194002123 - 1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL
Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE1. Unscrew the drain plug on the crankcase sump and drain the engine oil. | Collect the engine oil in a suitable container. |
1. Disconnect the electrical connection from the rpm sensor.2. Disconnect the electrical connection from the engine oil level sensor.3. Disconnect the electrical connection for the engine oil pressure switch.
1. Disconnect the electrical connection from the throttle control shaft valve for the inlet ducts.
1. Disconnect the electrical connection for the EGR solenoid valve.2. Disconnect the electrical connection for the air temperature and pressure sensor.3. Disconnect the electrical connection for the fuel pressure regulator. | Description | Connector |
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| 3 | Fuel pressure regulator | See |
1. Disconnect the electrical connection from the engine temperature sensor.
1. Disconnect the electrical connection from the throttle casing.
1. Disconnect the electrical connection from the fuel pressure sensor.2. Disconnect the electrical connection from the fuel pressure regulator on the injector rail.3. Disconnect the electrical connections from the injectors.4. Disconnect the electrical connections from the heater plugs.5. Disconnect the electrical connection from the cam angle sensor.6. Unscrew the electrical wiring bolts.
7. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.8. Disconnect the electrical connection for the thermal coupling indicating catalytic converter overheating..
1. Apply a wrench to the moving tensioner (1a), then prise up and remove the auxiliary drive belt (1b).2. Undo the bolts and remove the service pulley on the crankshaft.3. Undo the bolts and remove the protective timing cover.4. Undo the bolt and remove the auxiliary drivebelt fixed tensioner.5. Undo the bolts and remove the power unit rigid support mount, timing side.
1. Loosen the moving timing belt tensioner bolt (1a), then release and remove the toothed timing drive belt (1b).
1. Unscrew bolts (1a), loosen collars (1b), then remove the turbocharger air inlet pipe (1c) complete with engine oil vapour recovery pipe.2. Undo the bolts (2a) and remove the engine oil dipstick tube assembly (2b).
- Undo the retaining nuts and remove the exhaust manifold heat shield.1. Loosen collar, unscrew bolts (1b) and disconnect the exhaust gas intake pipe from the exhaust manifold to the E.G.R. heat exchanger (1c), exhaust manifold side.2. Undo the connector and disconnect the engine oil supply pipe to the turbocharger, crankcase side.3. Undo the bolts and disconnect the engine oil return pipe from the turbocharger, crankcase side.4. Undo the nuts and remove the turbocharger and exhaust manifold assembly with catalytic converter.- Remove the exhaust manifold gasket.
1. Loosen the bands and disconnect the pipes from the thermostat.2. Unscrew bolts (2a), loosen collars (2b) and remove the engine oil heat exchanger rigid duplex delivery and return pipe (2c).
1. Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler.2. Undo the bolts, then remove the vacuum pipes.
1. Loosen the collars and disconnect the engine oil vapour recovery pipe and the engine oil recovery pipe.2. Undo the nuts and remove the bracket complete with engine oil vapour separator and vacuum reservoir.
1. Disconnect the linkage for the throttle control shaft valve for the inlet ducts.2. Undo the nuts and remove the throttle control shaft valve for the inlet ducts.
1. Unscrew the connectors and remove the pipes from the fuel manifold to the injectors.2. Undo the connectors and remove the pipe from the pressure pump to the fuel manifold.3. Loosen the band and disconnect the fuel return pipe from the fuel manifold, fuel return manifold side.4. Undo the bolts and remove the single fuel manifold pipe.5. Loosen the collar and disconnect the fuel return pipe from the injectors, fuel return manifold side.6. Push the clips by hand, then disconnect the fuel return pipe from the injectors, injector side, and remove.
1. Undo the injector bracket retaining nuts.2. Remove the injectors (2a) complete with brackets using the tools (2b).| Tool | Description | Function | Validity |
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| 1870897300 | Extractor | Removing injectors | 1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V |
| If a new injector/new inectors are fitted: read the identification code of the new injector/s off the engine ECU. Use an Examiner to check that the engine ECU has recognised the new injector/s. |
| Start the removal beginning with the injector for cylinder no. 1 and continue with the injectors for cylinders 2, 3 and 4. |
1. Undo the bolts (1a) and remove the camshaft housing assembly (1b).2. Remove the gasket.2. Remove the valve rockers.
1. Unscrew the glow plugs and remove.
1. Undo the bolts (1a) and remove the cylinder head assembly (1b).2. Remove the gasket.3. Remove the locating bushes.
- Rotate the engine through 180° on the overhaul stand.1. Undo the bolts securing the air conditioner compressor mount to the engine oil sump.2. Undo the bolts fixing the crankcase sump.3. Cut the crankcase sump sealant using the tool.| Tool | Description | Function | Validity |
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| 1870718000 | Blade | Cut the crankcase sump sealant | |
4. Remove the crankcase sump.
