199000405 - 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 engine coolant temperature sensor.

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

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

	Description	Connector
2	Rpm sensor	See K046 RPM SENSOR

3. Disconnect the electrical connection for the engine oil pressure warning light switch.

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

1. Disconnect the glow plug electrical connections.

	Description	Connector
1	Heater plugs	See A040 HEATER PLUGS

2. Disconnect the electrical connections for the injectors.

	Description	Connector
2	Injector	See N070 INJECTOR

3. Disconnect the electrical connection for the cam angle sensor.

	Description	Connector
3	Timing sensor	See K047 TIMING SENSOR

4. Disconnect the electrical connection for the air conditioning compressor engagement solenoid valve.

	Description	Connector
4	Air conditioning compressor engagement solenoid	See L021 AIR CONDITIONING COMPRESSOR ENGAGEMENT SOLENOID VALVE

5. Undo the bolts fixing the cable duct to the cylinder head.6. Release the electrical wiring (6a) from the fastenings (6b) and move it aside. 1. Disconnect the electrical connection for the fuel pressure sensor.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

2. Disconnect the electrical connection for the pressure relief sensor.

	Description	Connector
2	Supercharging sensor	See K082 SUPERCHARGING SENSOR

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

	Description	Connector
3	Fuel pressure regulator	See N077 FUEL PRESSURE REGULATOR

4. Disconnect the electrical connection for the E.G.R. solenoid valve.

	Description	Connector
4	EGR solenoid valve	See L030 EGR SOLENOID VALVE

5. Disconnect the electrical connection for the throttle (pneumatic) solenoid valve.

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

6. Release the electrical wiring (6a) from the bands (6b) securing the air intake chamber and remove it. 1. Undo the bolts (1a) and remove the oil filter guard (1b).2. Undo the connectors (2a) and remove the turbocharger engine oil supply pipe (2b).3. Undo the bolts securing the engine oil return pipe from the turbocharger, crankcase side.4. Undo the nuts (4a) and the bolt (4b) securing the engine lifting bracket and remove the exhaust manifold heat shield (4c). 1. Undo the nuts (1a) and remove the turbocharger (1b) complete with catalytic converter (1c). 1. Undo the bolts (1a) and remove the timing side rigid engine support (1b) complete with engine lifting bracket (1c). 1. Use a spanner in a clockwise direction on the moving tensioner (1a) and remove the engine components single drive belt (1b). 1. Undo the bolt (1a) and remove the engine components single belt moving tensioner (1b).2. Completely undo the fixing bolts (2a) loosened previously and remove the crankshaft pulley (2b).3. Undo the nuts (3a) and remove the coolant pump (3b) complete with gasket. 1. Completely undo the left bolt (1a) loosened previously and remove the pulley mounting flange on the crankshaft (1b).Refer to    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE 1. Undo the bolts (1a) and remove the intermediate driveshaft support (1b). 1. Undo retaining bolt (1a) and remove the engine oil dipstick tube (1b). - Rotate the engine through 180° on the overhaul stand.1. Undo the bolts (1a) and remove the support (1b).2. Undo the nuts (2a) and the bolts (2b) securing 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. 1. Undo the bolts (1a) and remove the crankcase oil sump partition (1b). - Rotate the crankcase through 180° on the overhaul stand.1. Undo the bolt (1a) and disconnect the connector (1b) for the engine oil vapour recovery pipe from the timing cover. 1. Undo the bolts (1a) and remove the timing cover (1b) complete with engine oil suction device (1c) and engine oil pump.- Remove the timing cover gasket.2. Keep the brackets. 1. Keep the tool fitted on the exhaust side camshaft.- Refer to    Op. 1004D10 POWER UNIT (MANUAL GEARBOX), REMOVED, DISMANTLE AND REASSEMBLE

Tool	Description	Function	Validity
1871000900	Template	Engine tuning	1.3 Multijet

1. Fit the camshaft timing adjustment tool.

Tool	Description	Function	Validity
1870900300	Template	Crankshaft tuning	1.3 Multijet

1. Undo the timing driven pulley fixing bolt.

Mark the position of the timing driven pulley, the timing drive pulley and the tmiing drive chain (if the chain removed is being reused); if the pullies are replaced, fit them with the writing facing outwards.

1. Undo the bolts (1a) and remove the timing chain fixed pad (1b).2. Undo the pin (2a) and remove the timing chain moving plate (2b).3. Remove the timing driven pulley (3a) together with the chain (3b) and the timing drive pulley (3c). 1. Undo the bolts (1a) and remove the mobile timing belt tensioner (1b). 1. Manually push the clips (1a) and disconnect the fuel outlet pipe from the injectors (1b).2. Loosen the connectors (2a) and remove the pipe from the pressure pump to the fuel manifold (2b).

Use a new pipe from the pressure pump to the fuel manifold when refitting.

3. Unscrew the connectors (3a) and remove the pipe from the fuel manifold to the injectors (3b).

Use new pipes from the fuel manifold to the injectors when refitting.

4. Loosen the band and disconnect the pipe (4a) from the fuel manifold (4b).5. Undo the bolts (5a) and remove the mounting bracket (5b) complete with single fuel manifold pipe (5c), fuel pressure regulator (5d) and fuel pressure sensor (5e). 1. Undo the injector fastening bracket nut.2. Keep the washer (2a) and the tapered washer (2b).3. Remove the injectors (3a), one at a time, using the tools (3b) and (3c).

If the injectors are being reused, mark the cylinder to which they belong so that they can be correctly refitted. If a new/new injector/s are fitted, run the initialisation procedure using an Examiner.

Tool	Description	Function	Validity
1870900700	Extractor	Removing injectors	1.3 Multijet

Tool	Description	Function	Validity
1870739000	Extractor	Removing injectors	1.3 Multijet1.9 Multijet

- Remove the injectors complete with bracket.

Replace the copper injector seals.

- Repeat the above procedure to remove the remaining pair of injectors.4. Remove the injector dust seals from the single camshaft housing.

These dust seals are replaced each time they are dismantled.

1. Undo the bolts (1a) and (1b) and remove the camshaft housing assembly (1c).2. Remove the seal. 1. Unscrew the bolt securing the water/exhaust gas heat exchanger for the EGR to the crankcase.2. Loosen the collar and disconnect the condensed engine oil recovery pipe, oil vapour separator side. 1. Loosen the band, undo the bolts (1a) and remove the coolant supply pipe to the engine oil heat exchanger (1b). 1. Loosen the band and disconnect the E.G.R. pipe from the thermostat. 1. Undo the bolts (1a) and remove the cylinder head assembly (1b).2. Remove the cylinder head gasket.