3315349 - 1004E10 engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal (Automatic transmission)

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

	Name	Connector
1	Cam angle 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 for the heater plugs.

	Name	Connector
3	Heater plugs	A40A

	Name	Connector
3	Heater plugs	A40B

	Name	Connector
3	Heater plugs	A40C

	Name	Connector
3	Heater plugs	A40D

	Name	Connector
3	Heater plugs	A40E

1. Disconnect the electrical connection from the supercharging sensor.

	Name	Connector
1	Turbocharging sensor	K82

2. Disconnect the electrical connection for 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 electric fan	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 coolant temperature sensor-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 lock in the housing in the engine block.

	Name	Country
1	Counter-torque	1.860.846.001

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

The fuel pipes should be replaced each time they are dismantled.

2. Undo the connector (2a) for 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 fastening band (1a) and disconnect the oil vapour recorvery pipe (1b) from the cylinder head.2. Open the fastening band (2a) and disconnect the oil vapour recovery pipe (2b) from the engine block.3. Open the fastening band (3a) and disconnect the oil vapour recovery pipe (3b) from the engine oil sump.4. Undo the fixing bolts (4a) and remove the oil vapour recovery tank complete with pipes (4b). 1. Undo the fixing bolts (1a) and remove the engine oil dipstick assembly (1b). 1. Using the fastening clips (1a), release the fuel vapour recovery pipe from the 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. Remove the pressure pump pulley (1b) using the extractor (1a).

	Name	Country
1a	Extractor	1.860.954.001

1. Undo the nuts (1a) and remove the pressure pump (1b). 1. Undo the bolts (1a) and remove the power steering pump pulley (1b). 1. Undo the bolts (1a) fixing the power assisted steering pump (1b) to the support. 1. Undo the bolts (1a) and remove the pressure pump mounting (1b).2. Remove the power assisted steering pump. 1. Undo the bolts (1a) fixing the rigid EGR pipe (1b).Keep the metal gasket underneath.2. Undo the fixing nuts (2a) and remove the intake manifold (2b).Keep the metal gasket underneath. 1. Open the bands (1a) fastening 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 water pump supply pipe (1b).Remove the metal gasket. 1. Undo the nuts (1a) and remove the brackets (1b) and the injectors (1c).

if the 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.- using the Examiner, check that the newinjector(s) is(are) recognized by the engine management control unit.

start the removal beginning with the injector for cylinder no. 1 and continuing with the injectors for 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 fixing bolts (3a) and remove the the engine oil filler (3b).4. Remove the metal gasket. 1. Undo the fixing bolts (1a) and remove the single camshaft housing (1b).2. Remove the metal gasket. 1. Undo the fixing bolts (1a) and remove the thermostat unit (1b).Remove the gasket. 1. Undo the fixing bolts (1a) and remove the coolant pump (1b).Remove the metal gasket.2. Undo the fixing bolt (2a) and remove the protective timing cover (2b).3. Remove the valve rocker arms. 1. Undo the bolts fixing the cylinder head to the cylinder block/crankcase.2. Remove the cylinder head.Remove the locating bushesRemove 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 engine oil sump sealant (3b) and then remove it. 1. Undo the fixing bolts and nut (1a) and remove the engine oil intake (1b). 1. Undo the bolt (left) (1a) and remove the drive pulley (1b). 1. Undo the retaining bolts (1a) and remove the clutch assembly (1b). 1. Undo the fixing bolts (1a) and remove the engine flywheel (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).