B-MAX 2012 – Engine – 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) – Engine5-Speed Manual Transmission B5/IB5 – Installation

Engine - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine—5-Speed Manual Transmission – B5/IB5

B-MAX 2012.75 (01/2012-)

Installation

Special Tool(s) / General Equipment

	204-609 Protection Cap, Ball Joint Gaiter
	205-775 Protector, Halfshaft Seal
	303-122 Lifting Bracket, Engine
Cable Ties
Floor Crane
Hose Clamp Remover/Installer
Lower Arm Down Force Lever
Mounting Table Set
Retaining Strap
Wooden Block

Materials

Name	Specification
?????? K-HT A88S-X1C220-AA	ESD-M1C220-A
?????? KS-PS YS5J-M1C9107-AA	SA-M1C9107-A

Install Special Service Tool: 303-122.
Use the General Equipment: Floor Crane

Apply a thin coating.
Material: ESD-M1C220-A (?????? K-HT / A88S-X1C220-AA)

Torque: 48 Nm

Torque: 48 Nm

Torque: 48 Nm

1. Torque: 25 Nm

Torque:
1 6 Nm
2 12 Nm
3 35 Nm

1. Torque: 48 Nm
1. Torque: 35 Nm

WARNING: Make sure that the engine and transmission assembly is on wooden blocks and secured with suitable retaining straps.
Use the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap

Remove Special Service Tool: 303-122.

NOTICE: Make sure that no components catch.
Lower the vehicle.
Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).

NOTICE: Make sure that a new bolt is installed.
Torque: 80 Nm

Torque: 10 Nm

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.

Remove the following items:
- Use the General Equipments: Mounting Table Set, Wooden Block, Retaining Strap

NOTICE:
The outer constant velocity (CV) joint must not be bent more than 45°.
The inner constant velocity (CV) joint must not be bent more than 18°.
Make sure that the strut is not moved more than necessary to prevent damage to top mount.
Take extra care not to damage the edges of the component.
Take extra care not to damage the mating faces.
Take extra care not to damage the seal.
Install Special Service Tool: 205-775.

NOTICE: Take extra care not to damage the seal.
Remove Special Service Tool: 205-775.

1. 1. NOTICE:
  The outer constant velocity (CV) joint must not be bent more than 45°.
  The inner constant velocity (CV) joint must not be bent more than 18°.
  Make sure that the strut is not moved more than necessary to prevent damage to top mount.
1. NOTE: Make sure that a new component is installed.
1. 3. NOTICE: Make sure that new nuts are installed.
  Torque:
  Stage 1:
  6 Nm
  Stage 2:
  25 Nm

Remove Special Service Tool: 204-609.

Use the General Equipment: Lower Arm Down Force Lever

WARNINGS:
Make sure that a new bolt is installed.
Make sure that a new nut is installed.
Torque: 52 Nm

Torque: 28 Nm

Refer to: Transmission Fluid Level Check (308-03 Manual Transmission - 5-Speed Manual Transmission – B5/IB5, General Procedures).
Refer to: Transmission Fluid Level Check (307-01 Automatic Transmission - 6-Speed PowerShift Transmission – DPS6/6DCT250, General Procedures).

If equipped.

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

Refer to: Front Halfshaft LH - 5-Speed Manual Transmission – B5/IB5/6-Speed PowerShift Transmission – DPS6/6DCT250 (205-04 Front Drive Halfshafts, Removal and Installation).

NOTE: Note the different lengths of the bolts.
NOTE: Install all the bolts finger tight before final tightening.
Torque:
1 70 Nm
2 63 Nm

Refer to: Transmission Fluid Level Check (308-03 Manual Transmission - 5-Speed Manual Transmission – B5/IB5, General Procedures).

Torque: 10 Nm

NOTICE: Make sure that the exhaust flexible pipe is not forcibly bent or twisted.
1. Apply a thin coating.
  Material: SA-M1C9107-A (?????? KS-PS / YS5J-M1C9107-AA)
1. Torque: 48 Nm

Remove the following items:
1. Use the General Equipment: Cable Ties

Vehicles without air conditioning

Torque: 25 Nm

All vehicles

Refer to: Generator (414-02A Generator and Regulator - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), Removal and Installation).

Refer to: Gearshift Cable Adjustment (308-00 Manual Transmission and Clutch - General Information, General Procedures).

If equipped.

1. If equipped.

1. If equipped.

Use the General Equipment: Hose Clamp Remover/Installer

Refer to: Clutch System Bleeding (308-00 Manual Transmission and Clutch - General Information, General Procedures).

Torque: 25 Nm

Torque:
3 11 Nm

Torque: 25 Nm

Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).

1. Torque: 10 Nm
1. Torque: 12 Nm

Torque: 48 Nm

Torque: 15 Nm

Use the General Equipment: Hose Clamp Remover/Installer

Use the General Equipment: Hose Clamp Remover/Installer
Torque:
1 11 Nm

Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY), General Procedures).

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