| 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 | | -
Location of the engine upper cover retaining clips. | | | -
CAUTION:Care must be taken when releasing the fourth retaining clip and maneuvering the engine upper cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor. NOTE:Only remove and install the engine upper cover in the sequence shown. Remove the engine upper cover. | | | -
Detach the brake fluid reservoir from the bulkhead extension panel. | | | -
Remove the windshield wiper arms. | | | -
Remove the cowl panel. - 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. | | | -
Drain the cooling system.
For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, General Procedures).
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Loosen the coolant pump pulley retaining bolts (engine shown removed for clarity). | | | -
Remove the accessory drive belt.
For additional information, refer to: Accessory Drive Belt - 1.8L Duratorq-TDCi (Lynx) Diesel (303-05 Accessory Drive, Removal and Installation).
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Install the special tools. | | | -
Detach the coolant expansion tank and secure it to one side. | 13. Remove the components in the order indicated in the following illustration(s) and table(s). 1 - Manifold absolute pressure (MAP) sensor electrical connector 6 - Charge air cooler outlet pipe support bracket retaining nut 7 - Charge air cooler outlet pipe support bracket 9 - Engine front mounting bracket retaining nuts 10 - Engine front mounting bracket retaining bolts 11 - Engine front mounting bracket 14 - Engine front mounting retaining bolts 18 - Coolant pump retaining bolts 14. To install, reverse the removal procedure. Removal Details Item 2 : Charge air cooler outlet pipe retaining clamp NOTE:Make a note of the orientation of the retaining clamp. Item 3 : Charge air cooler outlet pipe to intake manifold retaining clamp NOTE:Make a note of the orientation of the retaining clamp. Item 5 : Fuel supply and fuel return line front retaining clip | | -
Detach the fuel supply and fuel return line front retaining clip from the stud. | Item 8 : Fuel supply and fuel return line rear retaining clip | | -
Detach the fuel supply and fuel return line rear retaining clip from the stud. | Item 17 : Coolant pump upper retaining bolt | | -
Fabricate a piece of laminated card. - Fold the laminated card in two along its length.
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CAUTION:The fabricated piece of laminated card must be installed before removing the coolant pump upper retaining bolt. 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.
| Item 19 : Coolant pump NOTE:Discard the coolant pump gasket. Installation Details Item 19 : Coolant pump NOTE:Install a new coolant pump gasket. Item 17 : Coolant pump upper retaining bolt NOTE: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. | | -
Remove the piece of laminated card after the installation of the coolant pump upper retaining bolt. | Item 12 : Coolant pump pulley retaining bolts | | -
Do not fully tighten the coolant pump pulley retaining bolts at this stage. | Item 4 : Charge air cooler outlet pipe CAUTION:Make sure that the insides of the charge air cooler outlet ends are clean and free from any oil residue as this will reduce the installation grip of the pipes to the charge air cooler and intake manifold. Failure to follow this instruction may result in damage to the engine. Item 3 : Charge air cooler outlet pipe to intake manifold retaining clamp NOTE:Make sure the retaining clamp is in the same orientation as when removed. Item 2 : Charge air cooler outlet pipe retaining clamp NOTE:Make sure the retaining clamp is in the same orientation as when removed. | 
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