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.

 Refer to op.. 1004D40  engine - position on stand and removePosition a suitable container for collecting the engine lubrication fluid.1. Undo the engine oil sump plug and drain the lubrication system. 1. Disconnect the connection for the timing sensor.

	Name	Connector
1	Timing sensor	K47

2. Disconnect the electrical connections from the injectors.

	Name	Connector
2	Injector	N70A

	Name	Connector
2	Injector	N70B

	Name	Connector
2	Injector	N70C

	Name	Connector
2	Injector	N70D

	Name	Connector
2	Injector	N70E

3. Disconnect the electrical connections from the heater plugs.

	Name	Connector
3	Heater plug	A40A

	Name	Connector
3	Heater plug	A40B

	Name	Connector
3	Heater plug	A40C

	Name	Connector
3	Heater plug	A40D

	Name	Connector
3	Heater plug	A40E

1. Disconnect the electrical connection from the turbocharging sensor.

	Name	Connector
1	Turbocharging sensor	K82

2. Disconnect the electrical connection from the fuel pressure regulator.

	Name	Connector
2	Fuel pressure regulator	N77

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

	Name	Connector
3	Fuel pressure sensor	K83

1. Disconnect the electrical connection from the EGR solenoid.

	Name	Connector
1	EGR solenoid	L30

2. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
2	Rpm sensor	K46

1. Disconnect the electrical connection for the engine coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

1. Undo the fixing bolts (1a) and remove the engine wiring (1b), releasing it from any retaining clips. 1. Fit the flywheel locking tool in its seating on the engine block.

	Name	Country
1	Counter-torque	1.860.846.001

1. Undo retaining bolts (1a) and remove engine crankshaft pulley (1b).2. Undo the fixing bolt (2a) and remove the fixed tensioner (2b) for the engine components single belt. 1. Undo the fixing bolts (1a) and remove the timing covers (1b). 1. Undo the connectors (1a) and remove the fuel pipes (1b) from the fuel injectors to the single fuel pipe.

The fuel pipes must be replaced whenever they are removed.

2. Undo the connector (2a) of the fuel pipe (2b) from the pressure pump to the single fuel pipe.3. Undo the fixing bolts (3a) and remove the single fuel pipe (3b).4. Undo the fixing bolts (4a) and remove the rigid pipe (4b). 1. Undo the fixing bolts (1a), open the bands (1b) and remove the rigid recirculation pipe (1c). 1. Open the fixing band (1a) and disconnect the oil vapour recovery pipe (1b) from the cylinder head.2. Open the fixing band (2a) and disconnect the oil vapour recovery pipe (2b) from the engine block.3. Open the fixing band (3a) and disconnect the oil vapour recovery pipe (3b) from the oil sump.4. Undo the fixing bolts (4a) and remove the oil vapour recovery reservoir complete with pipes (4b). 1. Undo the fixing bolts (1a) and remove the complete engine oil dipstick tube (1b). 1. Release the fixing bands (1a) and remove the fuel recovery pipe from the fuel injectors (1b). 1. Disconnect the fuel pipe (1a), undo the fixing bolts (1b), then remove the fuel return manifold (1c).2. Undo the connector (2a) and remove the rigid fuel pipe (2b) from the pressure pump. 1. Slacken the nut on the timing belt moving tensioner.2. Remove the timing drive belt. 1. Stop the rotation of the pressure pump pulley using two bolts. 2. Undo the pressure pump pulley nut.Undo the two bolts fitted previously to stop the rotation of the pressure pump pulley. 1. Using the extractor (1a), remove the pressure pump pulley (1b).

	Name	Country
1a	Extractor	1.860.954.001

1. Undo the fixing nuts (1a) and remove pressure pump (1b). 1. Undo the fixing bolts (1a) and remove power steering pump pulley (1b). 1. Undo the nuts (1a) securing the power steering pump (1b) to the mounting. 1. Undo the bolts (1a) and remove the pressure pump mounting (1b).2. Remove the power steering pump. 1. Undo the bolts (1a) securing the EGR rigid pipe (1b).Recover the metal gasket underneath.2. Undo the fixing nuts (2a) and remove the intake manifold (2b).Recover the metal gasket underneath. 1. Open the bands (1a) securing the coolant pipes to the heat exchanger (1b).2. Undo the fixing bolts (2a) and remove the EGR heat exchanger (2b). 1. Undo the fixing bolts (1a) and remove the rigid supply pipe to the water pump (1b).Remove the metal gasket. 1. Undo the nuts (1a) and remove the brackets (1b) and fuel injectors (1c).

If the same fuel injectors are to be re-used:mark the cylinder to which they belong, so they are refitted in their original positions. If new fuel injectors are fitted:- determine the identification code stamped on the top;- check with the Examiner the recognition of the newfuel injector(s) by the engine control unit.

start removal from the fuel injector of cylinder 1, and then the fuel injectors of cylinders 2, 3, 4 and 5.

1. Undo and remove the heater plugs. 1. Undo the fixing bolts (1a) and remove the vacuum unit (1b).2. Remove the metal gasket.3. Undo the bolts (3a) and remove the engine oil filler (3b).4. Remove the metal gasket. 1. Undo the bolts (1a) and remove the single upper cylinder head (1b).2. Remove the metal gasket. 1. Undo the fixing bolts (1a) and remove the thermostat unit (1b).Remove the gasket. 1. Undo retaining bolts (1a) and remove coolant pump (1b).,Remove the metal gasket.2. Undo the fixing bolt (2a) and remove the side timing cover (2b).3. Remove the rocker arms. 1. Undo the bolts fixing the cylinder head to the block.2. Remove the cylinder head.Remove the locating bushes.Remove the metal gasket. Rotate the engine through 180° on the overhauling stand.1. Undo and remove the engine oil level sensor.2. Undo the fixing bolts (2a) using the tools (2b).

	Name	Country
2b	Spanner	1.860.833.001

	Name	Country
2b	Spanner	1.860.834.001

3. Using the special tool (3a), cut the bead of sealant on the engine oil sump (3b) and then remove the sump. 1. Undo the bolt and nut (1a) and remove the engine oil inlet (1b). 1. Undo the bolt (left-hand thread) (1a) and remove the drive pulley (1b). 1. Undo the retaining bolts (1a) and remove the complete clutch (1b). 1. Undo the fixing bolts (1a) and remove the engine flywheel shield (1b). 1. Remove the flywheel lock.

	Name	Country
1	Counter-torque	1.860.846.001

2. Undo the bolts (2a) and remove the engine flywheel guard (2b).