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303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Engine > < Assembly|Engine

C-MAX 2003.75 (06.2003-)

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

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
General Equipment
Workshop table
Securing straps

Installation

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.
All vehicles
  1. Install the transaxle to the engine.

  1. Install the transaxle left-hand lower retaining bolt.

  1. Install the transaxle right-hand retaining bolts.

  1. Install the transaxle left-hand upper retaining bolt.

  1. Install the transaxle lower retaining bolts.

  1. Install the transaxle upper retaining bolts.
  1. Install the starter motor.
    For additional information, refer to: Starter Motor - 1.8L Duratorq-TDCi (Kent) Diesel (303-06A Starting System, Removal and Installation).
  1. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)
    Jacking (Description and Operation),
    Lifting (Description and Operation).

  1. WARNING:
    WARNING:Support the engine and transaxle assembly on wooden blocks. Failure to follow these instruction may result in personal injury.
    CAUTION:
    CAUTION:Support the engine on the oil pan flange.
    Using suitable securing straps, secure the engine and transaxle assembly on the workshop table and position it under the vehicle.

  1. NOTE:
    NOTE:Install new engine rear mount retaining nuts.
    Install the engine rear mount.

  1. NOTE:
    NOTE:Install new engine front mount retaining nuts.
    Install the engine front mount.

  1. Attach the starter motor wiring harness bracket and engine ground cable to the transaxle housing.

  1. Attach the power steering line to the retaining bracket.

  1. CAUTION:
    CAUTION:If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.
    Attach the clutch slave cylinder supply line to the clutch slave cylinder.
    1. Install the retaining clip.
    1. Attach the bracket together with the rubber grommet.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner constant velocity joint must not be bent more than 18 degrees. The outer constant velocity joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    Attach the left-hand halfshaft to the transaxle.

  1. CAUTION:
    CAUTION:Support the halfshaft. The inner constant velocity joint must not be bent more than 18 degrees. The outer constant velocity joint must not be bent more than 45 degrees.
    CAUTION:
    CAUTION:Do not damage the halfshaft seal.
    NOTE:
    NOTE:Install new lock nuts and a new centre bearing cap.
    Attach the right-hand halfshaft to the transaxle and install the bearing cap.

  1. CAUTION:
    CAUTION:The catalytic converter to catalytic converter support bracket retaining nuts must be loosely installed to allow the catalytic converter to align with the turbocharger.
    NOTE:
    NOTE:Make sure that the catalytic converter to catalytic converter support bracket studs align with the holes in the catalytic converter support bracket.
    NOTE:
    NOTE:Do not fully tighten the catalytic converter to catalytic converter support bracket retaining nuts at this stage.
    Install the catalytic converter to catalytic converter support bracket retaining nuts.

  1. CAUTION:
    CAUTION:Never use jointing compound forward of the catalytic converter.
    NOTE:
    NOTE:Do not fully tighten the catalytic converter to turbocharger retaining nuts at this stage.
    Install the catalytic converter to turbocharger retaining nuts.

  1. Tighten the catalytic converter to turbocharger retaining nuts in the sequence shown.

  1. Tighten the catalytic converter to catalytic converter support bracket retaining nuts.

  1. CAUTION:
    CAUTION:Take care when installing the exhaust hanger insulators to prevent damage.
    NOTE:
    NOTE:Check the exhaust hanger insulators for damage. Install new exhaust hanger insulators if required.
    Install the exhaust hanger insulators.

  1. CAUTION:
    CAUTION:Twisting the exhaust flexible pipe more than 2 degrees may cause damage resulting in failure.
    NOTE:
    NOTE:Use a pry bar to prevent the exhaust flexible pipe from twisting when installing the catalytic converter to muffler and tailpipe assembly retaining nuts.
    NOTE:
    NOTE:Install a new catalytic converter to muffler and tailpipe assembly gasket and retaining nuts.
    Install the catalytic converter to muffler and tailpipe assembly retaining nuts.

  1. CAUTION:
    CAUTION:Over bending of the exhaust flexible pipe may result in failure.
    Remove the exhaust flexible pipe support wrap or splint.

