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

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.  Refer to op.. 1004D40  engine - position on stand and remove

Support the engine on the overhauling stand using suitable tools.

1. Undo the bolt (1a) and the nut (1b) and remove the single drive belt guard (1c).2. Adjust the automatic belt tensioner with a wrench to slacken the tension of the single drive belt.3. Remove the single drive belt.4. Undo the bolt (4a) and remove the fixed single drive belt tensioner (4b). 1. Undo the bolts (1a) and remove the upper timing belt guard (1b).2. Slacken the timing belt tensioner nut.3. Remove the timing belt from the camshaft pullies.4. Disconnect the electrical connection for the air conditioning compressor.5. Undo the bolts (5a) and remove the air conditioner compressor (5b). 1. Disconnect the coolant outlet pipe connection from the water-oil heat exchanger.2. Undo the bolts (2a) and remove the air conditioner compressor mounting (2b).3. Undo the bolt securing the exhaust manifold to the mounting bracket on the engine block.4. Undo the nuts (4a) and remove the exhaust manifold (4b).5. Undo the bolt (5a) and remove the oil dipstick (5b). 1. Disconnect the intermediate connection on the coolant supply pipe to the water-oil heat exchanger.2. Undo the bolts (2a) and nuts (2b) and remove the rigid coolant inlet pipe to the pump (2c).3. Remove the seal.4. Undo the bolts (4a) and remove the timing belt left side guard (4b). 1. Disconnect the electrical connection for the timing sensor.

	Name	Connector
1	Timing sensor	K47

2. Undo the bolts (2a) and move aside the power steering fluid reservoir (2b).3. Undo the bolt (3a) and remove the power assisted steering fluid reservoir mounting bracket (3b).4. Undo the bolt (4a) and remove the timing belt right side guard (4b).5. Disconnect the electrical connection for the rpm and timing sensor.

	Name	Connector
5	Rpm sensor	K46

6. Disconnect the electrical connection for the knock sensor.

	Name	Connector
6	Detonation sensor - 1	K50

Disconnect the electrical wiring from the rpm and timing sensor and the knock sensor from the bands located under the air chamber.1. Undo the bolts securing the mounting bracket to the air intake chamber.2. Disconnect the electrical connections from the ignition coils and disconnect the electrical wiring from the bands.

	Name	Connector
2	Ignition coil	A30

3. Disconnect the earth lead from the cylinder head.4. Disconnect the high-tension leads (4a) from the spark plugs using the tool (4b).

	Name	Country
4b	Pliers	1.820.636.000

5. Disconnect the oil vapour recovery pipe from the rocker cover. 1. Undo the bolts (1a) and remove the bracket (1b) complete with ignition coils and high-tension leads.2. Undo the bolts (2a) and remove the tappet cover (2b) complete with seal.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 engine components drive pulley (1b).2. Undo the bolts (2a) and remove the timing belt bottom guard (2b). 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 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 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.