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 from the rpm sensor.

	Description	Connector
1	Rpm sensor	See K046 RPM SENSOR

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

	Description	Connector
1	Engine oil pressure sensor (switch)	See K030 ENGINE OIL PRESSURE SENSOR (SWITCH)

1. Detach the electrical connection for the swirl actuator.

	Description	Connector
1	Flow modifier solenoid	See L064 FLOW MODIFYING SOLENOID VALVE

1. Disconnect the electrical connection for the EGR solenoid.

	Description	Connector
1	E.G.R. solenoid	See L030 EGR SOLENOID VALVE

2. Disconnect the electrical connection for the air temperature and pressure sensor.

	Description	Connector
2	Air pressure - temperature sensor	See K044 AIR TEMPERATURE/PRESSURE SENSOR

3. Detach the electrical connection for the fuel pressure regulator.

	Description	Connector
3	Fuel pressure regulator	See N077 FUEL PRESSURE REGULATOR

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

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

1. Detach the electrical connection for the throttle casing.

	Description	Connector
1	Integrated throttle casing actuator	See N075 BUILT-IN THROTTLE BODY ACTUATOR

1. Disconnect the electrical connection from the fuel pressure sensor.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

2. Detach the electrical connections from the injectors.

	Description	Connector
2	Injector	See N070 INJECTOR

3. Detach the electrical connections from the glow heater plugs.

	Description	Connector
3	Glow heater plugs	See A040 HEATER PLUGS

4. Disconnect the electrical connection from the cam angle sensor.

	Description	Connector
4	Timing sensor	See K047 TIMING SENSOR

5. Disconnect the electrical connection from the air conditioning compressor engagement electromagnet.

	Description	Connector
5	Air conditioning compressor engagement electro-magnet	See L020 AIR CONDITIONING COMPRESSOR ENGAGEMENT ELECTRO-MAGNET

6. Disconnect the earth lead for the air conditioning compressor.

	Description	Connector
6	Compressor earth	See C039 COMPRESSOR EARTH

1. Apply a wrench to moving tensioner (1a), then prise up and remove 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 control 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 moving timing belt tensioner fastening (1a), then release and remove toothed timing drive belt (1b). - Undo the bolts and remove the engine oil dipstick tube assembly. - Loosen the bands and disconnect the pipes from the thermostat. - Loosen the band and disconnect the engine oil vapour recovery pipe from the engine oil filler. 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 tank. 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 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 injectors (2a) complete with brackets, using tool (2b).

Tool	Description	Function	Validity
1870897300	Extractor	Removing injectors	1.9 JTD 16v

If new injector/s is/are fitted: read the identification code of the new injector/s off the engine control unit. Use an Examiner to check that the engine control unit 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 bolts (1a) and remove cylinder head extension assembly (1b).2. Remove the gasket.2. Remove the valve rockers. 1. Unscrew the glow heater plugs and remove. 1. Undo bolts (1a) and remove 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
1870718000	Blade	Cut sealant

4. Remove the crankcase sump.