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Disassembly and Assembly > < Heater Core - LHD

C-MAX 2003.75 (06.2003-)

Heating and Ventilation - Heater Core—RHD C-MAX 2003.75 (06/2003-)
Removal and Installation

All vehicles
  1. Drain the cooling system. For additional information, refer to:
    Cooling System Draining, Filling and Bleeding (303-03A Engine Cooling - 1.6L Duratec-16V (Sigma), General Procedures),
    Cooling System Draining, Filling and Bleeding (303-03B Engine Cooling - 1.6L Duratec-16V Ti-VCT (Sigma), General Procedures),
    Cooling System Draining, Filling and Bleeding (303-03C Engine Cooling - 1.8L Duratec-HE (MI4)/2.0L Duratec-HE (MI4), General Procedures),
    Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures),
    Cooling System Draining, Filling and Bleeding (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
Vehicles with manual transmission
  1. Remove the engine undershield (if fitted).

  1. CAUTION:
    CAUTION:If brake fluid comes into contact with the paintwork, rinse off the affected areas with cold water without delay.
    Detach the clutch slave cylinder pressure pipe and the brake fluid reservoir hose from the clutch master cylinder.
    • Remove the retaining clips.
  1. Lower the vehicle.
Vehicles built from 10/2004
  1. Remove the engine cover (1.8L shown).
    • Remove the oil filler cap.

  1. CAUTION:
    CAUTION:Close off the coolant lines to prevent fluid loss or dirt ingress.
    Detach the coolant lines from the heater core.
    • Turn the coolant line snap ring counter-clockwise to the stop and detach the coolant line.
All vehicles
  1. Remove the driver's side footwell trim.
  1. Remove the center console extension.
    For additional information, refer to: Floor Console Extension (501-12 Instrument Panel and Console, Removal and Installation).
Vehicles built from 03/2007
NOTE:
NOTE:This operation is only required on vehicles with centre armrest.
  1. Remove the center console.
    For additional information, refer to: Floor Console - Vehicles Built From: 03/2007, Vehicles With: Center Armrest (501-12 Instrument Panel and Console, Removal and Installation).

  1. Remove the gearshift console bracket.
Vehicles with adjustable pedal unit
  1. Move the adjustable pedal unit towards the bulkhead into its end position.

  1. Detach the operating rod of the adjustable clutch pedal from the clutch pedal.
Vehicles with manual transmission
  1. Detach the clutch pedal position (CPP) switch from the clutch pedal bracket.

  1. Detach the clutch pedal return spring from the clutch pedal (if present).

  1. CAUTION:
    CAUTION:Ensure that no brake fluid gets into the footwell in order to prevent soiling of the carpet.
    Remove the clutch pedal bracket nuts.
    • Discard the nuts.
  1. Remove the clutch pedal together with the clutch pedal bracket and the clutch master cylinder.

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

 
Item
Part Number
Description
1
-
Gearshift console nuts
2
-
Gearshift console

 
Item
Part Number
Description
3
-
Gearshift console reinforcing element bracket bolts
4
-
Gearshift console reinforcing element bracket
5
-
Gearshift console reinforcing element bolts
6
-
Gearshift console reinforcing element
See Removal Detail
WARNING:
WARNING:Never perform work on the electric booster heater before the electric booster heater element has cooled to ambient temperature. Failure to observe this instruction can lead to injury.

 
Item
Part Number
Description
7
-
Electric booster heater ground connector (if fitted)
8
-
Electric booster heater voltage supply connector with bracket (if fitted)
9
-
Electric booster heater control wiring connector (if fitted)
10
-
Remove the heater core upper cover bolts.
11
-
Heater core upper cover
CAUTION:
CAUTION:Ensure that no coolant gets into the footwell in order to prevent soiling of the carpet.
CAUTION:
CAUTION:Close off the heater core and coolant lines to prevent fluid loss or dirt ingress.

 
Item
Part Number
Description
12
-
Bulkhead aperture cover section bolts
13
-
Bulkhead aperture cover section
14
-
Bulkhead aperture spacer
15
-
Coolant line retaining clips
See Removal Detail
See Installation Detail
16
-
Coolant line ends
See Removal Detail
See Installation Detail
17
-
Heater core
See Removal Detail
See Installation Detail

18. To install, reverse the removal procedure.

NOTE:
NOTE:Install new clutch pedal bracket retaining nuts.
  1. Bleed the clutch system.
    For additional information, refer to: Clutch System Bleeding (308-00 Manual Transmission/Transaxle and Clutch - General Information, General Procedures).
  1. Perform an operation check on the adjustable pedal unit (if equipped).

Removal Details

Item 6 : Gearshift console reinforcing element
  1. Remove the heater core / evaporator core housing side bolt.

  1. Remove the rear footwell air duct.

Item 15 : Coolant line retaining clips
  1. NOTE:
    NOTE:Only for vehicles built up to 10/2004
    Release the coolant line retaining clips.
    • Slide the coolant line ends forward.

Item 16 : Coolant line ends
  1. NOTE:
    NOTE:Only for vehicles built from 10/2004
    Saw through the heater core coolant lines.
    • Slide the coolant line ends forward.

Item 17 : Heater core
  1. NOTE:
    NOTE:Only for vehicles built from 10/2004
    Remove the heater core coolant line ends.
    • Pull the coolant line ends out towards the vehicle interior and discard them.

Installation Details

Item 17 : Heater core
  1. NOTE:
    NOTE:Only for vehicles built from 10/2004
    Install the heater core coolant line ends.
    • Slide in the coolant line ends working from inside the vehicle interior.

Item 16 : Coolant line ends

CAUTION:
CAUTION:Make certain that the seals of the heater core coolant lines are installed.

Item 15 : Coolant line retaining clips
  1. Engage the coolant line retaining clips.

Disassembly and Assembly > < Heater Core - LHD