panel brace.

  1. CAUTION:
    CAUTION:Using suitable cable ties, support the rear muffler and exhaust tailpipe assembly to prevent damage to the exhaust hanger insulators.
    Remove the exhaust flexible pipe to catalytic converter retaining nuts.
    • Discard the gasket and nuts.

Item 9 : Engine support insulator
  1. Remove the engine support insulator retaining bolts.
    • Discard the engine support insulator to transaxle retaining bolt.

Item 10 : Powertrain control module (PCM) electrical connectors
  1. File a flat across the PCM security bracket welded nut.

  1. Remove the PCM security bracket sheer bolt.
    • Drill a 2 mm pilot hole 3 mm from the outer edge of the security bracket welded nut at an angle of approximately 2 degrees.
    • Drill a 5 mm hole in the security bracket welded nut and remove the security bracket sheer bolt.
  1. Slide the security bracket off the PCM.

  1. Disconnect the PCM electrical connectors in the sequence shown.

Item 11 : Air conditioning (A/C) compressor
  1. Disconnect the A/C compressor electrical connector.

  1. Detach the A/C compressor from the mounting bracket and secure it to one side.

Item 13 : Selector lever cable
  1. Disconnect the transmission range (TR) sensor electrical connector.

  1. CAUTION:
    CAUTION:Do not kink the selector lever cable.
    Detach the selector lever cable from the transaxle.
    1. Detach the selector lever cable from the selector mechanism.
    1. Lift the locking tab, press the locking pins together and detach the selector lever cable from the bracket.

Item 14 : Radiator to thermostat housing coolant hose
  1. Using the special tool, disconnect the radiator to thermostat housing coolant hose.

Item 15 : Thermostat housing degas hose
  1. Disconnect the degas hose from the thermostat housing.

Item 16 : Transmission fluid cooler feed and return lines
  1. CAUTION:
    CAUTION:The automatic transmission contains components and assemblies which are sensitive to electrostatic charging.
    Disconnect the automatic transmission central electrical connector.
    • Turn the automatic transmission central electrical connector counter-clockwise.

  1. Unclip the transmission fluid cooler feed and return lines from the retaining bracket.

  1. WARNING:
    WARNING:When releasing the transmission fluid, take care to prevent scalding. Failure to follow this instruction may result in personal injury.
    CAUTION:
    CAUTION:Plug the transmission fluid cooler feed and return lines to prevent fluid loss or dirt ingress.
    NOTE:
    NOTE:Mark the position of the feed and return lines to aid installation.
    Disconnect the transmission fluid cooler feed and return lines from the automatic transaxle.
    1. Push the transmission fluid cooler feed and return line quick release connector toward the transaxle.
    1. Press together the retaining tabs and disconnect the transmission fluid cooler feed and return lines from the automatic transaxle.
    • Allow the fluid to drain into a suitable container.

Item 17 : Engine rear mount
  1. CAUTION:
    CAUTION:Do not support the engine and transaxle assembly directly on the oil pan.
    NOTE:
    NOTE:Support the engine and transaxle assembly with wooden blocks.
    Using securing straps, secure the engine and transaxle assembly on the workshop table.

  1. Remove the engine rear mount retaining bolt.
    • Discard the bolt.

Item 18 : Engine front mount
  1. Remove the engine front mount.
    • Discard the engine front mount retaining bolts and nuts.

Item 19 : Starter motor
  1. Remove the vacuum reservoir (if equipped) (starter motor cable shown removed for clarity).
    • Disconnect the vacuum lines.
    • Remove the vacuum reservoir retaining bolt.
  1. Remove the starter motor.
    For additional information, refer to: Starter Motor - 1.6L Duratorq-TDCi (DV) Diesel, Vehicles With: Automatic Transaxle (303-06 Starting System, Removal and Installation).

Item 20 : Torque converter retaining nuts
  1. Install the special tool.

  1. Remove the torque converter retaining nuts.
    • Turn the crankshaft to gain access to the four retaining nuts.
    • Discard the torque converter retaining nuts.

Item 21 : Transaxle retaining bolts
  1. Remove the transaxle upper retaining bolts.
    • Detach the ground cable from the transaxle.

  1. Remove the torque converter housing cover.

  1. Remove the transaxle right-hand retaining bolts.
    1. Remove the vacuum reservoir bracket.
    1. Remove the retaining bolt.

  1. Remove the catalytic converter bracket bolt.

  1. Remove the transaxle left-hand retaining bolts.

  1. Remove the transaxle lower retaining bolts.
    • Remove the bolt from the catalytic converter bracket.

  1. WARNING:
    WARNING:Make sure that the torque converter remains in the torque converter housing.
    Remove the transaxle lower retaining bolt.
    • Remove the bolt while pulling the transaxle away from the engine.

In-vehicle Repair|Disassembly > < Engine - Vehicles With: Manual Transaxle