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.

Adjust the automatic belt tensioner with a wrench to slacken the tension of the single engine component drive belt.1. Remove the single drive belt. 1. Undo the bolt (1a) and remove the fixed single drive pulley (1b).2. Undo the bolts (2a) and remove the power unit reaction rod attachment bracket (2b). 1. Undo the bolts (1a) and remove the timing drive belt guard (1b).2. Loosen the timing belt tensioner nut.3. Remove the timing drive belt. Undo the bolts and remove the oil dip stick assembly.1. Undo the side bolts fixing the pressure pump mounting.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. Disconnect the pipe from the pressure pump to the rigid fuel return pipe, rigid pipe side. 1. Undo the remaining front bolts (1a) and remove the support complete with pressure pump (1a). 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 assembly (3b) .4. Remove the bracket. 1. Disconnect the water supply pipe to the water/oil heat exchanger from the thermostatic casing.2. Disconnect the water outlet pipe from the water/oil heat exchanger from the manifold.3. Undo the bolt for the water-oil heat exchanger water inlet pipe.4. Undo the bolts (4a) and remove the heat shield (4b) from the turbocharger.5. Undo the nuts (5a) and disconnect the exhaust gas recirculation pipe (5b) complete with gasket (5c). Undo the exhaust gas recirculation pipe bracket bolt.1. Undo the nut securing the exhaust manifold bracket to the crankcase.2. Undo the bolts (2a) and remove the protection for the oil return pipe to the sump from the turbocharger (2b).3. Disconnect the oil return pipe to the sump from the turbocharger.4. Disconnect the oil inlet pipe from the turbocharger.5. Undo the nuts (5a) and remove the exhaust manifold (5b) complete with turbocharger and E.G.R. valve.6. Remove the seal. 1. Undo the bolts (1a) and remove the tappet cover (1b), complete with seal.2. Undo the bolts (2a) and remove the complete cylinder head (2b).3. Remove the cylinder head gasket. Rotate the engine through 180° on the overhauling stand.1. Undo the bolt 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 the 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.