199000405 - 1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL

1. Undo the bolts (1a) and remove the timing belt inner guard (1b). 1. Disconnect the electrical connection for the engine rpm sensor.

	Description	Connector
1	Rpm sensor	See K046 RPM SENSOR

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

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

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

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

2. Undo the bolt and remove the earth lead from the auxiliary support. 1. Undo the nut and remove the alternator earth lead.2. Detach the electrical connection for the air conditioning compressor.

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

1. Disconnect the injector wiring coupling.

	Description	Connector
1	Injector coupling	See D081 INJECTOR JUNCTION

1. Disconnect the electrical connection for the knock sensor.

	Description	Connector
1	Knock sensor	See K050 DETONATION SENSOR

2. Disconnect the electrical connection for the fuel vapour solenoid valve.

	Description	Connector
2	Fuel vapour recovery solenoid valve	See L010 FUEL VAPOUR RECOVERY SOLENOID VALVE

3. Open the retaining clips and move the wiring to one side. 1. Detach the electrical connection for the throttle body.

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

2. Disconnect the electrical connection for the pressurized air by-pass solenoid valve.

	Description	Connector
2	Turbocharger by-pass solenoid	See L102 TURBOCHARGER BY-PASS SOLENOID VALVE

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

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

1. Undo the bolt and remove the earth lead.2. Disconnect the electrical connections for the ignition coils.

	Description	Connector
2	Ignition coil	See A030 IGNITION COIL

3. Detach the timing sensor electrical connection.

	Description	Connector
3	Timing sensor	See K047 TIMING SENSOR

4. Undo the bolt and remove the engine wiring. 1. Adjust the moving tensioner, lock it using a suitable pin and remove the engine components single belt. 1. Undo the bolts (1a) and remove the air conditioner compressor (1b).2. Undo the bolts (2a) and remove the alternator (2b). 1. Undo the fastenings (1a) and remove the alternator and air conditioning compressor mounting (1b) complete with moving tensioner. 1. Undo the bolts (1a) and remove the intermediate shaft bearing support (1b). 1. Undo the bolt (1a) and remove the engine oil dipstick tube (1b). 1. Undo the bolts (1a) and remove the bracket (1b).2. Loosen the band and remove the oil vapour supply pipe to the air chamber. 1. Undo the bolts (1a) and remove the air chamber (1b). 1. Undo the bolts (1a) and remove the oil vapour separator (1b). 1. Undo the fastenings and remove the bracket (1a) complete with pressurized air by-pass solenoid valve (1b). 1. Unscrew the bolts and remove the engine oil filter heat shield.2. Undo the bolts and remove the water-engine oil heat exchanger heat shield. 1. Undo the fastenings and remove the turbocharger heat shield. 1. Undo the bolts securing the turbocharger lubrication oil return pipe to the engine block, turbocharger side.2. Undo the bolts securing the turbocharger lubrication oil return pipe to the engine block, engine block side.3. Undo the intermediate connector securing the turbocharger lubrication oil return pipe to the engine block, engine oil heat exchanger side and remove it. 1. Unscrew the connector for the coolant delivery pipe to the engine oil heat exchanger, heat exchanger side.2. Unscrew the connector for the coolant delivery pipe to the engine oil heat exchanger, thermostat side.3. Undo the bolt (3a) and remove the engine oil heat exchanger water supply pipe (3b). 1. Unscrew the connector for the coolant return pipe from the engine oil heat exchanger, heat exchanger side.2. Undo the connector for the water return pipe from the engine oil heat exchanger, rigid return pipe side to the water pump and remove it. 1. Undo the connector for the turbocharger lubrication oil supply pipe, heat exchanger side.2. Undo the turbocharger lubrication oil supply pipe connector, turbocharger side.3. Undo the bolt fixing the turbocharger lubrication oil supply pipe intermediate bracket and remove it. 1. Undo the turbocharger coolant return pipe connector, turbocharger side.2. Undo the turbocharger coolant return pipe connector, rigid return pipe to the water pump and remove it. 1. Undo the nuts (1a) and remove the exhaust manifold heat shield (1b). 1. Undo the nuts (1a) and remove the exhaust manifold-turbocharger assembly (1b). 1. Undo the bolt fixing the water pump rigid return pipe, cylinder head side.2. Undo the bolt fixing the water pump rigid return pipe, cylinder block/crankcase side.3. Remove the rigid return pipe to the water pump complete with seal. 1. Undo the bolt fixing the oil filter mounting and engine oil heat exchanger assembly, cylinder block/crankcase side.2. Undo the connector (2a) securing the oil filter mounting and engine oil heat exchanger assembly (2b), crankshaft front oil seal cover side and remove it. 1. Undo the bolts (1a) and remove the crankshaft pulley (1b).2. Undo the bolts (2a) and remove the timing belt guards (2b). 1. Undo the bolts (1a) and remove the rigid power unit support (1b). 1. Loosen the nut securing the timing drive belt moving tensioner.2. Remove the timing belt. 1. Undo the bolts and remove the ignition coils. 1. Fit the tool (1a) locking the camshaft driven pulley (1b).

Tool	Description	Function	Validity
2000015800	Counter-torque	Camshaft driven pulley lock	1.4 16v

1. Undo the nuts (1a) and remove the cover (1b). 1. Loosen the bolts (1a) securing the camshaft rear gears (1b). 1. Undo the bolt (1a) and remove the crankshaft driven pulley (1b). - Undo the bolt and remove the camshaft driven pulley locking tool.1. Undo the protective caps for the bolts fixing the camshaft housing to the cylinder head.2. Using the tool (2a), undo the bolts (2b) fixing the camshaft housing to the cylinder head.

Tool	Description	Function	Validity
1860834000	Spanner	Loosen/tighten the cylinder head extension bolts	1.4 16v

3. Position the tool (3a) for retaining the tappets underneath the camshaft housing (3b) and remove it.

Tool	Description	Function	Validity
1860988000	Tappet retaining tool	Tappet retaining	1.4 16v

4. Remove the seal. 1. Undo the bolts (1a), remove the cylinder head (1b) and keep the gasket (1c).2. Remove the locating dowels. - Rotate the engine through 180° on the overhaul stand.1. Undo bolts (1a) and nuts (1b) securing the engine oil sump to the crankcase.2. Using the tool, cut the silicone sealant along the entire perimeter of the engine oil sump.

Tool	Description	Function	Validity
1870718000	Blade	Cut sealant

3. Remove the engine oil sump. - Clean the contact surfaces between the crankcase and the oil sump thoroughly.