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Assembly|Installation > < Cylinder Head

C-MAX 2003.75 (06.2003-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine C-MAX 2003.75 (06/2003-)
Assembly

Special Tool(s)

Universal Flange Holding Wrench

205-072

Lifting Bracket, Engine

303-122

Gauge, Bolt Angle

303-174

Timing Peg, Crankshaft TDC

303-193

Installer, Camshaft Seal

303-199A

Alignment Plate, Camshaft

303-376

Locking Tool, Flywheel

303-393

Remover/Installer, Hose Clamp

303-397

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Aligner, Oil Pump

303-652

Timing Tool, Crankshaft

303-710

Aligner, Clutch Disc

308-204
Materials
Name
Specification
Silicone Sealant
WSE-M4G323-A4 
Gasket Eliminator Sealant
WSK-M2G348-A5 
Engine Oil - 5W-30
WSS-M2C912-A1 

Assembly

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:Do not disassemble or clean inside the fuel injection supply manifold, even with an ultrasonic cleaner. Always install a new fuel injection supply manifold if necessary
CAUTION:
CAUTION:Always carry out the cleaning process before carrying out any repairs to fuel system components to prevent foreign material entering the components.
All vehicles
  1. Coat the crankshaft main bearing journals, bearing shells and thrust half washers with clean engine oil.
  1. Position the crankshaft in the cylinder block.
  1. NOTE:
    NOTE:The grooves in the thrust half washers must face outwards.
    Install the crankshaft thrust half washers into the 3rd crankshaft main bearing with the oil grooves facing outwards.

  1. NOTE:
    NOTE:Install the crankshaft main bearing caps with the arrows pointing towards the front of the engine. Caps are identified 1, 2, 3, 4 and 5 from the front to the rear.
    Tighten the crankshaft main bearing cap retaining bolts in three stages in the sequence shown.
    • Stage 1: 45 Nm.
    • Stage 2: 70 Nm.
    • Stage 3: 60 degrees.
  1. Coat the cylinder bores with clean engine oil.

  1. NOTE:
    NOTE:Install the pistons with the arrows pointing towards the front of the engine.
    NOTE:
    NOTE:The piston ring gaps and oil supply ring elements must be distributed evenly around the circumference of the piston.
    Using a suitable piston ring compressor, install the pistons.

  1. NOTE:
    NOTE:Install new connecting rod bearing cap retaining bolts.
    NOTE:
    NOTE:The connecting rod identification marks must point towards the front of the engine.
    NOTE:
    NOTE:Lubricate the connecting rod journals with clean engine oil after installation.
    Using the special tool, install the connecting rod bearing caps.
    • Tighten the connecting rod bearing caps retaining bolts in four stages.
    • Stage 1: Tighten the bolts finger tight.
    • Stage 2: 27 Nm.
    • Stage 3: 60 degrees.
    • Stage 4: 20 degrees.

  1. NOTE:
    NOTE:Install a new timing chain rear housing gasket.
    Install the timing chain rear housing.
  1. NOTE:
    NOTE:Install a new ladder frame gasket.
    NOTE:
    NOTE:Align the ladder frame flush with the cylinder block.
    Install the ladder frame.
    • Tighten the ladder frame retaining bolts in the sequence shown.

  1. NOTE:
    NOTE:Install a new oil pump pickup tube O-ring seal.
    Install the oil pump pickup tube.

  1. NOTE:
    NOTE:Install new oil pump connecting pipe O-ring seals.
    Install the oil pump connecting pipe.

  1. NOTE:
    NOTE:A new crankshaft rear seal carrier is supplied with an alignment sleeve that must be removed following installation.
    NOTE:
    NOTE:Do not fully tighten the crankshaft rear seal carrier retaining bolts at this stage.
    Install the crankshaft rear seal carrier.

  1. Tighten the crankshaft rear seal carrier retaining bolts.

  1. Remove the crankshaft rear seal carrier alignment sleeve.

  1. Using the special tool, install the crankshaft position (CKP) sensor retaining bracket.
  1. CAUTION:
    CAUTION:Make sure that the sealant does not enter the ladder frame blind holes. Failure to follow this instruction may result in damage to the engine assembly.
    NOTE:
    NOTE:Do not damage the mating faces.
    NOTE:
    NOTE:The mating faces and blind holes must be free of oil and sealant residue.
    Clean the mating faces of the oil pan and ladder frame.
  1. NOTE:
    NOTE:Install the oil pan within 10 minutes of applying the sealant.
    NOTE:
    NOTE:Once the oil pan has contact with the ladder frame it must not be removed.
    Apply a 2,5 mm diameter bead of sealant to the ladder frame (dotted line)and install the oil pan.
    • Tighten oil pan retaining nuts and bolts in the sequence shown.

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

  1. NOTE:
    NOTE:Install new flywheel retaining bolts.
    NOTE:
    NOTE:Do not fully tighten the flywheel retaining bolts at this stage.
    Install the flywheel.

