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In-vehicle Repair|Oil Pan > < Exhaust Manifold

C-MAX 2003.75 (06.2003-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Cylinder Head C-MAX 2003.75 (06/2003-)
In-vehicle Repair

Special Tool(s)

Lifting Bracket, Engine

303-122 (21-068A)

Gauge, Bolt Angle

303-174 (21-540)

Remover/Installer, Hose Clamp

303-397 (24-003)
General Equipment
Worldwide Diagnostic System (WDS)
Pneumatic vacuum gun
Materials
Name
Specification
Cleaner
WSK-M5B401-A1 
Engine Oil - 5W-30
WSS-M2C912-A1 

Removal

  1. 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 mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:Do not carry out any repairs to the fuel injection system without checking that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C. Failure to follow these instructions may result in personal injury.
    WARNING:
    WARNING:Do not carry out any repairs to the fuel injection system with the engine running. The fuel pressure within the system is approximately 1600 bar. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
    CAUTION:
    CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    Using datalogger in Worldwide Diagnostic System (WDS), check that the fuel pressure has dropped to zero and that the fuel temperature is below 30°C.
  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. Drain the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
  1. Remove the timing belt.
    For additional information, refer to: Timing Belt (303-01E Engine - 1.8L Duratorq-TDCi (Kent) Diesel, In-vehicle Repair).
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Kent) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. Remove the camshaft pulley.

  1. Detach the timing belt rear cover from the cylinder head (engine shown removed for clarity).

  1. Detach the fuel filter retaining bracket from the cylinder head.
    1. Remove the glow plug wire terminal block cable electrical connector retaining bolt.
    1. Remove the glow plug relay to glow plug wire terminal block cable.
    1. Disconnect the fuel heater electrical connector.
    1. Disconnect the oil pressure switch electrical connector.
    1. Remove the fuel filter retaining bracket retaining bolt.

  1. Disconnect the fuel injector electrical connectors.
    • Detach the wiring harness clips from the cylinder head.

  1. Disconnect the fuel temperature sensor electrical connector.

  1. Disconnect the fuel metering valve and fuel pressure regulator electrical connectors.
    1. Fuel metering valve electrical connector.
    1. Fuel pressure regulator electrical connector.

  1. NOTE:
    NOTE:Protect the fuel high-pressure sensor electrical connector with lint free cloth to prevent contamination from the cleaning fluid.
    Disconnect the fuel high-pressure sensor electrical connector.

  1. Disconnect the fuel pump fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Disconnect the heater core to exhaust gas recirculation (EGR) cooler coolant hose from the EGR cooler.

  1. Detach the wiring harness from the intake manifold.

  1. Disconnect the EGR valve electrical connector and detach the wiring harness electrical connector from the wiring harness support bracket.

  1. Remove the oil baffle.

  1. Install the camshaft bearing cap retaining nuts.

  1. NOTE:
    NOTE:Make a note of the position of the turbocharger to exhaust manifold retaining clamp.
    Remove the turbocharger to exhaust manifold retaining clamp.
    • Discard the turbocharger to exhaust manifold retaining clamp.

  1. Detach the oil level indicator tube from the cylinder block and secure it to one side.

  1. Detach the vacuum pipe from the brake booster vacuum pump.

  1. Using the special tool, detach the upper coolant hose from the thermostat housing.

  1. Detach the thermostat housing from the cylinder block.
    • Discard the thermostat housing gasket.

  1. Remove the fuel pump support bracket.
  1. Protect the generator with lint-free material to prevent contamination from the cleaning fluid.
  1. Clean the area around the fuel injection supply manifold, high pressure fuel supply lines and surrounding areas.
    For additional information, refer to: Fuel Injection Component Cleaning (303-04D Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures).
  1. Detach the unions. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, fuel pump and the fuel rail prior to removing the fuel rail high-pressure fuel supply line.

