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Water Pump Removal 1. Drain the cooling system. Refer to Section 03-03. 2. Disconnect the battery ground cable (14301) . 3. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 4. Raise and support the vehicle. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts. 6. Remove the water pump pulley from the water pump (8501) . 7. Remove the crankshaft pulley (6312) . Refer to the procedure in this section 8. Remove the five lower engine front cover bolts and the lower engine front cover (6019) . NOTE: Make a note of the location of the one water pump bolt with the threads in the bolt head for ease of installation. 9. Remove the six water pump bolts. 10. Remove the water pump . Installation NOTE: Ensure the mating surfaces between the water pump and the cylinder block (6010) are cleaned of any sealant material. 1. Install a continuous 2.0-3.0mm (0.079-0.118 inch) wide bead of Gasket Maker E2AZ-19562-B or equivalent meeting Ford specification WSK-M2G348-A5, on the water pump and position the water pump on the cylinder block . NOTE: Refer to the note made during removal for the location of the bolt with the threads in the bolt head. 2. Install the six water pump bolts. Tighten the water pump bolts to 16-21 Nm (12-15 lb-ft). 3. Install the crankshaft pulley . Refer to the procedure in this section. 4. Position the water pump pulley on the water pump and install the four water pump pulley bolts. 5. Use Strap Wrench D85L-6000-A or equivalent to hold the water pump pulley , and tighten the four water pump pulley bolts to 16-21 Nm (12-15 lb-ft). 6. Install the lower engine front cover and the five lower engine front cover bolts. Tighten the five lower engine front cover bolts to 3-5 Nm (27-44 lb-in). 7. Lower the vehicle. 8. Install and adjust the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05. 9. Connect the battery ground cable . 10. Fill the cooling system. Refer to Section 03-03. 11. Start the engine (6007) and check for leaks.

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Power Steering Gear Special tools, testers and auxiliary items required Hose clamps up to 25 mm dia. 3094 Torque wrench V.A.G 1331 Torque wrench V.A.G 1332 Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2 Notes for repair work on power steering gear All work on the power steering must be carried out with utmost cleanliness. Thoroughly clean all connections and the surrounding area before disconnecting. If repairs will not be carried out immediately, place removed parts onto a clean surface and cover. Only use lint-free cloths. Only unpack replacement parts immediately prior to installation. Only use parts in their original packing. Removing Remove bolts – 1 – . Remove cover – A – . Remove bolt – 1 – from universal joint. Remove universal joint from steering gear. Clamp off hose from reservoir using hose clamps up to 25 mm dia. 3094 . Clamp off hose on power steering pump using hose clamps up to 25 mm dia. 3094 . Remove sound-deadening pan. Place drip tray underneath. . Press off tie rod from steering knuckle. A – Tie rod puller (standard), e.g. Kukko 128/2 Remove hose lines at steering gear and plug using a plastic bag and tape. Seal threaded holes on power steering gear using plastic screw plugs – 1 – and – 2 – . Remove bolts – 1 – and – 2 – . With TDI Engines Remove bracket for front exhaust pipe at subframe – arrows – and disengage. Continuation for All Support subframe using engine/transmission jack V.A.G 1383 A . Loosen bolts – 1 – . Remove bolts – 2 – and – 3 – . Lower subframe using engine/transmission jack V.A.G 1383 A . Remove bolts – 1 – for power steering gear. Remove power steering gear toward right. Installing Note: . Use new O-rings for hose/line connections. Coat seal on steering gear with lubricant, e.g. lubricating soap, before installing steering gear. After placing steering gear on to universal joint shaft, make sure that seal on steering gear makes contact on assembly plate without kinks and opening to footwell is correctly sealed. Ingress of water and/or noises may result otherwise. Make sure sealing surfaces are clean.

