B-MAX 2012 – Engine – 1.6L Duratec-16V Ti-VCT (77kW/105PS) Sigma – Engine – Installation

Engine - 1.6L Duratec-16V Ti-VCT (77kW/105PS) – Sigma - EngineB-MAX 2012.75 (01/2012-)

Installation

Special Tool(s) / General Equipment

Click to resize E75372

204-609
Protection Cap, Ball Joint Gaiter

Click to resize E47098

205-775
Protector, Halfshaft Seal

Click to resize 21068A

303-122
Lifting Bracket, Engine

Click to resize 16089

308-256
Remover, Halfshaft
Cable Ties
Floor Crane
Hose Clamp Remover/Installer
Lower Arm Down Force Lever
Magnetic Socket
Mounting Table Set
Retaining Strap
Wooden Block
  1. Install Special Service Tool: 303-122.
    Use the General Equipment: Floor Crane

Click to resize E152980

  1. cautionNOTICE: Make sure that the component aligns with the installation mark.

    NOTE: This step is only necessary when installing a new component.

Click to resize E154119

  1. heavy hand

    NOTE: Make sure that the component is installed to the position noted before removal.

Click to resize E141320

  1. cautionNOTICE: Make sure that the locating dowels remain installed.

    Tighten on both sides simultaneously.
    Torque: 48 Nm

Click to resize E159657

  1. Torque: 48 Nm

Click to resize E159658

  1. Torque: 48 Nm

Click to resize E159213

  1. NOTICE:

    caution Make sure that new nuts are installed.

    caution Only rotate the crankshaft clockwise.

    Use the General Equipment: Magnetic Socket
    Torque:
    Stage 1:
    5 Nm
    Stage 2:
    25 Nm

Click to resize E140491

  1. NOTE: The gasket is to be reused unless damaged.

Click to resize E141321

  1.  
    1. Torque: 6 Nm
    1. Torque: 12 Nm
    1. Torque: 35 Nm
    1. Torque: 25 Nm

Click to resize E159214

  1. NOTICE:

    caution Make sure that the terminals or pins/sockets of the transmission control module (TCM) and the TCM electrical connector are not bent or damaged.

    caution Take extra care not to damage the wiring harnesses.

    caution Take extra care when handling the component terminals.

    NOTE: Make sure that the wiring harnesses are correctly located.

Click to resize E135047

Click to resize E135048

  1. Torque: 25 Nm

Click to resize E159409

  1. Torque: 8 Nm

Click to resize E159212

  1. warningWARNING: Always secure engines, transmissions, or other heavy components to the support fixture with straps and wooden support blocks. Improperly secured assemblies could fall off the fixture, resulting in serious personal injury.

    Use the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap

Click to resize E107062

  1. Remove Special Service Tool: 303-122.
    Remove the General Equipment: Floor Crane

Click to resize E152980

  1. cautionNOTICE: Make sure that no components catch.

    Lower the vehicle.
    Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

Click to resize E103239

  1. NOTE: Make sure that the component is installed to the position noted before removal.

    1. NOTE: Only tighten the bolts finger tight at this stage.

    1. Torque: 125 Nm

Click to resize E150061

  1. Torque: 8 Nm

Click to resize E152981

  1. NOTE: Make sure that the component is installed to the position noted before removal.

    1. Torque: 80 Nm

    1. NOTE: Only tighten the bolts finger tight at this stage.

Click to resize E148816

  1. Remove the General Equipments: Retaining Strap, Wooden Block, Mounting Table Set
  1. Torque: 48 Nm

Click to resize E152332

  1. Torque: 90 Nm

Click to resize E150101

  1. cautionNOTICE: Jointing compound must not be used forward of the catalytic converter.

    Torque:
    Stage 1:
    20 Nm
    Stage 2:
    55 Nm

Click to resize E158760

  1. Torque: 10 Nm

Click to resize E158757

Click to resize E158758

  1. cautionNOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

Click to resize E126592

  1. NOTE: Install all the bolts finger tight before final tightening.

    1. Torque: 51 Nm
    1. Torque: 25 Nm

Click to resize E149137

  1. cautionNOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.

