Try updating your part in the schematic; it sound like it is out of date from the changes you made in the library.
FWIW - I define a CAP_0402 part and a CAP_0603 part to avoid issues in the design (sch and pcb can get out of sync; library update may change back to the default part, etc.). If your engineer can't provide a proper size to the layout designer then he hasn't provided enough information. I know because I'm the engineer and the designer!