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 REMOVEPosition a suitable container for collecting the engine lubricant.1. Unscre the engine oil sump plug and drain the lubrication system. 1. Disconnect the electrical connection for the timing sensor.

	Description	Connector
1	Timing sensor	K047

2. Disconnect the electrical connections for the injectors.

	Description	Connector
2	Injector	N070A

	Description	Connector
2	Injector	N070E

	Description	Connector
2	Injector	N070D

	Description	Connector
2	Injector	N070C

	Description	Connector
2	Injector	N070B

3. Disconnect the glow plug electrical connections.

	Description	Connector
3	Heater plugs	A040A

	Description	Connector
3	Heater plugs	A040E

	Description	Connector
3	Heater plugs	A040D

	Description	Connector
3	Heater plugs	A040C

	Description	Connector
3	Heater plugs	A040B

1. Disconnect the electrical connection for the turbo sensor.

	Description	Connector
1	Supercharging sensor	K082

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

	Description	Connector
2	Fuel pressure regulator	N077

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

	Description	Connector
3	Fuel pressure sensor	K083

1. Disonnect the electrical connection for the EGR solenoid valve.

	Description	Connector
1	EGR solenoid valve	L030

2. Disconnect the electrical connection for the engine rpm sensor.

	Description	Connector
2	Rpm sensor	K046

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

	Description	Connector
1	Engine coolant temperature sensor/sender unit	K036

1. Undo the retaining bolts (1a) and remove engine wiring (1b), releasing from any clips that are present. 1. Fit the flywheel retaining tool in its seat on the engine block.

	Description	Code	Function
1	Flywheel lock	1.860.846.001	Prevent the rotation of the crankshaft

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

The fuel pipes must be replaced whenever they are removed.

2. Undo connector (2a) of fuel pipe (2b) from pressure pump to 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. Unscrew bolt (1a), open band (1b) and remove the rigid recirculation pipe (1c). 1. Open the securing band (1a) and disconnect the oil vapour pipe (1b) from the cylinder head.2. Open the securing band (2a) and disconnect the oil vapour pipe (2b) from the engine block.3. Open the securing band (3a) and disconnect the oil vapour recovery pipe (3b) from the engine oil sump.4. Undo bolts (4a) and remove the oil vapour recovery tank with pipes (4b). 1. Undo the fixing bolts (1a) and remove the engine oil dipstick pipe assembly (1b). 1. Undo retaining clips (1a) and prise up the fuel recovery pipe from injectors (1b). 1. Disconnect fuel pipe (1a), unscrew bolts (1b), then remove the fuel return manifold (1c).2. Undo connector (2a) and remove the rigid fuel pipe (2b) from the pressure pump. 1. Loosen the moving timing tensioner nut.2. Remove the toothed timing belt. 1. Lock the rotation of the pressure pump drive pulley using two bolts.2. Undo the pressure pump drive pulley nut.Undo the two bolts for locking the rotation of the pressure pump drive pulley fitted previously. 1. Use extractor (1a) to remove the pressure pump pulley (1b).

	Description	Code	Function
1a	Extractor	1.860.854.001	Pressure pump control pulley removal

1. Undo the fixing nuts (1a) and remove the pressure pump (2b). 1. Undo the fixing bolts (1a) and remove the power steering pump pulley (1b). 1. Undo the bolts (1a) fixing the power steering pump (1a) to the support. 1. Undo the fixing bolts (1a) and remove the pressure pump mounting (1b).2. Remove the power assisted steering pump. 1. Undo bolts (1a) securing rigid EGR pipe (1b).Recover the underlying metal sealing gasket.2. Undo the fixing nuts (2a) and disconnect the intake manifold (2b).Recover the underlying metal sealing gasket. 1. Open bands (1a) securing the coolant hoses to the heat exchanger (1b).2. Undo the fixing bolts (2a) and remove the EGR heat exchanger (2b). 1. Undo the bolts (1a) and remove the water pump delivery pipe (1b).Remove the metal gasket. 1. Undo the bolts (1a) and remove the brackets (1b) and the injectors (1c).

if the injectors are reused, mark the matching cyliner to ensure they are correctly refitted. If a new injector/new inectors are fitted:

begin removal with the injector for the 1st cylinder and then move on to the 2nd, 3rd, 4th and 5th cylinders.

1. Unscrew the glow plugs and remove. 1. Undo retaining bolts (1a) and remove vacuum pump (1b).2. Remove the metal gasket.3. Undo the bolts (3a) and remove the engine oil filler fitting (3b).4. Remove the metal gasket. 1. Undo the fixing bolts (1a) and remove the single cylinder head extension (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 bolts (2a) and remove the side protective timing cover (1b).3. Remove the valve rockers. 1. Loosen the bolts fixing the cylinder head to the engine block2. Remove the cylinder head.Remove the locating bushes.Remove the metal gasket. Rotate the engine through 180° on the overhaul stand.1. Undo and remove the engine oil level sensor.2. Undo the fixing bolts (2a) using tools (2b).