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TIMING BELT Removal 1. Disconnect negative battery cable. Remove upper engine torque strut attaching bolts and remove engine torque strut. See Fig. 5 . Remove engine torque strut bracket from strut tower. On PT Cruiser (Turbo), discharge and evacuate A/C system. Disconnect A/C lines at junction block near upper timing belt cover. 2. On all models, remove upper timing belt cover bolts and remove cover. See Fig. 6 . Raise vehicle on hoist and remove right front wheel. Remove splash shield. See Fig. 7 . Remove accessory drive belts. Remove crankshaft damper. See Fig. 8 . Remove pencil strut. See Fig. 2 . Remove lower engine torque strut. See Fig. 5 . 3. Disconnect exhaust system front pipe from manifold. Disconnect A/C pressure switch at rear of compressor housing. Lower vehicle and support engine with a jack. If not done previously, discharge and evacuate A/C system. Disconnect A/C lines at junction block. Remove screw attaching ground strap to strut bracket. Remove torque strut bracket from strut tower. Remove upper radiator closure panel. Without disconnecting lines from power steering pump, remove pump and bracket and set pump aside. 4. With engine properly supported, remove right engine mount through-bolt. See Fig. 5 . Raise engine with jack until engine support bracket bolts are accessible, and remove engine support bracket. See Fig. 9 . Remove lower timing belt cover bolts and remove cover. See Fig. 6 . CAUTION: When aligning crankshaft and camshaft timing marks, always rotate engine from crankshaft. Camshaft should not be rotated after timing belt is removed, or damage to valve components may occur. CAUTION: Crankshaft sprocket TDC mark is located on the trailing edge of sprocket tooth. Failure to align trailing edge of sprocket tooth to TDC mark on oil pump housing will cause camshaft timing marks to be misaligned. 5. Before removal of timing belt, rotate crankshaft until TDC mark on oil pump housing aligns with the TDC mark on crankshaft sprocket (trailing edge of sprocket tooth). See Fig. 10 . 6. Loosen timing belt tensioner lock bolt, and insert a 6-mm Allen wrench into hexagon opening located on top plate of belt tensioner pulley. See Fig. 11 . Rotate top plate clockwise until there is enough slack in timing belt to allow for removal. If reusing old timing belt, mark belt with arrow to indicate original direction of rotation. Remove timing belt. CAUTION: If timing belt was damaged due to incorrect rotating tracking (alignment), belt tensioner pulley and bracket must be replaced as an assembly.

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Crankshaft front seal replacement is recommended whenever the engine front cover (6019) has been removed. 1. Disconnect battery ground cable (14301). Drain crankcase. 2. Drain cooling system. Refer to Section 03-03. 3. Remove drive belts (8620). Refer to Section 03-05. 4. Remove bolts attaching fan shroud (8146) to radiator (8005). 5. Remove fan blade (8600) from fan clutch (8A616) and remove fan shroud. 6. Remove fan clutch and water pump pulley (8509) from water pump (8501). 7. Disconnect upper radiator hose (8260) and lower radiator hose (8286) at engine (6007). Disconnect transmission oil cooler lines at radiator. 8. Remove upper radiator support bracket and remove radiator. 9. Remove generator pivot and attaching bolts. Remove generator (GEN) (10300) from generator mounting bracket (10153) and generator adjusting arm (10145). 10. Remove two bolts attaching generator adjusting arm to water pump and generator mounting bracket and remove generator adjusting arm. 11. Remove air pump pivot and attaching bolts. Remove secondary air injection pump (AIR pump) (9A486) from generator mounting bracket. 12. Remove four bolts attaching generator mounting bracket to cylinder head (6049), cylinder blocks (6010) and water pump, and remove generator mounting bracket. 13. Remove power steering pump pulley (3A733) from power steering pump (3A674). 14. Remove power steering lines from power steering pump. Remove four bolts attaching power steering pump to A/C compressor mounting bracket (2882) and remove power steering pump from A/C compressor mounting bracket. 15. Remove four bolts attaching A/C compressor (19703) to A/C compressor mounting bracket. Remove four bolts and one nut attaching A/C compressor mounting bracket to cylinder head and water pump. Remove A/C compressor mounting bracket from engine. 16. Remove the crankshaft pulley (6312) from the crankshaft vibration damper (6316). 17. Remove bolt and washer attaching crankshaft vibration damper. Remove crankshaft vibration damper using Crankshaft Damper Remover T58P-6316-D or Rotunda Gear and Pulley Puller 014-00293 or equivalent. Remove Woodruff key and crankshaft damper spacer from crankshaft (6303).

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Removal and Installation 1. Rotate the tensioner clockwise and remove the belt from the power steering pump pulley. 2. Loosen the fitting and disconnect the power steering pressure hose. 3. Disconnect the electrical connector. 4. Disconnect the power steering return line. 5. Using the special tool, remove the power steering pump pulley. 6. Remove the power steering pump mounting bolts and the pump. 7. To install, reverse the removal procedure. 8. NOTE: The pulley must be installed within 0.25 mm (0.010 in) flush with the power steering pump shaft. Using the special tool, install the power steering pump pulley. 9. Using the special tool, install a new seal on the power steering pressure hose fitting. 10. Fill and leak check the system. For additional information, refer to Section 211-00.