B-MAX 2012 – Engine – 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU) – Cylinder Head – Removal and Installation

Engine - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU) - Cylinder HeadB-MAX 2012.75 (01/2012-)
Removal and Installation

General Equipment
Plastic Scraper
Materials
NameSpecification
????? H-BW
CU7J-BNDRT-AA
-
RTV Silicone Sealant
WSE-M4G323-A6
Engine Oil - 0W-30
WSS-M2C950-A

Removal

  1. Refer to: Diesel Fuel System Health and Safety Precautions (100-00 General Information, Description and Operation).
    Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
    Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
    Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03D Engine Cooling - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Refer to: Diesel Particulate Filter (DPF) (309-00E Exhaust System - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), Removal and Installation).
  1. Refer to: Air Cleaner (303-12E Intake Air Distribution and Filtering - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), Removal and Installation).
  1. NOTE: Be prepared to collect escaping fluid.

    NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.

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  1. NOTE: Be prepared to collect escaping fluid.

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  1. NOTE: Be prepared to collect escaping fluid.

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. NOTICE:

    caution Make sure that all openings are sealed with clean blanking caps.

    caution Extreme cleanliness must be exercised when handling the components.

    caution Use an open-ended wrench to prevent the component from turning.

    caution Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned.

    caution Use suitable paper to absorb any escaping fluid.

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  1. NOTE: Note the position of the components before removal.

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Refer to: Timing Belt (303-01F Engine - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), Removal and Installation).

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  1. NOTE: Be prepared to collect escaping fluid.

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  1. NOTE: Note the position of the components before removal.

    NOTE: Use a new seal.

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  1. NOTE: Note the position of the components before removal.

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Installation

  1. NOTE: Make sure that a new component is installed.

    Determine the cylinder head gasket.
    Refer to: Specifications (303-01G Engine - 1.6L Duratorq-TDCi (70kW/95PS) (T3), Specifications).

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  1. NOTICE:

    caution Make sure that no fluids are present in the cylinder head bolt threaded bores.

    caution Take extra care not to damage the mating faces.

    caution Make sure that new bolts are installed.

    caution Make sure that the mating faces are clean and free of foreign material.

    Torque:
    Stage 1:
    20 Nm
    Stage 2:
    40 Nm
    Stage 3:
    260°

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

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

    NOTE: Use new seals.

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  1. NOTE: Use new seals.

    NOTE: Make sure that a new component is installed.

    Torque: 30 Nm

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  1. NOTE: Make sure that the mating faces are clean and free of foreign material.

    1. Use the General Equipment: Plastic Scraper

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  1. NOTE: Make sure that the mating faces are clean and free of foreign material.

    NOTE: The component must be installed within 5 minutes of applying the sealant.

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  1. Torque: 10 Nm

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  1. Refer to: Timing Belt (303-01F Engine - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), Removal and Installation).
  1. Torque: 20 Nm

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  1. Torque:
    1: 13 Nm
    2: 8 Nm

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Torque: 8 Nm

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  1. Torque:
    10 Nm
    14 Nm
    10 Nm
    10 Nm

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  1. Torque: 10 Nm

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).
    Torque: 8 Nm

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  1. Torque: 14 Nm

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  1. Torque: 5 Nm

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  1. NOTE: Make sure that a new component is installed.

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  1. NOTE: Make sure that the components are installed to the position noted before removal.

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  1. NOTE: Make sure that new bolts are installed.

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

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  1. Torque:

    Stage 1:
    7 Nm
    Stage 2:
    85°

    Stage 1:
    7 Nm
    Stage 2:
    80°

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  1. NOTICE:

    caution Extreme cleanliness must be exercised when handling the components.

    caution Use an open-ended wrench to prevent the component from turning.

    caution Make sure that the fuel line remains in contact at both ends until both unions nuts have been unscrewed and the area around the joints thoroughly cleaned.

    caution Use suitable paper to absorb any escaping fluid.

    NOTE: Make sure that new components are installed.

    1. Torque:
      Stage 1:
      20 Nm
      Stage 2:
      25 Nm

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Torque: 20 Nm

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  1. NOTE: Make sure that a new O-ring seal is installed.

    NOTE: Make sure that a new oil filter is installed.

    NOTE: Make sure that the component is clean, free of foreign material and lubricant.

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  1. Torque: 7 Nm

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  1. Torque:
    8 Nm
    8 Nm
    20 Nm

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  1. Torque:
    8 Nm
    8 Nm

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  1. Torque:
    25 Nm
    25 Nm

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  1. NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.

    Torque: 35 Nm

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  1. Refer to: Air Cleaner (303-12E Intake Air Distribution and Filtering - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), Removal and Installation).
  1. Refer to: Diesel Particulate Filter (DPF) (309-00E Exhaust System - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), Removal and Installation).
  1. Torque: 8 Nm

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  1. Refer to: Quick Release Coupling (310-00E Fuel System - General Information - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).

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  1. Torque:
    10 Nm
    10 Nm

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  1. cautionNOTICE: Make sure that the engine oil is to specification.

    NOTE: Make sure that fluid level is to the MAX mark.

    Refer to: Specifications (303-01G Engine - 1.6L Duratorq-TDCi (70kW/95PS) (T3), Specifications).

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  1. Refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
    Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03D Engine Cooling - 1.5L Duratorq-TDCi (55kW/75PS), General Procedures).
    Refer to: Fuel System Bleeding (310-00F Fuel System - General Information - 1.5L Duratorq-TDCi (70kW/95PS)/1.5L Duratorq-TDCi (55kW/75PS) (XU), General Procedures).

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