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.

Proceed with the removal  Refer to op.. 1004D40  engine - position on stand and remove . 1. Disconnect the electrical connections from the ignition coils.

	Name	Connector
1	Ignition coil	A30

2. Undo nut (2a) and disconnect earth lead (2b) from the cam cover.3. Undo the bolts (3a) and move the cable duct (3b) aside. 1. Undo the bolts (1a) and remove the ignition coil (1b). 1. Undo the bolts (1a) and remove the tappet cover (1b), complete with seal. 1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolts (2a) and rmeove the lower timing cover (2b). 1. Loosen the nut for the counter-balance shaft toothed drive belt tensioner.2. Release and remove the counter-balance shaft drive belt. 1. Loosen the nut securing the timing belt mobile tensioner.2. Prise off and remove the timing belt. 1. Undo the bolts (1a) and remove the side timing protective cover (1b). 1. Disconnect the electrical connection for the cam angle sensor and release the wiring from the fastening on the modular intake manifold.

	Name	Connector
1	Timing sensor	K47

1. Undo the nut securing the coolant supply/return pipes to the engine oil heat exchanger.2. Loosen the band and disconnect the connector for the coolant outlet pipe from the engine oil heat exchanger on the water pump rigid inlet pipe side. 1. Loosen the band and disconnect the engine oil heat exchanger flexible coolant supply pipe, rigid pipe side. 1. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
1	Rpm sensor	K46

2. Disconnect the electrical connection for the knock sensor.

	Name	Connector
2	Detonation sensor - 1	K50

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

	Name	Connector
3	Engine oil pressure sensor	K30

1. Undo the bolts (1a) and remove the cylinder head (1b).2. Remove the cylinder head gasket. 1. Undo the plug and drain the engine oil.

Recover the engine oil in a suitable container.

Rotate the engine through 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. Cut the crankcase sump sealant using the tool.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump.