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Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine

C-MAX 2003.75 (06.2003-)

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

Special Tool(s)

Slide Hammer

205-047

Universal Flange Holding Wrench

205-072

Lifting Bracket, Engine

303-122

Locking Tool, Flywheel

303-393

Remover/Installer, Hose Clamp

303-397

Mounting Stand

303-435

Mounting Bracket for 303-435

303-435-06

Adapter for 205-047

303-633

Remover, Camshaft Sprocket

303-651
General Equipment
Pneumatic vacuum gun
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.
CAUTION:
CAUTION:Do not disassemble fuel injectors or clean the nozzles, even with an ultrasonic cleaner. Always install new fuel injectors if necessary.
All vehicles
  1. Using the special tool, secure the engine to the mounting stand.

  1. Remove the special tool.
  1. Drain the engine oil.
    • Allow the oil to drain into a suitable container.

  1. NOTE:
    NOTE:The turbocharger oil supply pipe union banjo bolt cannot be removed from the pipe.
    Detach the turbocharger oil supply pipe from the oil cooler.

  1. NOTE:
    NOTE:The turbocharger oil supply pipe union banjo bolt cannot be removed from the pipe.
    Remove the turbocharger oil supply pipe.
    • Discard the turbocharger oil supply pipe.

  1. Remove the turbocharger oil return tube.
    • Discard the turbocharger oil return tube gaskets.

  1. Disconnect the knock sensor (KS) electrical connector.
    • Detach the KS sensor electrical connector from the engine wiring harness support bracket.

  1. Using the special tool, disconnect the coolant hose from the oil cooler.

  1. Detach the coolant pipe from the cylinder block.

  1. Remove the turbocharger support bracket.

  1. Remove the oil filter.
    • Discard the oil filter.

  1. Remove the oil cooler.
    • Discard the oil cooler gasket.

  1. Using the special tool, disconnect the positive crankcase ventilation (PCV) hoses from the PCV lower pipe.

  1. Using the special tool, disconnect the PCV hoses from the valve cover.

  1. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    1. Detach the electrical connector from the PCV housing.
    1. Disconnect the CHT sensor electrical connector.

  1. Detach the PCV housing from the fuel filter retaining bracket.

  1. Using the special tool, disconnect the PCV hose from the brake booster vacuum pump.

  1. Remove the brake booster vacuum pump.
    • Discard the brake booster vacuum pump O-ring seal.

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

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

  1. Disconnect the oil pressure switch electrical connector.

  1. Detach the oil level indicator tube bracket from the thermostat housing.

  1. Remove the KS heat shield.

  1. Remove the KS.

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

  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. 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. 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 injection supply manifold.
  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 injection supply manifold.
  1. Using the pneumatic vacuum gun, vacuum foreign material from the high-pressure fuel supply line, the fuel pump and the fuel injection supply manifold.
  1. Install clean blanking caps to the open threaded ports on the fuel pump and the fuel injection supply manifold.

  1. Remove the fuel injection supply manifold.

  1. Remove the fuel injection supply manifold retaining bracket.

  1. Remove the fuel injectors.
    • Discard the fuel injector bolts.

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

  1. Remove the timing belt cover.

  1. Detension the timing belt.
    • Loosen the timing belt tensioner retaining bolt by three turns.
  1. Remove and discard the timing belt.

  1. Remove the timing belt tensioner.

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

  1. Using the special tool, remove the camshaft pulley.

  1. Remove the fuel pump pulley.

  1. Remove the fuel pump seal retainer.
    • Discard the fuel pump seal retainer.

  1. Remove the timing belt rear cover.

  1. Remove the valve cover.
    • Discard the valve cover gasket.

  1. Remove the oil baffle.

  1. CAUTION:
    CAUTION:Remove the cylinder head retaining bolts in the sequence shown.
    NOTE:
    NOTE:Do not discard the cylinder head gasket at this stage.
    Remove the cylinder head.
    • Discard the cylinder head retaining bolts.

  1. Remove the engine front mount bracket.

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

  1. Remove the coolant pump.
    • Discard the coolant pump gasket.

  1. Using the special tool, remove the crankshaft pulley.
    • Discard the crankshaft pulley retaining bolt.

  1. Remove the timing chain housing cover.
    • Discard the timing chain housing cover gasket.

  1. Remove the timing chain tensioner.

  1. Detach the fuel pump sprocket.

  1. Remove the timing chain, sprockets and guides.

  1. Remove the fuel pump.
    • Discard the fuel pump gasket.

  1. Remove the fuel pump support bracket.

  1. Using the special tool, disconnect the upper coolant hose from the coolant distribution pipe.

  1. Remove the coolant distribution pipe.
Vehicles with air conditioning
  1. Remove the generator drive coupling.
    1. Remove the driveshaft intermediate bearing retaining bolts.
    1. Loosen the vibration damper retaining bolts.

  1. Remove the generator.

  1. Remove the generator support bracket.
Vehicles without air conditioning
  1. Remove the accessory drive belt idler pulley.

  1. Remove the generator.

  1. Remove the generator support bracket.
All vehicles
  1. Remove the fuel pump retaining bracket.

  1. CAUTION:
    CAUTION:Loosen the clutch pressure plate retaining bolts by 2 turns at a time in the sequence shown.
    Remove the clutch disc and pressure plate.
    • Discard the clutch pressure plate retaining bolts.

  1. Using the special tool, remove the flywheel.
    • Discard the flywheel retaining bolts.

  1. Remove the crankshaft position (CKP) sensor.
    • Discard the CKP sensor.

  1. Remove the oil pan retaining nuts and bolts (16 bolts, two nuts).

  1. Using the special tools, remove the oil pan.

  1. Remove the CKP sensor retaining bracket.

  1. Remove the crankshaft rear seal carrier.
    • Discard the crankshaft rear seal carrier.

  1. Remove the oil pump connecting pipe.
    • Discard the oil pump connecting pipe O-ring seal.

  1. Remove the oil pump pickup tube.
    • Discard the oil pump pickup tube O-ring seal.

  1. Remove the ladder frame.
    • Discard the ladder frame gasket.

  1. Remove the timing chain rear housing.
    • Discard the timing chain rear housing gasket.

  1. NOTE:
    NOTE:Make a note of the position of the connecting rod bearings, bearing caps and pistons to make sure that they are installed in the same position.
    Remove the pistons.
    • Discard the connecting rod bearing cap retaining bolts.

  1. NOTE:
    NOTE:Make a note of the position of the crankshaft main bearing caps to make sure that they are installed in the same position.
    Remove the crankshaft main bearing caps.
  1. Remove the crankshaft.
  1. NOTE:
    NOTE:Make a note of the position of the crankshaft thrust half washers to make sure that they are installed in the same position.
    Remove the crankshaft thrust half washers.

Disassembly and Assembly of Subassemblies > < In-vehicle Repair|Engine