  1. Using the special tool, lock the flywheel in position.

  1. Using the special tools, tighten the flywheel retaining bolts in two stages.
    • Stage 1: 35 Nm.
    • Stage 2: 45 degrees.
  1. Remove the special tools.
  1. Inspect the flywheel.
    For additional information, refer to: Flywheel Inspection (303-00 Engine System - General Information, General Procedures).

  1. Using the special tool, centralize the clutch disc on the pressure plate.

  1. CAUTION:
    CAUTION:Tighten the clutch pressure plate retaining bolts finger tight and then evenly by 2 turns at a time in the sequence shown to the specified torque.
    NOTE:
    NOTE:Install new clutch pressure plate retaining bolts.
    Using the special tool, install the clutch disc and pressure plate.

  1. NOTE:
    NOTE:Install a new crankshaft position (CKP) sensor.
    NOTE:
    NOTE:The CKP sensor must make contact with the flywheel.
    Install the CKP sensor.

  1. Install the fuel pump retaining bracket.
Vehicles without air conditioning
  1. Install the generator support bracket.

  1. Install the generator.

  1. Install the accessory drive belt idler pulley.
Vehicles with air conditioning
  1. Install the generator support bracket.

  1. Install the generator.

  1. Install the generator drive coupling.
All vehicles
  1. Install the coolant distribution pipe.

  1. Using the special tool, connect the upper coolant hose to the coolant distribution pipe.

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

  1. Install the timing chain, sprockets and guides.

  1. Install the fuel pump sprocket.

  1. Install the timing chain tensioner.

  1. NOTE:
    NOTE:Install a new timing chain housing cover gasket.
    Using the special tool, install the timing chain housing cover.
    • Tighten the timing chain housing cover retaining bolts in the sequence shown in three stages.
    • Stage 1: Bolts 1 through 5: 10 Nm.
    • Stage 2: Bolt 6: 23 Nm.
    • Stage 3: Bolts 7 through 19: 10 Nm.

  1. NOTE:
    NOTE:Install a new crankshaft pulley retaining bolt.
    Using the special tool, install the crankshaft pulley.
    • Tighten the crankshaft pulley retaining bolt in two stages.
    • Stage 1: 100 Nm.
    • Stage 2: 180 degrees.

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

  1. Using the special tool, install the coolant pump pulley.

  1. Install the engine front mount bracket.

  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:Install new unoiled cylinder head retaining bolts.
    NOTE:
    NOTE:"TOP (OBEN)" mark.
    Install the cylinder head gasket.
    • Discard the old cylinder head gasket.

  1. CAUTION:
    CAUTION:Install new cylinder head retaining bolts.
    Install the cylinder head retaining bolts.
    • Using the special tool, tighten the cylinder head retaining bolts in four stages in the sequence shown.
    • Stage 1: 20 Nm.
    • Stage 2: 54 Nm.
    • Stage 3: 90 degrees.
    • Stage 4: short bolts: 70 degrees, long bolts: 90 degrees.

  1. Install the oil baffle.

  1. Install the timing belt rear cover.

  1. NOTE:
    NOTE:Install a new fuel pump seal retainer.
    Install the fuel pump seal retainer.
    • Tighten the fuel pump seal retainer retaining bolts in the sequence shown.

  1. NOTE:
    NOTE:The fuel pump pulley is sealed to the fuel pump sprocket and the fuel pump pulley retaining bolts will require thorough cleaning before installation.
    Attach the fuel pump pulley to the fuel pump sprocket.
    • Apply sealant to the fuel pump pulley and to the outer edge of the fuel pump pulley retaining bolt holes.

  1. Install the fuel pump pulley.

  1. NOTE:
    NOTE:Install a new camshaft seal.
    Using the special tool, install the camshaft seal.

  1. NOTE:
    NOTE:Do not fully tighten the camshaft pulley retaining bolt at this stage.
    Install the camshaft pulley retaining bolt.

  1. Install the special tool.

  1. Install the special tool.
    • Remove the cylinder block blanking plug and install the special tool.
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft to top dead center (TDC).
    • Rotate the crankshaft slowly until the crankshaft stops.

  1. CAUTION:
    CAUTION:Make sure that the crankshaft does not rotate during installation of the special tool.
    CAUTION:
    CAUTION:Make sure that the engine is at the TDC position before locking the special tool.
    CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    Using the special tool, lock the crankshaft in position.

  1. NOTE:
    NOTE:Install only latest level timing belts. These are identified by a laser etched Ford logo.
    Check the new timing belt.

  1. Check the timing belt tensioner.
    1. Make sure that the timing belt tensioner pointer rotates clockwise freely.
    1. Arrow denotes counterclockwise rotation of the timing belt tensioner.

  1. NOTE:
    NOTE:Move timing belt tensioner adjustment arm to the 3 o'clock position.
    NOTE:
    NOTE:Do not fully tighten the timing belt tensioner retaining bolt at this stage.
    Install the timing belt tensioner.
  1. CAUTION:
    CAUTION:Never install a used timing belt.
    CAUTION:
    CAUTION:Install the timing belt with the direction arrows in the direction of engine rotation.
    NOTE:
    NOTE:Install a new timing belt.
    Install the timing belt.