  1. CAUTION:
    CAUTION:Make sure that the fuel rail high-pressure fuel supply line remains in contact with both the fuel pump and fuel rail until all unions have been detached and cleaned. Failure to follow this instruction may result in foreign material ingress to the fuel injection system
    Remove the fuel rail high-pressure fuel supply line. Using the pneumatic vacuum gun, vacuum foreign material from the fuel pump and the fuel rail open threaded ports.
    • Discard the fuel rail high-pressure fuel supply line.
  1. Install clean blanking caps to the open threaded ports on the fuel pump and fuel rail.
  1. Detach the unions. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector high-pressure fuel supply line, the fuel injector and the fuel rail prior to removing the fuel injector high-pressure fuel supply lines.

  1. CAUTION:
    CAUTION:Make sure that the fuel injector high-pressure fuel supply line remains in contact with both the fuel injector and the fuel rail until both unions have been detached and cleaned. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    Remove the fuel injector high-pressure fuel supply lines in the sequence shown. Using the pneumatic vacuum gun, vacuum foreign material from the fuel injector and the fuel rail open threaded ports.
    • Discard the fuel injector high-pressure fuel supply lines.
  1. Install clean blanking caps to the open threaded ports on the fuel injectors and fuel rail.

  1. Detach the brake booster vacuum pump from the cylinder head.
    • Discard the brake booster vacuum pump O-ring seal.

  1. Remove the fuel supply manifold bracket lower retaining bolt.

  1. Remove the fuel supply manifold bracket and the fuel supply manifold.

  1. CAUTION:
    CAUTION:Remove the cylinder head retaining bolts in the sequence shown.
    Remove the cylinder head retaining bolts.
    • Discard the cylinder head retaining bolts.

  1. NOTE:
    NOTE:Do not discard the cylinder head gasket at this stage.
    Using the special tool, remove the cylinder head.

Installation

All vehicles
  1. 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 mixtures are always present and may ignite. Failure to follow these instructions may result in personal injury.
    CAUTION:
    CAUTION:Diesel fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always fit blanking plugs to any open orifices or lines.
    CAUTION:
    CAUTION:Always carry out the cleaning process before carrying out any repairs to the fuel injection system components. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    Clean the mating faces of the cylinder head and cylinder block with cleaner.
  1. Check the cylinder head for distortion.
    For additional information, refer to: Cylinder Head Distortion (303-00 Engine System - General Information, General Procedures).

  1. CAUTION:
    CAUTION:The thickness of the new cylinder head gasket must be the same as that of the old one (hole/tooth marked).
    NOTE:
    NOTE:"TOP/OBEN" mark.
    Install a new cylinder head gasket.
    • Discard the old cylinder head gasket.

  1. NOTE:
    NOTE:The pistons must not be at TDC. Make sure that the special tool is engaged in the camshaft groove.
    Using the special tool, position the cylinder head on the cylinder block.
    • Remove the special tool.

  1. CAUTION:
    CAUTION:Install new unoiled cylinder head retaining bolts.
    Tighten the cylinder head retaining bolts in the sequence shown in four stages.
    • Stage 1: 20 Nm.
    • Stage 2: 54 Nm.
    • Stage 3: 90 degrees.
    • Stage 4: Short bolts: 70 degrees, long bolts: 90 degrees.

  1. NOTE:
    NOTE:Do not fully tighten the fuel supply manifold retaining bracket upper retaining bolts at this stage.
    Install the fuel supply manifold retaining bracket and the fuel supply manifold.

  1. NOTE:
    NOTE:Do not fully tighten the fuel supply manifold retaining bracket lower retaining bolt at this stage.
    Install the fuel supply manifold retaining bracket lower retaining bolt.

  1. CAUTION:
    CAUTION:Remove the blanking caps from the high-pressure fuel supply lines, fuel rail and fuel injectors at the last possible moment. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    CAUTION:
    CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system.
    NOTE:
    NOTE:To aid installation of the high-pressure fuel supply line, the unions at the fuel rail end are colored gold.
    NOTE:
    NOTE:Install new fuel injector high-pressure fuel supply lines.
    NOTE:
    NOTE:Do not fully tighten the fuel injector high-pressure fuel supply line unions at this stage.
    Install the fuel injector high-pressure fuel supply lines in the sequence shown.
    • Remove and discard the blanking caps.
    • Install the unions finger tight.

