1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL - Alfa - 156 - eLearn

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. 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.

Position the engine on the overhauling stand Refer to op.. 1004D40 engine - position on stand and remove . 1. Undo the bolt fixing the protective timing cover to the water pump rigid inlet pipe.

1. Loosen the band and disconnect the coolant outlet pipe from the water/exhaust gas heat exchanger for the E.G.R. system, heat exchanger side. 2. Undo the bolts (2a) and remove the water pump rigid inlet pipe (2b).3. Remove the gasket.

1. Undo the nuts (1a) and remove the exhaust manifold heat shield (1b).

1. Undo the bolts fixing the exhaust gas outlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, E.G.R. system solenoid valve side.

1. Tighten the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system to the cylinder head.2. Loosen the band and disconnect the coolant inlet pipe from the water/exhaust gas heat exchanger for the E.G.R. system, heat exchanger side.

1. Undo the bolts fixing the exhaust gas inlet pipe to the water/exhaust gas heat exchanger for the E.G.R. system, exhaust manifold side.2. Remove the EGR system water/exhaust valve heat exchanger.3. Remove the gaskets.

1. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side.

1. Undo connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side.

1. Undo the nuts (1a) and remove the exhaust manifold (1b) complete with turbocharger (1c).2. Remove the exhaust manifold gasket.

1. Release the electrical wiring from the band on the timing cover.2. Disconnect the electrical connection for the cam angle sensor.

	Name	Connector
1	Timing sensor	K47

3. Disconnect the electrical connections from the injectors.

	Name	Connector
3	Injector	N70

4. Undo the cable duct fixing bolts.

1. Releasethe electrical wiring from the bands fastening it to the engine coolant supply reservoir coolant return pipe.2. Disconnect the electrical connections from the heater plugs.

	Name	Connector
2	Heater plug	A40

3. Disconnect the electrical connection from the fuel pressure sensor.

	Name	Connector
3	Fuel pressure sensor	K83

1. Disconnect the electrical connection from the excess pressure sensor.

	Name	Connector
1	Turbocharging sensor	K82

2. Release the electrical wiring from the securing band.3. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
3	Fuel pressure regulator	N77

1. Disconnect the electrical connection from the E.G.R. valve.

	Name	Connector
1	EGR solenoid	L30

1. Disconnect the electrical connection from the engine oil pressure warning light switch.

	Name	Connector
1	Engine oil pressure sensor	K30

Remove the engine wiring.1. Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler, then release it from the retaining band. 2. Loosen the band and disconnect the oil vapour recovery pipe from the engine crankcase.3. Loosen the band and disconnect the condensation oil recirculation pipe from the crankcase sump.4. Undo the bolts (4a) and remove the bracket (4b) complete with engine oil vapour separator (4c) and pipes.

1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolt (2a) and remove the single drive belt fixed tensioner (2b).

1. Undo the bolts (1a) and remove the timing gear covers (1b).

1. Undo the bolts (1a) and remove the bracket on the engine for the reaction rod (1b).

1. Loosen the nut securing the timing belt mobile tensioner.2. Prise off and remove the timing belt.

1. Loosen the band and disconnect the coolant return pipe from the engine coolant reservoir, thermostat side.

1. Loosen the band and disconnect the coolant outlet pipe from the cylinder head, engine coolant return pipe to the coolant reservoir side. 2. Undo the bolts (2a) and remove hose (2b) carrying coolant to the coolant supply reservoir.

1. Disconnect the pipe from the injectors to the fuel return manifold, fuel return manifold side.2. Loosen the band and disconnect the pipe from the pressure pump to the fuel return manifold, fuel return manifold side.3. Undo the bolts (3a) and remove the fuel return manifold (3b).

1. Undo the connectors (1a), (1b) and remove the pipe from the pressure pump to the fuel manifold (1c).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

2. Manually push springs (2a) and disconnect the pipe from the injectors to the fuel recovery manifold (2b), injectors side and remove it.3. Undo the connectors (3a), (3b) and remove the pipes from the fuel manifold to the injectors (3c).

Use new piping from from fuel manifold to injectors upon reassembly.

4. Undo the bolts (4a) and remove the single fuel manifold pipe (4b) complete with fuel pressure sensor (4c).

1. Undo the bolts (1a) and remove the power assisted steering pump/alternator protection (1b).

1. Undo the bolts (1a) and remove the power steering pump pulley (1b).

1. Undo the bolts (1a) and remove the power assisted steering pump (1b).2. Undo the front bolt fixing the pressure pump support.

1. Undo the bolts (1a) and remove the pressure pump support (1b) complete with pressure pump (1c).

1. Undo the nuts (1a) and remove the brackets (1b) and injectors (1c).

If the same injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted.

If new injector(s) is(are) being fitted, it is necessary to:

determine the identification code stamped on the top;
check that the new injectors(s) is (are) recognized by the engine management control unit using the Examiner.

Start the removal beginning with the injector for cylinder no. 1 and continuing with the injectors for cylinders 2, 3 and 4.

1. Undo the bolts (1a) and remove the camshaft housing assembly (1b).2. Remove the gasket.3. Remove the valve rocker arms.

1. Undo the bolts (1a) and remove the air chamber assembly (1b).Remove the gasket.

1. Undo the bolt (1a) and remove the timing gear cover (1b).

1. Undo and remove the heater plugs.

1. Undo the bolts (1a) and remove the lower cylinder head assembly (1b).2. Remove the gasket.3. Remove the locating bushes

1. Fit the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

1. Undo the (left hand thread) bolt (1a) and remove the drive pulley (1b).

1. Undo the bolts (1a) and remove the engine flywheel (1b).

The engine flywheel retaining bolts are treated with a compound to prevent them coming undone they should therefore be replaced whenever they are removed.

2. Remove the flywheel lock.

	Name	Country
2	Counter-torque	1.860.846.001

1. Undo the bolts (1a) and remove the engine flywheel protection (1b).

Rotate the engine throughi 180° on the overhauling stand.1. Undo the front and rear bolts (1a) securing the crankcase sump using tool (1b).

	Name	Country
1b	Spanner	1.860.833.001

2. Undo the side bolts (2a) securing the crankcase sump using tool (2b).

	Name	Country
2b	Spanner	1.860.834.001

3. Use the tool to cut the crankcase sump sealant.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump.