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C-MAX 2003.75 (06.2003-)

Engine - 1.8L Duratorq-TDCi (Lynx) Diesel - Cylinder Head C-MAX 2003.75 (06/2003-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Mounting Bracket, Engine/Differential

205-329

Installer, Valve Stem Seal

303-037

Compressor, Valve Spring

303-060

Adapter for 303-060

303-060-05

Installer, Camshaft Seal

303-199A

Installer, Valve Stem Collets

303-362

Pliers, Valve Stem Seal

303-390

Remover/Installer, Hose Clamp

303-397

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Socket, Cylinder Head Temperature Sensor

303-680
Materials
Name
Specification
Engine Oil - 5W-30
WSS-M2C912-A1 
Gasket Eliminator Sealant
WSK-M2G348-A5 

Disassembly

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:This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. 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:Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors if necessary.
  1. Using the special tools, attach the cylinder head to the mounting stand.

  1. Using the special tool, disconnect the exhaust gas recirculation (EGR) cooler to cylinder head coolant hose from the cylinder head.

  1. Using the special tool, disconnect the EGR cooler to cylinder head coolant hose from the EGR cooler.

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

  1. Remove the EGR cooler.
    • Discard the EGR cooler gaskets.

  1. Remove the exhaust manifold.
    • Discard the exhaust manifold gasket and retaining nuts.

  1. Remove the intake manifold.
    • Discard the intake manifold gaskets and retaining nuts.

  1. Remove the coolant outlet connector.
    • Discard the coolant outlet connector.

  1. Remove the oil pressure switch.

  1. Using the special tool, remove the cylinder head temperature (CHT) sensor.
    • Discard the CHT sensor.

  1. Disconnect the fuel injector fuel return lines from the fuel injectors.
    1. Using a suitable screwdriver, remove the fuel injector fuel return line clip.
    1. Disconnect the fuel injector fuel return line from the fuel injector.
    • Install a clean blanking cap to the fuel injector return line port.
    • Discard the fuel injector fuel return line O-ring seals and the fuel injector fuel return line clips.

  1. Remove the engine front lifting eye.

  1. Remove the glow plug wiring harness.

  1. Remove the glow plugs.

  1. NOTE:
    NOTE:Make a note of the position of the fuel injectors to make sure that they are installed in the same position.
    Remove the fuel injectors and retaining clamps.
    • Discard the fuel injector retaining clamps retaining bolts.
    • Discard the fuel injector retaining clamps.
    • Discard the fuel injector to cylinder head sealing washers.

  1. CAUTION:
    CAUTION:Loosen the camshaft bearing cap retaining nuts by 1 turn each until the camshaft is released.
    NOTE:
    NOTE:Make a note of the position of the camshaft bearing cap retaining nuts and camshaft caps to make sure that they are installed in the same position.
    Remove the camshaft.
    • Discard the camshaft seal.

  1. NOTE:
    NOTE:Make a note of the position of the camshaft bearing cap shells to make sure that they are installed in the same position.
    Remove the camshaft bearing cap shells.

  1. NOTE:
    NOTE:Make a note of the position of the valve tappets and adjustment shims to make sure that they are installed in the same position.
    Remove the valve tappets and valve adjustment shims.

  1. NOTE:
    NOTE:Make a note of the position of the camshaft lower bearing shells to make sure that they are installed in the same position.
    Remove the camshaft lower bearing shells.

  1. Remove the brake booster vacuum pump drive tappet.

  1. Using the special tools, remove the valve collets.
  1. NOTE:
    NOTE:Make a note of the position of the valve springs and valve retainers to make sure that they are installed in the same position.
    Remove the valve springs and the valve retainers.

  1. Using the special tool, remove the valve stem seals.
    • Discard the valve stem seals.
  1. NOTE:
    NOTE:Make a note of the position of the valves to make sure that they are installed in the same position.
    Remove the valves.

