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Positive Crankcase Ventilation (PCV) Valve > < Exhaust Gas Recirculation (EGR) Valve

C-MAX 2003.75 (06.2003-)

Engine Emission Control - 2.0L Duratorq-TDCi (DW) Diesel - Exhaust Gas Recirculation (EGR) Cooler C-MAX 2003.75 (06/2003-)
Removal and Installation

Special Tool(s)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)
  1. Drain the cooling system. For additional information, refer to Section  303-03A Engine Cooling / 303-03B Engine Cooling / 303-03C Engine Cooling / 303-03D Engine Cooling / 303-03E Engine Cooling / 303-03F Engine Cooling.
NOTE:
NOTE:Make sure that the windshield wiper motor is in the park position.
  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the engine upper cover.

  1. Detach the brake fluid reservoir from the bulkhead extension panel.

  1. Remove the windshield wiper arms.

  1. Remove the cowl panel grille.
    1. Detach the cowl panel grille retaining clips.
    1. Detach the cowl panel grille from the windshield glass lower weatherstrip and remove.

  1. Remove the bulkhead extension panel.

8. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Turbocharger intake pipe positive crankcase ventilation hose
See Removal Detail
2
-
Heater core to EGR cooler coolant hose quick release coupling
See Removal Detail
3
-
Coolant bypass to EGR cooler coolant hose retaining clamp
See Removal Detail
4
-
Coolant bypass to EGR cooler coolant hose
5
-
EGR cooler tube heat shield
6
-
EGR cooler retaining clamp
See Removal Detail
See Installation Detail
7
-
EGR cooler tube retaining nuts
See Installation Detail
8
-
EGR cooler tube
9
-
EGR cooler tube gasket
10
-
EGR cooler support bracket retaining nut
See Installation Detail
11
-
EGR cooler retaining bolts
See Installation Detail
12
-
EGR cooler

9. To install, reverse the removal procedure.

  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Removal Details

Item 1 : Turbocharger intake pipe positive crankcase ventilation hose
  1. Detach the positive crankcase ventilation hose from the turbocharger intake pipe.

Item 2 : Heater core to EGR cooler coolant hose quick release coupling
  1. Disconnect the heater core to EGR cooler coolant hose quick release connector.
    1. Remove the retaining clip.

Item 3 : Coolant bypass to EGR cooler coolant hose retaining clamp
  1. Using the special tool, detach the coolant bypass to EGR cooler coolant hose retaining clamp.

Item 6 : EGR cooler retaining clamp
  1. Make a note of the position of the EGR cooler retaining clamp before removal.

Installation Details

Item 11 : EGR cooler retaining bolts

  1. Loosely install the EGR cooler retaining bolts.

Item 10 : EGR cooler support bracket retaining nut

  1. Loosely install the EGR cooler support bracket retaining nut.

Item 7 : EGR cooler tube retaining nuts

  1. Loosely install the EGR cooler tube retaining nuts.

Item 6 : EGR cooler retaining clamp
  1. Install a new EGR cooler retaining clamp in the same position as when removed.

  1. Tighten the EGR cooler components in the order indicated.
    1. EGR cooler retaining bolts.
    1. EGR cooler tube retaining nuts.
    1. EGR cooler retaining nut.

Positive Crankcase Ventilation (PCV) Valve > < Exhaust Gas Recirculation (EGR) Valve