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 air conditioning compressor engagement solenoid.

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

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 fixing 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

2. Disconnect the electrical connection for the engine oil level sensor.

	Description	Connector
2	Engine oil level sensor	See K032 ENGINE OIL LEVEL SENSOR

1. Disconnect the glow plug electrical connections.

	Description	Connector
1	Heater plugs	See A040 HEATER PLUGS

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

	Description	Connector
2	Fuel pressure regulator on rail	See N087 FUEL PRESSURE REGULATOR ON RAIL

1. Disconnect the electrical connections for the injectors.

	Description	Connector
1	Injector	See N070 INJECTOR

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

	Description	Connector
2	EGR solenoid valve	See L030 EGR SOLENOID VALVE

3. Disconnect the electrical connection for the turbo sensor.

	Description	Connector
3	Supercharging sensor	See K082 SUPERCHARGING SENSOR

1. Disconnect the electrical connection for the air 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 throttle casing.

	Description	Connector
2	Integrated throttle casing 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. Loosen the bands and remove the heater water supply and return pipes.2. Undo the nut (2a), loosen the bands (2b) and (2c) and remove the duplex pipes (2d). 1. Disconnect the pipes from the vacuum reservoir.2. Undo the bolts and remove the mounting complete with vacuum reservoir. 1. Undo the bolts and remove the protective timing cover. 1. Undo the bolts and remove the timing belt (1b) side guard (1a).2. Undo the bolts (2a), disconnect the hose (2b) and remove the water pump rigid return pipe (2c).3. Undo the bolts (3a) and remove the engine oil dipstick tube (3b). - Undo the bolts and disconnect the E.G.R. exhaust gas intake hose from the exhaust manifold.1. Undo the turbocharger engine oil supply pipe and disconnect it.2. Undo the bolts and disconnect the engine oil return hose from the turbocharger.3. Undo the nuts (3a) and remove the exhaust manifold - turbocharger assembly complete with precatalyzer (3b).- Remove the gasket. 1. Adjust the moving tensioner (1a) using a spanner to slacken the single engine component drivebelt (1b) tension and remove it.2. Undo the bolts (2a) and remove the crankshaft pulley (2b).3. Undo the bolt (3a) and remove the auxiliary drive belt fixed tensioner (3b). 1. Undo the bolts (1a) and remove the rigid power unit support (1b). 1. Undo the moving tensioner (1a) bolt and remove the timing belt (1b). 1. Undo the pressure pump support side bolts.2. Undo the connectors (2a), (2b) and remove the rigid pipe from the pressure pump to the fuel manifold (2c).

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

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

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

3. Undo the side bolts fixing the crankcase sump.4. Remove the sealant using the tool (4a) and remove the engine oil sump (4b).

Tool	Description	Function	Validity
1870718000	Blade	Cut sealant