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 Head

B-MAX 2012.75 (01/2012-)

Removal and Installation

General Equipment

Plastic Scraper

Materials

Name	Specification
????? H-BW CU7J-BNDRT-AA	-
RTV Silicone Sealant	WSE-M4G323-A6
Engine Oil - 0W-30	WSS-M2C950-A

Removal

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).

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

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).

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).

NOTE: Be prepared to collect escaping fluid.
NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.

NOTE: Be prepared to collect escaping fluid.

NOTE: Be prepared to collect escaping fluid.

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

NOTICE:
Make sure that all openings are sealed with clean blanking caps.
Extreme cleanliness must be exercised when handling the components.
Use an open-ended wrench to prevent the component from turning.
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.
Use suitable paper to absorb any escaping fluid.

NOTE: Note the position of the components before removal.

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

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

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

NOTE: Be prepared to collect escaping fluid.

NOTE: Note the position of the components before removal.
NOTE: Use a new seal.

NOTE: Note the position of the components before removal.

Installation

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).

NOTICE:
Make sure that no fluids are present in the cylinder head bolt threaded bores.
Take extra care not to damage the mating faces.
Make sure that new bolts are installed.
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°

NOTE: Make sure that the component is installed to the position noted before removal.
Material: WSS-M2C950-A (Engine Oil - 0W-30)

NOTE: Make sure that the component is installed to the position noted before removal.
NOTE: Use new seals.
Material: WSS-M2C950-A (Engine Oil - 0W-30)

NOTE: Use new seals.
NOTE: Make sure that a new component is installed.
Torque: 30 Nm

NOTE: Make sure that the mating faces are clean and free of foreign material.
1. Use the General Equipment: Plastic Scraper
1. Material: - (????? H-BW / CU7J-BNDRT-AA)

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.
Material: WSE-M4G323-A6 (RTV Silicone Sealant)

Torque: 10 Nm

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

Torque: 20 Nm

Torque:
1: 13 Nm
2: 8 Nm

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

Torque: 8 Nm

Torque:
1 10 Nm
2 14 Nm
3 10 Nm
4 10 Nm

Torque: 10 Nm

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

Torque: 14 Nm

Torque: 5 Nm

NOTE: Make sure that a new component is installed.

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

NOTE: Make sure that new bolts are installed.
NOTE: Only tighten the bolts finger tight at this stage.

Torque:
1
Stage 1:
7 Nm
Stage 2:
85°
2
Stage 1:
7 Nm
Stage 2:
80°

NOTICE:
Extreme cleanliness must be exercised when handling the components.
Use an open-ended wrench to prevent the component from turning.
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.
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

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

Torque: 20 Nm

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.

Torque: 7 Nm

Torque:
1 8 Nm
2 8 Nm
3 20 Nm

Torque:
1 8 Nm
2 8 Nm

Torque:
1 25 Nm
2 25 Nm

NOTE: The oil drain plug with O-ring seal is to be reused unless damaged.
Torque: 35 Nm

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).

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).

Torque: 8 Nm

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

Torque:
1 10 Nm
2 10 Nm

NOTICE: 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).

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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