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

2400985 - 1004E10 engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal

Position the engine on the overhauling stand Refer to op.. 1004D40 engine - position on stand and remove . 1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Name	Connector
1	Engine temperature sender unit	K36

2. Disconnect the electrical connection for the rpm sensor.

	Name	Connector
2	Rpm sensor	K46

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

	Name	Connector
3	Engine oil pressure sensor (switch)	K30

1. Disconnect the electrical connections from the heater plugs.

	Name	Connector
1	Heater plug	A40

2. Disconnect the electrical connections from the injectors.

	Name	Connector
2	Injector	N70

3. Disconnect the electrical connection from the cam angle sensor.

	Name	Connector
3	Timing sensor.	K47

4. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.

	Name	Connector
4	Air conditioning compressor engagement electro-magnet	L20

5. Undo the bolts fixing the cable duct to the cylinder head.6. Release the electrical wiring (6a) from the fastenings (6b) and move it sideways.

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

	Name	Connector
1	Fuel pressure sensor	K83

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

	Name	Connector
2	Turbocharging sensor	K82

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

	Name	Connector
3	Fuel pressure regulator	N77

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

	Name	Connector
4	EGR solenoid	L30

5. Release the electrical wiring (5a) from the bands (5b) fastening it to the air chamber and remove it.

Remove the protective plates located by the oil filter and the engine oil heat exchanger.1. Undo the bolts securing the engine oil return pipe from the turbocharger, engine crankcase side.2. Undo connector (1a) and remove engine oil supply pipe to the turbocharger (1b).

1. Undo the bolts (1a) and the nut (1b) and remove the exhaust manifold heat shield (1c) complete with engine lifting bracket (1d).2. Undo the bolt fixing the coolant supply pipe to the engine oil heat exchanger, to the cylinder block/crankcase.3. Undo the bolts (3a), loosen the band (3b) and remove the coolant supply pipe to the engine oil heat exchanger (3c) complete with seal.

1. Undo the nuts (1a) and remove the turbocharger (1b) complete with catalytic converter (1c).

1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c).

1. Use a spanner on the moving tensioner (1a) and remove the engine components single drive belt (1b).

1. Undo the bolt (1a) and remove the single drive belt tensioner (1b).2. Completely undo the bolts (2a) loosened previously and remove the crankshaft pulley (2b).3. Undo the nuts (3a) and remove the water pump (3b) complete with gasket.

1. Completely undo the left hand bolt (1a) loosened previously and remove the pulley mounting flange on the crankshaft (1b) Refer to op.. 1004D40 engine - position on stand and remove .

Undo the bolts and remove the intermediate driveshaft support.1. Undo the bolt (1a) and remove the complete engine oil dipstick tube (1b).

Rotate the engine through 180° on the overhauling stand.1. Undo the bolts (1a) and remove the support (1b).2. Undo the nuts (2a) and the bolts (2b) fixing the crankcase sump.3. Use the tool to cut the crankcase sump sealant.

	Name	Country
3	Blade	1.870.718.000

4. Remove the crankcase sump.

1. Undo the bolts (1a) and remove the crankcase oil sump partition (1b).

Rotate the engine through 180° on the overhauling stand.1. Undo the bolt (1a) and disconnect the connector (1b) for the engine oil vapour recovery pipe from the timing cover.

1. Undo the bolts (1a) and remove the timing cover (1b) complete with engine oil suction device (1c) and engine oil pump.Remove the timing cover gasket.2. Recover the brackets.

1. Keep the tool fitted on the exhaust side camshaft. Refer to op.. 1004D10 power unit (manual gearbox), removed, remove and re-build

	Name	Country
1b	Template	1.871.000.900

1. Fit the crankshaft timing tool.

	Name	Country
1b	Template	1.870.900.300

1. Undo the bolt securing the driven timing pulley.

Mark the position of the timing driven pulley, the toothed drive ulley and the timing drive chain (if the chain that has been removed is being reused). If the pulleys are replaced, fit them with the writing turned to the outside.

1. Remove the timing driven driven pulley (1a) together with the chain (1b) and the toothed drive pulley (1c).2. Undo the bolts (2a) and remove the timing chain fixed plate (2b).3. Undo the pin (3a) and remove the timing chain moving plate (3b).

1. Undo the bolts (1a) and remove the moving timing belt tensioner (1b).

1. Manually push the clips (1a) and disconnect the fuel outlet pipe from the injectors (1b).2. Loosen the connectors (2a) and remove the pipe from the pressure pump to the fuel manifold (2b).

When refitting, fit a new pipe from the pressure pump to the fuel manifold.

3. Undo the connectors (3a) and remove the pipes from the fuel manifold to the injectors (3b).

Use new pipes from the fuel manifold to the injectors when refitting.

4. Loosen the band and disconnect the return pipe from the pressure pump to the fuel manifold, pressure pump side.5. Undo the bolts (5a) and remove the mounting bracket (5b) complete with single fuel manifold pipe (5c), fuel pressure regulator (5d) and fuel pressure sensor (5e).

1. Undo the injector mounting bracket nut.2. Remove the washer (2a) and tapered washer (2b).3. Fit the injectors (3a), one at a time, using tools (3b) and (3c).

If the same injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted. If new fuel injector(s) are fitted, the self-learning procedure with the Examiner must be carried out.

	Name	Country
3b	Extractor	1.870.900.700

	Name	Country
3c	Extractor	1.870.739.000

Remove the fuel injectors complete with bracket.

Replace the fuel injector copper rings.

Repeat the above procedure to remove the remaining pair of injectors.4. Remove the injector dust seals from the camshaft housing.

These dust seals are replaced at each refitting.

1. Undo the bolts (1a) and (1b), then remove the camshaft housing assembly (1c).2. Remove the gasket

1. Undo the bolts fixing the water/exhaust gas heat exchanger for the E.G.R. system.2. Loosen the band and disconnect the condensed engine oil recovery pipe, oil vapour separator side.

1. Undo the bolts (1a) and remove the complete cylinder head (1b).2. Remove the cylinder head gasket.