198002910 - 1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL

    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE 1. Disconnect the electrical connection for the air conditioning compressor engagement solenoid.

	Description	Connector
1	Air conditioning compressor engagement solenoid	See L020 AIR CONDITIONING COMPRESSOR ENGAGEMENT ELECTRO-MAGNET

1. Disconnect the electrical connection for the minimum engine oil pressure switch.

	Description	Connector
1	Insufficient engine oil pressure sensor	See K030 ENGINE OIL PRESSURE SENSOR (SWITCH)

2. Undo the nuts and disconnect the electrical connections for the alternator.

	Description	Connector
2	Alternator	See A010 ALTERNATOR

1. Disconnect the electrical connection for the rpm sensor.

	Description	Connector
1	Rpm sensor	See K046 RPM SENSOR

1. Disconnect the glow heater plug electrical connections.

	Description	Connector
1	Glow heater plugs	See A040 HEATER PLUGS

1. Detach the electrical connections for the injectors.

	Description	Connector
1	Injector	See N070 INJECTOR

2. Disconnect the electrical connection for the E.G.R. solenoid.

	Description	Connector
2	EGR solenoid	See L030 EGR SOLENOID VALVE

3. Disconnect the electrical connection for the turbocharging sensor.

	Description	Connector
3	Turbocharging sensor	See K044 AIR TEMPERATURE/PRESSURE SENSOR

1. Detach the air temperature sensor electrical connection.

	Description	Connector
1	Engine coolant temperature sensor/sender unit	See K036 ENGINE COOLANT TEMPERATURE SENSOR/SENDER UNIT

2. Detach the electrical connection for the throttle body.

	Description	Connector
2	Integrated throttle body actuator	See N075 BUILT-IN THROTTLE BODY ACTUATOR

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

	Description	Connector
3	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

- Remove the engine wiring. 1. Disconnect the pipes from the vacuum tank.2. Undo the bolts and remove the mounting complete with vacuum tank. 1. Undo the bolts and remove the timing belt protective cover. - Undo the bolts and remove the timing belt side protection.- Undo the bolts and remove the water pump rigid return pipe.- Undo the bolt and remove the engine oil dipstick tube. 1. Adjust moving tensioner (1a) using a spanner to slacken auxiliary drivebelt (1b) tension and remove it.2. Undo bolts (2a) and remove crankshaft pulley (2b).3. Undo bolt (3a) and remove auxiliary drive belt fixed tensioner (3b). 1. Undo moving tensioner (1a) bolt and remove timing belt (1b). 1. Undo the pressure pump support side bolts.2. Undo connectors (2a), (2b) and remove the rigid pipe from the pressure pump to fuel manifold (2c).

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

3. Loosen bands (3a) and (3b) and remove the pipe from the pressure pump to fuel return manifold pipe (3c). 1. Undo front bolt (1a) and remove pressure pump mounting (1b) complete with alternator (1c). 1. Undo bolts (1a) and remove tappet cover (1b) complete with gasket.2. Undo bolts (2a) and remove cylinder head assembly (2b).3. Remove the cylinder head gasket. 1. Undo bolts (1a) and remove mounting (1b) complete with air conditioning compressor (1c). - Rotate the engine through 180° on the overhaul stand.1. Undo the bolts securing the oil sump to the gearbox.2. Unscrew bolts (2a) securing the sump to the crankcase, timing-side and gearbox-side, using tool (2b).

Tool	Description	Function	Validity
1860833000	Spanner	Loosen/tighten the bolts securing the crankcase sump, timing side and gearbox side	1.9 JTD

3. Undo the side bolts securing the crankcase sump.4. Cut the sealant using tool (4a) and remove oil sump (4b).

Tool	Description	Function	Validity
1870718000	Blade	Cut sealant