  1. Install the catalytic converter retaining bracket.

  1. Install the floor panel brace.

  1. Install the engine support insulator.

  1. Attach the gearshift cables to the abutment.
    1. Attach the gearshift cable to the abutment and secure by turning the catch clockwise.
    1. Attach the selector cable to the abutment and secure by turning the catch clockwise.

  1. Attach the gearshift cables to the selector mechanism.
    1. Press the gearshift cable catch and attach the gearshift cable to the gear lever.
    1. Press the selector cable catch and attach the selector cable to the selector lever.

  1. Connect the starter motor electrical connector and the power supply.

  1. Connect the glow plug relay electrical connector.

  1. Connect the powertrain control module (PCM) electrical connectors in the sequence shown.
  1. Install a new PCM security bracket and security bracket sheer bolt (if equipped).
    • Tighten the security bracket sheer bolt until the head of the sheer bolt is sheered off.

  1. Install the fender splash shield.

  1. CAUTION:
    CAUTION:Using a soft cloth, protect the ball joint seal.
    Attach the lower arm to the wheel knuckle on both sides (left-hand side shown).

  1. NOTE:
    NOTE:Install a new tie-rod end retaining nut.
    Attach the tie-rod end to the wheel knuckle on both sides.

  1. NOTE:
    NOTE:Use a 5 mm Allen key to prevent the ball joint stud from rotating.
    Attach the stabilizer bar link to the stabilizer bar on both sides.
  1. Install the radiator.
    For additional information, refer to: Radiator (303-03G Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
  1. Install both front wheels and tires.
    For additional information, refer to: Wheel and Tire (204-04 Wheels and Tires, Removal and Installation).

  1. Using the special tool, connect the coolant hose to the oil cooler.
Vehicles with air conditioning
  1. Attach the air conditioning (A/C) compressor.

  1. Connect the A/C compressor clutch electrical connector and attach the wiring harness to the A/C compressor.
All vehicles
  1. Install the charge air cooler.
    For additional information, refer to: Charge Air Cooler - 1.6L Duratorq-TDCi (DV) Diesel/2.0L Duratorq-TDCi (DW) Diesel (303-12A Intake Air Distribution and Filtering, Removal and Installation).

  1. Connect the horn electrical connector and the horn wiring harness.

  1. Install the crashbox (if equipped).
    • 1: Bolt M10x16.
    • 2: Bolt M10x25.
  1. Install the accessory drive belt.
    For additional information, refer to: Accessory Drive Belt Tensioner - 1.8L Duratorq-TDCi (Kent) Diesel (303-05A Accessory Drive, Removal and Installation).

  1. Install the engine undershield.
  1. Lower the vehicle.

  1. Connect the reverse lamp switch electrical connector.
  1. Attach the ground cables to the side member.

  1. Connect the cooling fan motor electrical connector and attach the cooling fan wiring harness to the cooling fan shroud.
  1. Connect the fuel supply line and fuel return line quick release couplings.
    For additional information, refer to: Quick Release Coupling (310-00 Fuel System - General Information, General Procedures).

  1. Using the special tool, connect the cooling hoses to the thermostat housing and to the coolant distribution pipe.

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

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

  1. Install the fuel line retaining clip.

  1. Install the charge air cooler outlet pipe.
    1. Tighten the charge air cooler outlet pipe retaining clamps.
    1. Connect the the manifold absolute pressure (MAP) sensor electrical connector.
    1. Install the charge air cooler outlet pipe retaining nut.
    1. Install the fuel line retaining clip.

  1. Attach the coolant expansion tank to the wheel housing.

  1. Connect the engine wiring harness electrical connector.

  1. Install the central junction box (CJB) cover.
  1. Install the battery tray.
    For additional information, refer to: Battery Tray - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Kent) Diesel/2.0L Duratorq-TDCi (DW) Diesel (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner - 1.8L Duratorq-TDCi (Kent) Diesel (303-12A Intake Air Distribution and Filtering, Removal and Installation).
  1. Fill and bleed the cooling system.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding - 2.0L (303-03G Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
  1. Adjust the gearshift cable.
    For additional information, refer to: Gearshift Cable Adjustment - Vehicles With: 5-Speed Manual Transaxle (MTX-75) (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Install the cowl panel grille.
    For additional information, refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).

303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel|Engine > < Assembly|Engine