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 remove

Support the engine on the overhauling stand using suitable tools.

1. Use the tool on the automatic belt tensioner to loosen the single engine components drive belt tension.

	Name	Country
1	Key	1.860.966.000

2. Insert the tool in the special opening to keep the automatic tensioner in the 'fixed' position.

	Name	Country
2	Clip	1.870.645.000

3. Remove the engine components single drive belt tensioner plug.4. Loosen the bolt for the engine components single drive belt bolt.5. Remove the single drive belt.6. Remove the engine components single drive belt tensioner pulley plug.7. Undo the bolt (7a) and remove the engine components single drive belt pulley (7b). 1. Undo the bolts (1a) and remove the timing drive belt guard (1b).2. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b).3. Loosen the timing belt tensioner nut.4. Remove the timing drive belt. 1. Disconnect the fuel supply pipe from the filter from the pressure pump.2. Disconnect the pressure pump side connector from the pipe leading from the pressure pump using a suitable spanner. 3. Undo the connector (3a) using a suitable ordinary spanner and remove the supply pipe from the pressure pump to the manifold (3b).

Fit a new high pressure pipe from the pressure pump to the fuel manifold upon reassembly.

4. Loosen the pressure pump support side bolts.5. Loosen the pressure pump support front bolts.6. Undo the bolts (6a) and remove the complete oil dip stick (6b). 1. Undo the connector (1a) and disconnect the oil inlet pipe from the turbocharger (1b). 1. Undo the bolts (1a) and remove the oil outlet pipe protective guard (1b) from the turbocharger.2. Disconnect the oil outlet pipe from the turbocharger from the oil sump. 1. Undo the nuts (1a) and disconnect the exhaust gas recirculation pipe (1b).2. Remove the seal.3. Undo the pipe securing bracket bolt.4. Undo the bolt fixing the exhaust manifold bracket to the cylinder block/crankcase.5. Undo the nuts (5a) and remove the exhaust manifold (5b) complete with turbocharger and E.G.R. valve.6. Remove the seal. 1. Disconnect the oil vapour recovery pipe from the cylinder block/crankcase.2. Disconnect the condensation oil recovery pipe from the crankcase sump.3. Undo the nuts (3a) and remove the oil vapour separator (3b) complete with pipes.4. Remove the bracket.5. Disconnect the return pipe from the fuel filter to the return manifold.6. Undo the nuts (6a) and remove the complete fuel filter (6b).7. Undo the bolts (7a) and remove the tappet cover (7b) complete with seal. 1. Disconnect the water supply pipe to the water/oil heat exchanger from the thermostat.2. Disconnect the water outlet pipe from the water/oil heat exchanger from the manifold.3. Undo the bolts (3a) and remove the complete cylinder head (3b).4. Remove the cylinder head gasket. Rotate the engine through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the plates (1b) connecting the crankcase sump to the intermediate shaft support.2. Undo the front and rear bolts (2a) for the crankcase sump using the tool (2b).

	Name	Country
2b	Key	1.822.145.000

3. Undo he side bolts (3a) for the crankcase sump using the tool (3b).

	Name	Country
3b	Key	1.822.144.000

4. Remove the crankcase sump.To loosen the sump from the crankcase, apply gentle blows using a resin hammer, then use a screwdriver for leverage in the special projections at the side of the crankcase sump.