| Removal and Installation Special Tool(s) | | Support Bar, Engine 303-290A (21-140A) | | | Adapter for 303-290A 303-290-01 (21-140-01) | | | Adapter for 303-290A 303-290-02 (21-140-02) | | | Adapter for 303-290A 303-290-03A (21-140-03A) | General Equipment Removal All vehicles | | -
Disconnect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
| | | -
Detach the coolant expansion tank and position it to one side. | | | -
Remove the air deflector. | | | -
NOTE:Make a note of the orientation of the charge air cooler intake hose retaining clamp. Disconnect the charge air cooler intake hose. - Discard the charge air cooler intake hose retaining clamp.
| | | -
NOTE:Make a note of the orientation of the charge air cooler outlet hose retaining clamp. Disconnect the charge air cooler outlet hose and the intake air temperature (IAT) sensor electrical connector. - Discard the charge air cooler outlet hose retaining clamp.
| | | -
Remove the charge air cooler. | | | -
Detach the power steering pipe retaining bracket from the cylinder head. | | | -
Install the special tools. | Vehicles built up to 04/2001 | | -
Remove the engine front mount. | Vehicles built 04/2001 onwards | | -
Remove the engine front mount. | All vehicles | | -
Loosen the coolant pump pulley retaining bolts. | | | -
Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 1.8L Diesel (303-05 Accessory Drive, Removal and Installation).
| | | -
Remove the engine front mount retaining stud. | | | -
Remove the timing belt cover. | | | -
Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
| | | -
Remove the engine mounting bracket. | | | -
Remove the water pump pulley. | | | -
Fabricate a piece of laminated card. - Fold the laminated card in two along its length.
| CAUTION:The fabricated piece of laminated card must be positioned on the timing belt before the coolant pump upper retaining bolt is removed. Failure to follow this instruction may result in damage to the timing belt. | | -
Install the fabricated piece of laminated card between the timing belt and the coolant pump upper retaining bolt. - Using the fabricated piece of laminated card to protect the timing belt, remove the coolant pump upper retaining bolt.
| | | -
NOTE:The engine will need to be raised using the special tool 21-140 to allow removal of the water pump. Remove the water pump. | | | -
Remove and discard the water pump gasket. | Installation All vehicles | | -
CAUTION:Make sure the fabricated piece of laminated card is correctly positioned between the timing belt and coolant pump before installing the coolant pump upper retaining bolt. NOTE:Install a new coolant pump gasket. NOTE:Install the water pump onto the dowels before installing the retaining bolts. Install the coolant pump. | | | -
Remove the piece of laminated card. | | | -
Install the coolant pump pulley. - Install the coolant pump pulley retaining bolts hand tight.
| | | -
Install the engine mounting bracket. | | | -
Install the timing belt cover. | | | -
Install the engine front mount retaining stud. | | | -
Install the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 1.8L Diesel (303-05 Accessory Drive, Removal and Installation).
| | | -
Tighten the coolant pump pulley retaining bolts. | | | -
Using the special tool 21-140, lower the engine. | Vehicles built up to 04/2001 | | -
Install the engine front mount. | Vehicles built 04/2001 onwards | | -
Install the engine front mount. | All vehicles | | -
Remove the special tools. | | | -
Install the power steering pipe retaining bracket. | | | -
Install the charge air cooler. | | | -
NOTE:Install a new charge air cooler outlet hose retaining clamp. NOTE:Make sure the charge air cooler outlet hose retaining clamp is in the same orientation as when removed. Connect the charge air cooler outlet hose and the IAT sensor electrical connector. | | | -
NOTE:Install a new charge air cooler inlet hose retaining clamp. NOTE:Make sure the charge air cooler inlet hose retaining clamp is in the same orientation as when removed. Connect the charge air cooler intake hose. | | | -
Install the air deflector. | | | -
Install the coolant expansion tank. | | | -
Connect the battery ground cable.
For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
| | | -
Refill and bleed the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
| | | -
Initialize the door window motors.
For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).
| |