Assembly

  1. Coat the valves with clean engine oil.

  1. NOTE:
    NOTE:Cover the collet grooves with adhesive tape during installation of the valve stem seal.
    NOTE:
    NOTE:Install new valve stem seals.
    Using the special tool, install the valve stem seals.
  1. NOTE:
    NOTE:Make sure that the valve springs and valve retainers are installed in their original position.
    Install the valve springs and valve retainers.

  1. Using the special tools, install the valve collets.
  1. Coat the brake booster vacuum pump drive tappet with clean engine oil.

  1. Install the brake booster vacuum pump drive tappet.

  1. NOTE:
    NOTE:Make sure that the camshaft bearing cap shells are installed in their original position.
    Install the camshaft bearing cap shells.
  1. Coat the camshaft bearing cap shells with clean engine oil.

  1. NOTE:
    NOTE:Make sure that the camshaft lower bearing shells are installed in their original position.
    Install the camshaft lower bearing shells.
  1. Coat the camshaft lower bearing shells with clean engine oil.
  1. Coat the valve tappets and adjustment shims with clean engine oil.

  1. NOTE:
    NOTE:The lettering on the valve adjustment shims faces downwards.
    Install the valve tappets and valve adjustment shims.

  1. NOTE:
    NOTE:The larger semi-circle points upwards.
    Position the camshaft on the cylinder head.

  1. Apply sealant to bearing cap number 1 at the positions shown.

  1. NOTE:
    NOTE:The arrows on the camshaft bearing caps must point towards the front of the engine.
    NOTE:
    NOTE:Do not fully tighten the camshaft bearing cap retaining nuts at this stage.
    Install the camshaft bearing caps.

  1. NOTE:
    NOTE:Tighten the camshaft bearing cap retaining nuts evenly, a turn at a time.
    Tighten the camshaft bearing cap retaining nuts.

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

  1. NOTE:
    NOTE:Make sure that the fuel injectors are installed in their original position.
    NOTE:
    NOTE:Install new fuel injector to cylinder head sealing washers.
    NOTE:
    NOTE:Install new fuel injector retaining clamps.
    NOTE:
    NOTE:Install new fuel injector retaining clamps retaining bolts.
    Install the fuel injectors and retaining clamps.
    • Tighten the bolts in two stages.
    • 5 Nm
    • 90 degrees

  1. Install the glow plugs.

  1. Install the glow plug wiring harness.

  1. Install the engine front lifting eye.

  1. CAUTION:
    CAUTION:Push the fuel injector fuel return lines gently into the fuel injectors. Failure to follow this instruction my result in damage to the fuel injector fuel return line O-ring seals.
    NOTE:
    NOTE:Install new fuel injector fuel return line O-ring seals and new fuel injector fuel return line clips.
    Attach the fuel return lines to the fuel injectors.
    1. Connect the fuel injector fuel return line to the fuel injector.
    1. Install the fuel injector fuel return line clip.

  1. NOTE:
    NOTE:Install a new cylinder head temperature (CHT) sensor.
    Using the special tool, install the CHT sensor.

  1. Install the oil pressure switch.

  1. NOTE:
    NOTE:Install a new coolant outlet connector.
    Install the coolant outlet connector.

  1. NOTE:
    NOTE:Install new intake manifold gaskets and retaining nuts.
    Install the intake manifold.

  1. NOTE:
    NOTE:Install a new exhaust manifold gasket retaining nuts.
    Install the exhaust manifold.

  1. CAUTION:
    CAUTION:Failure to follow this sequence may result in premature failure of the exhaust gas recirculation (EGR) cooler.
    NOTE:
    NOTE:Install new EGR cooler gaskets.
    Handstart all of the EGR cooler retaining bolts and then tighten in the sequence shown.

  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.

  1. Using the special tool, connect the EGR cooler to cylinder head coolant hose to the EGR cooler.

  1. Using the special tool, connect the EGR cooler to cylinder head coolant hose to the cylinder head.

  1. Detach the cylinder head from the mounting stand.
    • Remove the special tools.

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