  1. NOTE:
    NOTE:The camshaft pulley must be able to turn freely on the camshaft taper.
    Tighten the camshaft pulley bolt finger tight and then loosen by one-half turn.

  1. NOTE:
    NOTE:Using an Allen key, maintain the tension on the timing belt until the timing belt tensioner retaining bolt is tightened.
    Tension the timing belt.
    1. Rotate the timing belt tensioner adjustment arm counterclockwise to tension the timing belt slightly.
    1. The timing belt tensioner pointer must be positioned between the sides of the window.
    1. Tighten the timing belt tensioner retaining bolt.

  1. Using the special tool, tighten the camshaft pulley retaining bolt.

  1. Remove the special tool.

  1. Release the special tool.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    NOTE:
    NOTE:Using paint or typing correction fluid, mark the crankshaft pulley to show top dead center (TDC).
    Rotate the crankshaft 6 revolutions.

  1. Install the special tool.
  1. NOTE:
    NOTE:Only rotate the crankshaft in the normal direction of rotation.
    Rotate the crankshaft to TDC.
    • Rotate the crankshaft slowly until it stops.

  1. CAUTION:
    CAUTION:Make sure that the crankshaft is at the TDC position before locking the special tool.
    CAUTION:
    CAUTION:Make sure that the special tool engages correctly.
    Using the special tool, lock the crankshaft.
  1. Lower the vehicle.

  1. CAUTION:
    CAUTION:If the timing belt tensioner pointer is not visible in the timing belt tensioner window, the timing belt tensioning steps must be repeated.
    Check that the timing belt tensioner pointer is positioned in the window.

  1. CAUTION:
    CAUTION:If the special tool cannot be installed, the timing belt tensioning steps must be repeated.
    Install the special tool.

  1. Remove the special tool.

  1. Remove the special tool.

  1. NOTE:
    NOTE:Install a new valve cover gasket if necessary.
    Install the valve cover.

  1. Install the timing belt cover.

  1. NOTE:
    NOTE:Install new fuel injector bolts.
    Install the fuel injectors.
    • Tighten the bolts in two stages.
    • Stage 1: 5 Nm
    • Stage 2: 90 degrees

  1. Install the fuel injection supply manifold retaining bracket.

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

  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 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. Tighten the fuel injection supply manifold retaining bolts.

  1. Install the fuel pump support bracket.

  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 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 high-pressure fuel sensor electrical connector.

  1. Install the knock sensor (KS).

  1. Install the KS heat shield.

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

  1. Using the special tool, connect the positive crankcase ventilation (PCV) hose to the brake booster vacuum pump.

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

  1. Attach the oil level indicator tube bracket to the thermostat housing.

  1. CAUTION:
    CAUTION:Make sure that the crankcase vent oil separator is located into the locking tang on the fuel filter retaining bracket before installing the crankcase vent oil separator retaining bolt. Failure to follow this instruction may result in damage to the crankcase vent oil separator.
    Attach the PCV housing to the fuel filter retaining bracket.

  1. Install the PCV housing to the fuel filter retaining bracket retaining bolt.

  1. Connect the cylinder head temperature (CHT) sensor electrical connector.
    1. Connect the CHT sensor electrical connector.
    1. Attach the electrical connector to the PCV housing.

  1. Connect the camshaft position (CMP) sensor electrical connector.

  1. Connect the oil pressure switch electrical connector.

  1. Using the special tool, connect the PCV hoses to the valve cover.

  1. Connect the high-pressure fuel injector electrical connectors.
    • Attach the wiring harness clips from the cylinder head.

  1. Using the special tool, connect the PCV hoses to the lower PCV pipe.

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

  1. NOTE:
    NOTE:Install a new oil filter.
    Install the oil filter.

  1. NOTE:
    NOTE:Do not fully tighten the turbocharger support bracket retaining bolts at this stage.
    Install the turbocharger support bracket.

  1. NOTE:
    NOTE:Do not fully tighten the coolant pipe to cylinder head retaining bolt at this stage.
    Attach the coolant pipe to the cylinder block.

  1. Using the special tool, connect the coolant hose to the oil cooler.

  1. Connect the KS electrical connector.
    • Attach the KS electrical connector to the engine wiring harness support bracket.

  1. NOTE:
    NOTE:Install new turbocharger oil return tube gaskets.
    Install the turbocharger oil return tube.

  1. NOTE:
    NOTE:Install a new turbocharger oil supply pipe.
    NOTE:
    NOTE:Install new turbocharger oil supply pipe sealing washers.
    Attach the turbocharger oil supply pipe to the turbocharger.

  1. NOTE:
    NOTE:Install new turbocharger oil supply pipe sealing washers.
    Install the turbocharger oil supply pipe.

  1. Tighten the turbocharger support bracket retaining nuts and bolts.
    1. Turbocharger support bracket retaining nuts and bolt.
    1. Turbocharger to turbocharger support bracket retaining bolts.
  1. Fill the engine with engine oil.
    For additional information, refer to: Specifications (303-01 Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, Specifications).

  1. Install the special tool.

  1. Remove the special tool.

Assembly|Installation > < Cylinder Head