3239060 - 1004D40 engine - position on stand and remove

Secure and support the engine using a hydraulic hoist fitted with suitable chains. 1. Adjust the engine components single drive belt moving tensioner (1a) using the spanner (1b), then insert the tool (1c) in the hole in the tensioner.

	Name	Country
1b	Key	1.860.966.000

	Name	Country
1c	Clip	1.870.645.000

2. Remove the plug for the auxiliary components single belt cam tensioner.3. Loosen the cam tensioner bolt.4. Remove the auxiliary components single drive belt. 1. Undo the fixing nut (1a) and disconnect the alternator electrical connection (1b).

	Name	Connector
1b	Alternator	A10

1. Undo the bolts (1a) and remove the alternator (1b). 1. Undo the fixing bolts (1a) and remove the alternator upper mounting bracket (1b). 1. Undo the bolts (1a) and remove the rear alternator mounting bracket (1b). 1. Disconnect the electrical connection for the engine oil level sensor.

	Name	Connector
1	Engine oil level sensor	K32

2. Fit the rear bracket for positioning the engine on the overhauling stand.

	Name	Country
2	Brackets	1.861.001.039

1. Disconnect the electrical connection from the air conditioning compressor.

	Name	Connector
1	Air conditioning compressor "on" electromagnet	L20

2. Undo the bolts (2a) and remove the air conditioning compressor assembly and front engine mounting (2b). 1. Fit the front bracket for positioning the engine on the overhauling stand.

	Name	Country
1	Brackets	1.861.001.039

1. Undo the fixing nuts (1a) and remove the exhaust manifold heat shield (1a). 1. Open the band (1a) and disconnect the oil return pipe from the turbocharger (1b).2. Undo the connector (2a) and disconnect the oil supply pipe to the turbocharger (2b) from the engine block. 1. Undo the fixing bolts (1a) of the EGR rigid pipe (1b) to the exhaust manifold and remove the gasket (1c).2. Undo the nuts (2a) securing the exhaust manifold (2b) to the cylinder head. 1. Undo the bolt securing the turbine mounting bracket to the engine block.2. Remove the exhaust manifold and turbocharger assembly (2a) and the relevant metal gasket (2b). 1. Undo the fixing bolt (1a) and remove the power steering pump shield (1b).2. Using a hydraulic hoist, position the engine (2a) on the rotary overhauling stand.

	Name	Country
2b	Rotating stand	1.861.000.000

Instead of the above-mentioned overhauling stand, the following stand may be used:

	Name	Country
-	Rotating overhaul stand	1.871.001.000

Secure the mounting brackets to the overhauling stand.Release the engine from the hydraulic lift fastenings. Proceed as follows to remove the engine from the rotary overhauling stand.Secure and support the engine using a hydraulic hoist fitted with suitable chains. Undo the fixings and remove the engine complete with mounting brackets. Remove the brackets for positioning the engine on the overhaul stand.

	Name	Country
-	Brackets	1.861.001.039

1. Fit the new metal gasket (1a) in its seating and then fit the exhaust manifold and turbine assembly (1b).2. Tighten the bolt securing the turbine mounting bracket to the engine block. 1. Tighten the nuts (1a) securing the exhaust manifold (1b) to the cylinder head, to the correct torque.

	Fastening	Component	Ø	Value(daNm)
1a	Nut	EXHAUST MANIFOLD/S	M8	2.5

2. Fit the new gasket (2a) in its seating and tighten the bolts (2b) securing the rigid EGR pipe (2c) to the exhaust manifold/turbine, to the correct torque. 1. Connect the oil return pipe from the turbocharger (1) and secure it with the band (1b).2. Connectc the oil supply pipe to the turbocharger (2a) on the engine block and tighten the connector (2b) to the specified torque. 1. Position the exhaust manifold heat shield (1a) in its seating and tighten the nuts (1b) to the correct torque. 1. Position the air conditioning compressor assembly in its seating and the front engine mounting (1a) and tighten the fixing bolts (1b) to the specified torque.2. Connect the electrical connection to the air conditioner compressor.

	Name	Connector
2	Air conditioning compressor "on" electromagnet	L20

1. Connect the electrical connection for the engine oil level sensor.

	Name	Connector
1	Engine oil level sensor	K32

2. Fit the power steering pump guard (2a) in its seating and tighten the fixing bolt (2b). 1. Fit the rear engine mounting (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M10 x 1.25	5

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	POWER UNIT RIGID REAR MOUNT	M8	2.5

1. Fit the alternator top mounting bracket (1a) and tighten the bolts (1b) to the specified torque. 1. Fit the alternator (1a) in its seating and tighten the bolts (1b) to the specified torque.

	Fastening	Component	Ø	Value(daNm)
1b	Bolt	ALTERNATOR ASSEMBLY	M10 x 1.25	5

	Fastening	Component	Ø	Value(daNm)
1b	Nut	ALTERNATOR ASSEMBLY	M12 x 1.25	7

1. Connect the electrical connection to the alternator.

	Name	Connector
1	Alternator	A10

Fit the single engine component belt by adjusting the moving tensioner using a wrench. Release the engine from the hydraulic lift fastenings.