3239062 - 1004E10 engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal

 Refer to op.. 1004D40  engine - position on stand and removeSupport the engine on the overhauling stand using suitable tools.1. Disconnect the earth cable from the left cylinder head tappet cover.2. Disconnect the electrical connection of the motorized throttle body actuator.

	Name	Connector
2	Throttle body actuator	N75

1. Disconnect the oil vapour recovery pipe.2. Disconnect the condensation oil return pipe from the separator. Slacken the bolts on the clips securing the air intake ducts to the intake chamber.1. Undo the bolts (1a) and remove the complete intake duct (1b). 1. Disconnect the electrical connection for the cam angle sensor E (light blue).

	Name	Connector
1	Timing sensor	K47

2. Disconnect the electrical connection for the engine rpm and timng sensor (black).

	Name	Connector
2	Rpm sensor	K46

3. Disconnect the electrical connection for the rear detonation sensor (black).

	Name	Connector
3	Detonation sensor - 1	K50

4. Disconnect the electrical connection from the combined sender unit for the engine coolant temperature gauge and warning light.

	Name	Connector
4	Coolant temperature sender unit	K35

5. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
5	Engine temperature sensor	K45

6. Disconnect the earth cable from the left cylinder head tappet cover. 1. Undo the bolts (1a) and remove the left cylinder head ignition coils cover (1b). 1. Disconnect the electrical connection for the air conditioning compressor. 1. Disconnect the electrical connection for the front detonation sensor.

	Name	Connector
1	Knock sensor - 2	K51

2. Undo the bolts (2a) and remove the electrical wiring securing brackets (2b).3. Disconnect the electrical connections from the injectors.

	Name	Connector
3	Injector	N70

4. Disconnect the electrical connections from the ignition coils.

	Name	Connector
4	Ignition coil	A30

5. Remove the electrical wiring after releasing it from the securing bands. 1. Loosen the engine components drive belt tension by adjusting the belt tensioner.2. Lock the belt tensioner with the belt slack inserting a suitable peg.3. Remove the engine components single drive belt. 1. Undo the bolts (1a) and remove the timing belt guards (1b).2. Undo the bolt joining the timing belt rear guards. 1. Slacken the timing belt tensioner bolts.2. Remove the timing belt from the camshaft pulleys. 1. Disconnect the flexible pipe from the fuel distribution manifold rigid pipe.2. Undo the bolts (2a) and remove the bracket (2b) securing the timing belt guard. 1. Undo the bolts (1a) and remove the ignition coils (1b) from the cylinder heads.

	Name	Connector
1	Ignition coil	A30

1. Disconnect, from the thermostat, the coolant supply pipe to the water/oil heat exchanger.2. Undo the bolts (2a) and remove the thermostat (2b). 1. Undo the upper bolt (1a), the lower nut (1b) and remove the engine oil dipstick (1c).2. Undo the nuts (2a) and remove the protection (2b) for the left cylinder head exhaust manifold.Undo the nuts (3a) and remove the exhaust manifolds (3b) from the cylinder heads. 1. Undo the bolt securing the alternator bracket to the right cylinder head.2. Remove the bolt securing the power steering pump to the left cylinder head.3. Undo the bolts (3a) and remove the tappet covers (3b).4. Undo the nuts (4a) and remove the cylinder heads (4b).5. Remove the cylinder head gaskets. 1. Fit the tools.

	Name	Country
1	Liner/bore holder	1.820.279.000

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b) from the engine sump.2. Undo the bolts (2a) and remove the rpm and timing sensor (2b) E from the crankcase sump.

	Name	Connector
2	Rpm sensor	K46

Undo the bolts (3a) and remove the engine sump. (3b).To release the sump, tap it gently with a wooden or resin hammer, then use a screwdriver to lever against the specific projections on the sides of the sump. Proceed with the removal  Refer to op.. 1004D40  engine - position on stand and remove . 1. Open the cover of the electrical connection box. 2. Disconnect the electrical connection for the knock sensor timing side.

	Name	Connector
2	Detonation sensor - 1	K50

1. Loosen the bands fixing the inlet ducts to the air chamber.2. Loosen the band fastening the engine oil vapour recovery pipe to the air chamber.3. Disconnect the electrical connection from the throttle casing integrated with the D.V.L.

