Removal and Installation Special Tool(s) | Remover/Installer, Cooling Hose Clamp 303-397 (24-003) | | -
Drain the cooling system. For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03D Engine Cooling - 1.6L Duratorq-TDCi (DV) Diesel, General Procedures). | | -
NOTE:Make sure that the windshield wiper motor is in the park position. Disconnect the battery ground cable. For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures). | | -
Remove the engine upper cover. | | -
Detach the brake fluid reservoir from the bulkhead extension panel. | | -
Remove the windshield wiper arms. | | -
Remove the cowl panel grille. - Detach the cowl panel grille retaining clips.
- Detach the cowl panel grille from the windshield glass lower weatherstrip and remove.
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Remove the bulkhead extension panel. - Remove the bulkhead extension panel retaining screws.
- Detach the bulkhead exstension panel retaning clips.
| 8. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Fuel injector harness retaining bolts 2 - Fuel injector electrical connectors 4 - Coolant bypass tube to EGR cooler coolant hose 6 - Heater core to EGR cooler coolant hose 7 - Glow plug wire support bracket 10 - EGR tube retaining bolts 9. To install, reverse the removal procedure. | -
Vehicles with global closing, initialize the door window motors. For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures). | Removal Details Item 3 : Coolant bypass tube to EGR cooler coolant hose retaining clamp | -
Using the special tool, detach the coolant bypass tube to EGR cooler coolant hose retaining clamp. | Item 5 : Heater core to EGR cooler coolant hose retaining clamp | -
Using the special tool, detach the heater core to EGR cooler coolant hose retaining clamp. | Item 8 : EGR cooler to EGR tube retaining clamp | -
Make a note of the position of the EGR cooler retaining clamp before removal. | Item 9 : EGR cooler to EGR tube retaining clamp | -
Make a note of the position of the EGR cooler to EGR tube clamp before removal. | Installation Details Item 9 : EGR cooler to EGR tube retaining clamp | -
Install the EGR cooler to EGR tube clamp in the same position as when removed. | Item 8 : EGR cooler to EGR tube retaining clamp | -
Install the EGR cooler retaining clamp in the same position as when removed. | |