    Remove the General Equipment: Cable Ties

Click to resize E98634

  1. Torque: 70 Nm

Click to resize E159631

Click to resize E159430

  1. NOTE: Install all the bolts finger tight before final tightening.

    Torque: 9 Nm

Click to resize E131244

  1. Use the General Equipment: Hose Clamp Remover/Installer

Click to resize E149152

Vehicles with air conditioning

  1. cautionNOTICE: Make sure that no strain is placed on the refrigerant lines.

    Remove the General Equipment: Cable Ties
    Torque: 25 Nm

Click to resize E149110

  1.  
    • Refer to: Generator (414-02C Generator and Regulator - 1.6L Duratec-16V Ti-VCT (77kW/105PS) – Sigma, Removal and Installation).
  1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
  1. If equipped.

Click to resize E158119

Click to resize E102938

Click to resize E145097

  1. cautionNOTICE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.

    Use the General Equipment: Lower Arm Down Force Lever

Click to resize E175105

  1. Install Special Service Tool: 204-609.

Click to resize E145100

Click to resize E172906

  1. warningWARNING: Be prepared to collect escaping fluid.

    NOTICE:

    caution Take extra care not to damage the edges of the component.

    caution Take extra care not to damage the mating faces.

    caution Take extra care not to damage the seal.

    Use Special Service Tool: 308-256.

Click to resize E144895

  1.  

    1. 1. cautionNOTICE: Take extra care not to damage the seal.

      Use Special Service Tool: 205-775.

    1. 2. NOTICE:

      caution The inner constant velocity (CV) joint must not be bent more than 18°.

      caution The outer constant velocity (CV) joint must not be bent more than 45°.

      caution Make sure that the strut is not moved more than necessary to prevent damage to top mount.

Click to resize E165905

  1. NOTICE:

    caution Make sure that the strut is not moved more than necessary to prevent damage to top mount.

    caution The inner constant velocity (CV) joint must not be bent more than 18°.

    caution The outer constant velocity (CV) joint must not be bent more than 45°.

Click to resize E130019

Click to resize E135834

  1. Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
  1. If equipped.

Click to resize E158119

Click to resize E102938

Click to resize E145097

  1. cautionNOTICE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.

    Use the General Equipment: Lower Arm Down Force Lever

Click to resize E175105

  1. Install Special Service Tool: 204-609.

Click to resize E145100

Click to resize E172989

  1. cautionNOTICE: Make sure that the strut is not moved more than necessary to prevent damage to top mount.

    NOTE: Be prepared to collect escaping fluid.

Click to resize E158127

  1. NOTICE:

    caution The outer constant velocity (CV) joint must not be bent more than 45°.

    caution The inner constant velocity (CV) joint must not be bent more than 18°.

    caution Make sure that the strut is not moved more than necessary to prevent damage to top mount.

    caution Take extra care not to damage the seal.

    Use Special Service Tool: 205-775.

Click to resize E165950

  1. NOTICE:

    caution Make sure that the strut is not moved more than necessary to prevent damage to top mount.

    caution The inner constant velocity (CV) joint must not be bent more than 18°.

    caution The outer constant velocity (CV) joint must not be bent more than 45°.

Click to resize E130018

  1. cautionNOTICE: Make sure that no strain is placed on the refrigerant lines.

    Use the General Equipment: Hose Clamp Remover/Installer
    Torque: 10 Nm

Click to resize E149108

Click to resize E159660

  1. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).
    Use the General Equipment: Hose Clamp Remover/Installer

Click to resize E149109

  1. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).

Click to resize E158748

  1. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).

Click to resize E159343

  1. Refer to: Quick Release Coupling (310-00B Fuel System - General Information - 1.4L Duratec-16V (66kW/90PS), General Procedures).

Click to resize E159344

  1.  
    1. Torque: 25 Nm
    1. Torque: 10 Nm

Click to resize E145017

  1.  
    1. Torque: 12 Nm

    1. 3. cautionNOTICE: Take extra care when handling the component terminals.

Click to resize E159659

  1. Torque: 15 Nm

Click to resize E149077

  1. Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
  1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling - 1.6L Duratec-16V Ti-VCT (77kW/105PS) – Sigma, General Procedures).
  1. Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission - 6-Speed PowerShift Transmission – DPS6/6DCT250, General Procedures).

Leave a Reply

Your email address will not be published. Required fields are marked *