	Name	Connector
3	Throttle body actuator	N75

1. Undo the bolt (1a) and disconnect the earth lead (1b) from the air capacity chamber.

	Name	Connector
1b	Earth on engine	C40

2. Undo the bolt fixing the reinforcement strut to the support on the engine for the reaction rod.3. Undo the bolts (3a) and remove the air chamber assembly (3b). 1. Undo the bolts (1a) and remove the intake pipes (1b) complete with hoses (1c).2. Remove the gaskets. 1. Disconnect the electrical connections from the right cylinder head injectors.

	Name	Connector
1	Injector	N70

2. Disconnect the electrical connections from the right cylinder head ignition coils.

	Name	Connector
2	Ignition coil	A30

3. Undo the bolts (3a) and move aside the electrical wiring (3b). 1. Undo the bolt (1a) and release the cam angle sensor (1b) from its housing.

Take care not to damage the cam angle sensor.

1. Undo the bolts (1a) and remove the ignition coils (1b) from the right cylinder head. 1. Disconnect the electrical connection from the coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

2. Open the cover of the electrical connection box. 3. Release the electrical connections and the wiring from the connector box. 1. Undo the bolts (1a) and remove the thermostat (1b) complete with connector box (1c). 2. Remove the adaptor. 1. Disconnect the electrical connection for the knock sensor flywheel side.

	Name	Connector
1	Knock sensor - 2	K51

2. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
2	Rpm sensor	K46

1. Undo nut (1a) and disconnect earth lead (1b) from the left cylinder head.

	Name	Connector
1b	Earth on engine	C40

1. Undo the bolts (1a) and remove the left cylinder head ignition coils cover (1b). 1. Disconnect the electrical connections from the left cylinder head injectors.

	Name	Connector
1	Injector	N70

2. Disconnect the electrical connections from the left cylinder head ignition coils.

	Name	Connector
2	Ignition coil	A30

3. Undo the bolts (3a) and move the electrical wiring (3b) aside.4. Remove the engine wiring. 1. Undo the bolts (1a) and remove the ignition coils (1b) from the left cylinder head. 1. Disconnect the rapid connector for the fuel manifold pipes. 1. Undo the bolts (1a) and remove the upper protective timing cover (1b). 1. Undo the bolts (1a) and remove the lower protective timing covers (1b). 1. Loosen the bolts fixing the timing belt moving tensioner.2. Release the timing drive belt from the driven pullies. 1. Undo the bolt fixing the left rear timing belt protective cover to the right cylinder head. 1. Undo the bolts (1a), the bolt (1b) and remove the bracket (1c). 1. Undo the bolt fixing the power assisted steering pump. 1. Undo the bolts (1a) and remove the tappet cover for the left cylinder head (1b), complete with gasket. 1. Undo the bolts (1a) fixing the driven pullies using the tool (1b) for counter-torque.

	Name	Country
1b	Counter-torque	1.822.146.000

1. Remove the driven pullies (1a) using the tool (1b).

	Name	Country
1b	Extractor	1.860.954.001

1. Undo the bolts (1a) and remove the timing belt fixed tensioners (1b).2. Undo the bolts (2a) and remove the left rear protective timing cover (2b). 1. Undo the nuts (1a) fixing the left cylinder head using the tool (1b).

	Name	Country
1b	Spanner	1.822.121.000

Remove the left cylinder head and gasket. 1. Undo the bolts (1a) and remove the right rear protective timing cover (1b). 1. Undo the bolts (1a) and remove the right cylinder head tappet cover (1b), complete with gasket. 1. Undo the bolts (1a) and remove the alternator bracket (1b). 1. Undo the nuts (1a) fixing the right cylinder head using the tool (1b).

	Name	Country
1b	Spanner	1.822.121.000

Remove the right cylinder head and gasket. 1. Fit the cylinder/bore locks.

	Name	Country
1	Liner/bore holder	1.820.279.000

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b). 1. Undo the bolts (1a) and remove the rpm sensor protection (1b).2. Remove the rpm sensor complete with support. 1. Undo the bolts fixing the engine oil sump.2. Cut the crankcase sump sealant using the tool.

	Name	Country
2	Blade	1.870.718.000

3. Remove the crankcase sump.