  1. CAUTION:
    CAUTION:Remove the blanking caps from the high-pressure fuel supply lines, the fuel rail and fuel pump at the last possible moment. Failure to follow this instruction may result in foreign material ingress to the fuel injection system.
    CAUTION:
    CAUTION:Do not allow the unions to hit the ends of the high-pressure fuel supply line. Failure to follow this instruction may result in damage to the ends of the line and allow foreign material to enter the fuel injection system.
    NOTE:
    NOTE:Install a new fuel rail high-pressure fuel supply line.
    NOTE:
    NOTE:Do not fully tighten the fuel rail high-pressure fuel supply line unions at this stage.
    Install the fuel rail high-pressure fuel supply line.
    • Remove and discard the blanking caps.
    • Install the unions finger tight.

  1. Tighten the fuel supply manifold retaining bracket upper retaining bolts.

  1. Tighten the fuel supply manifold retaining bracket lower retaining bolt.

  1. Tighten the fuel injector high-pressure fuel supply lines and the fuel rail high-pressure fuel supply line unions in the sequence shown.

  1. Tighten the fuel injector high-pressure fuel supply lines and the fuel rail high-pressure fuel supply line unions in the sequence shown.

  1. Install the fuel pump support bracket.

  1. NOTE:
    NOTE:Install a new brake booster vacuum pump O-ring seal.
    Attach the brake booster vacuum pump to the cylinder head.

  1. NOTE:
    NOTE:Install a new thermostat housing gasket.
    Attach the thermostat housing to the cylinder head.

  1. Using the special tool, attach the upper coolant hose to the thermostat housing.

  1. Attach the vacuum pipe to the brake booster vacuum pump.

  1. Attach the oil level indicator tube to the cylinder block.

  1. NOTE:
    NOTE:The turbocharger to exhaust manifold retaining clamp must be installed in the same position as removed.
    NOTE:
    NOTE:Install a new turbocharger to exhaust manifold retaining clamp.
    Install the turbocharger to exhaust manifold retaining clamp.

  1. Remove the camshaft bearing cap retaining nuts.

  1. Install the oil baffle.

  1. Connect the exhaust gas recirculation (EGR) valve electrical connector and attach the wiring harness electrical connector to the wiring harness support bracket.

  1. Attach the wiring harness to the intake manifold.

  1. Connect the heater core to EGR cooler coolant hose to the EGR cooler.

  1. Connect the fuel pump fuel return line quick release coupling.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Connect the fuel high-pressure sensor electrical connector.

  1. Connect the fuel metering valve and fuel pressure regulator electrical connectors.
    1. Fuel metering valve electrical connector.
    1. Fuel pressure regulator electrical connector.

  1. Connect the fuel temperature sensor electrical connector.

  1. Connect the fuel injector electrical connectors.
    • Attach the wiring harness clips to the cylinder head.

  1. Attach the fuel filter retaining bracket to the cylinder head.
    1. Install the fuel filter retaining bracket retaining bolt 3 turns.
    1. Install the glow plug relay to glow plug wire terminal block cable.
    1. Install the glow plug wire terminal block cable electrical connector retaining bolt.
    1. Connect the fuel heater electrical connector.
    1. Connect the oil pressure switch electrical connector.

  1. Attach the timing belt rear cover to the cylinder head (engine shown removed for clarity).

  1. NOTE:
    NOTE:Do not fully tighten the camshaft pulley retaining bolt at this stage.
    Install the camshaft pulley.
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Kent) Diesel (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Install the timing belt.
    For additional information, refer to: Timing Belt (303-01E Engine - 1.8L Duratorq-TDCi (Kent) Diesel, In-vehicle Repair).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
  1. Install 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. Change the engine oil and the oil filter.
    For additional information, refer to: Specifications (303-01E Engine - 1.8L Duratorq-TDCi (Kent) Diesel, Specifications).
Vehicles with front and rear power windows
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

In-vehicle Repair|Oil Pan > < Exhaust Manifold