3025985 - 1004E10 engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal

RemovingPosition the engine on the overhauling stand  - 1004D40  engine - position on stand and remove .

Support the engine on the overhauling stand using suitable tools.

1. Use a spanner on the moving tensioner to loosen the tension of the engine components single drive belt.2. Remove the single drive belt. 1. Undo the bolt (1a) and remove the fixed single drive belt tensioner (1b). 1. Undo the bolts (1a) and remove the timing gear covers (1b).2. Undo the bolts (2a) and remove the bracket on the engine for the reaction rod (2b).3. Slacken the nut on the timing belt moving tensioner.4. Remove the timing belt. Undo the bolts and remove the complete engine oil dipstick guide pipe. 1. Undo the side bolts fixing the pressure pump mounting.2. Undo the connectors (2a) and (2b) using a suitable spanner and remove the pipe from the pressure pump to the fuel manifold (2c).

When refitting, use a new high pressure pipe between the high pressure pump and the fuel manifold.

3. Loosen the bands (3a) and (3b) and remove the pipe from the pressure pump to the fuel return manifold pipe (3c). 1. Undo the remaining front bolts (1a) and remove the support (1b) complete with pressure pump (1c). 1. Disconnect the vacuum pipes from the vacuum reservoir.2. Undo the fastenings and remove the vacuum reservoir. 1. Slacken band (1a) and disconnect the flexible hose (1b) from the rigid coolant delivery pipe to the engine oil heat exchanger.2. Undo the bolts securing the rigid coolant supply pipe to the engine oil heat exchanger. 1. Loosen the band (1a) and disconnect the connector for the coolant outlet pipe from the engine oil heat exchanger on the side of the water pump rigid inlet pipe. 2. Undo bolts (2a) and remove exhaust manifold heat shield (2b). 1. Undo the bolts (1a) fixing the water/exhaust gas heat exchanger for the E.G.R. system (1b) to the exhaust manifold. 1. Undo the bolts (1a) and (1b), then remove the turbocharger mounting bracket (1c). 1. Undo the bolts (1a) and (1b), then remove the engine oil return pipe from the turbocharger (1c). 1. Undo connector (1a) and disconnect engine oil supply pipe to the turbocharger (1b), crankcase side. 1. Undo the nuts (1a) and remove the exhaust manifold (1b) complete with turbocharger (1c).2. Remove the gasket. 1. Undo the bolts (1a) and remove the pipe between the E.G.R. vacuum reservoir and the turbocharger vane position actuator solenoid valve (1b). 1. Undo the bolts (1a) and remove the tappet cover (1b), complete with seal.2. Undo the bolts (2a) using a spanner (USAG 233 1/2 S N. 14 L) and remove the complete cylinder head (2b).3. Remove the cylinder head gasket. Rotate the engine through 180° on the overhauling stand.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. Using the tool (4a), cut the sealant and remove the crankcase sump (4b).

	Name	Country
4a	Blade	1.870.718.001