	Description	Code	Function
2b	Undo the bolts securing the engine oil sump	1.860.833.001	Loosen/Tighten front and rear crankcase sump bolts

	Description	Code	Function
2b	Undo the bolts securing the engine oil sump	1.860.834.001	Loosen/Tighten crankcase sump side bolts

3. Use tool (3a) to cut the sealant strip from the engine oil sump (3b) and then remove. 1. Undo the fixing bolts (1a) and remove the engine oil intake duct (1b). 1. Undo the bolt (1a) (left hand thread) and remove the toothed drive pulley (1b). 1. Undo the fixing bolts (1a) and remove the clutch assembly (1b). 1. Undo retaining bolts (1a) and remove flywheel (1b). 1. Remove the flywheel lock.

	Description	Code	Function
1	Flywheel lock	1.860.846.001	Prevent the rotation of the crankshaft

2. Undo the fixing bolts (2a) and remove the engine flywheel protection (2b). See descriptions

Support the engine on the overhaul stand using the recommended equipment.

1. Adjust the automatic belt tensioner using the tool to slacken the single engine component drivebelt.

	Description	Code	Function
1	Spanner	1.860.966.000	Automatic belt tensioner rotation for single components belt

2. Insert the tool in the special opening to keep the automatic belt tensioner in the "fixed" position.

	Description	Code	Function
2	Lock	1.870.645.000	Automatic belt tensioner retainer for single components belt

3. Release the cap for the single engine components belt tensioner.4. Loosen the bolt for the single engine components belt tensioner.5. Remove the single engine components drive belt.6. Remove the engine components belt pulley cap.7. Undo the bolt (7a) and remove the engine components single belt pulley (7b). 1. Undo the bolts (1a) and remove the timing drive belt guards (1b).2. Undo the bolts (2a) and remove the power unit reaction rod bracket (2b).3. Loosen the timing belt tensioner nut.4. Release the timing drive belt. 1. Disconnect the fuel supply pipe from the filter from the pressure pump.2. Disconnect the pressure pump side connector for the supply pipe from the pressure pump to the manifold using a suitable spanner.3. Undo the connector (3a) using a suitable spanner and remove the supply pipe from the pressure pump to the manifold (3b).

Use a new high pressure pipe between the high pressure pump and the fuel manifold when refitting.

4. Loosen the pressure pump support side bolts.5. Loosen the pressure pump support front bolts.6. Undo the bolts (6a) and remove the oil dipstick assembly (6b). 1. Undo the connector (1a) and disconnect the turbocharger oil inlet pipe (1b). 1. Undo the bolts (1a) and remove the turbocharger oil outlet pipe guard (1b).2. Disconnect the turbocharger oil outlet pipe from the oil sump. 1. Undo the nuts (1a) and disconnect the exhaust gas recirculation pipe (1b).2. Remove the seal.3. Undo the pipe retainer bracket bolt.4. Undo the bolt fixing the exhaust manifold bracket to the cylinder block/crankcase.5. Undo the nuts (5a) and remove the exhaust manifold (5b) complete with turbocharger and E.G.R. valve.6. Remove the seal. 1. Disconnect the oil vapour recovery pipe from the cylinder block/crankcase.2. Disconnect the condensation oil recovery pipe from the crankcase sump.3. Undo the nuts (3a) and remove the oil vapour separator (3b) complete with pipes.4. Remove the bracket.5. Disconnect the return pipe from the fuel filter to the return manifold.6. Undo the nuts (6a) and remove the fuel filter assembly (6b).7. Undo the bolts (7a) and remove the tappet cover (7b) complete with gasket. 1. Disconnect the water/oil heat exchanger coolant supply pipe from the thermostat.2. Disconnect the water/oil heat exchanger coolant outlet pipe from the manifold.3. Undo the bolts (3a) and remove the cylinder head assembly (3b).4. Remove the cylinder head gasket. Rotate the engine through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the plates (1b) connecting the crankcase sump to the intermediate shaft support.2. Undo the front and rear bolts (2a) fixing the crankcase sump using the tool (2b).

	Description	Code	Function
2b	Spanner	1.860.834.000	Loosen/Tighten front and rear engine oil sump bolts

3. Undo the side bolts (3a) fixing the crankcase sump using the tool (3b).

	Description	Code	Function
1b	Spanner	1.860.833.000	Loosen/Tighten engine oil sump side bolts

4. Remove the crankcase sump.

To release the sump from the crankcase, tap it gently using a resin hammer, then use a screwdriver for leverage in the projections in the sides of the crankcase sump.