2585281 - 1004E10 engine, removed - remove cylinder head and oil sump for inspection - includes positioning on stand and removal

Place the engine on the overhaul stand.    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE.1. Disconnect the electrical connection from the engine coolant temperature sensor.

	Description	Connector
1	I.E. engine temperature sensor	See K45 COOLANT TEMPERATURE SENDER UNIT ( ENGINE )

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

	Description	Connector
2	Rpm sensor	See K46 RPM SENSOR ( ENGINE )

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

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

1. Disconnect the electrical connections from the heater plugs.

	Description	Connector
1	Heater plugs	See A040 HEATER PLUGS

2. Disconnect the electrical connections from the injectors.

	Description	Connector
2	Injector	See N070 INJECTOR

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

	Description	Connector
3	Timing sensor	See K47 TIMING SENSOR ( ENGINE )

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

	Description	Connector
4	Air conditioning compressor engagement electro-magnet	See L020 AIR CONDITIONING COMPRESSOR ENGAGEMENT SOLENOID

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 from the fuel pressure sensor.

	Description	Connector
1	Fuel pressure sensor	See K83 FUEL PRESSURE SENSOR ( ENGINE )

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

	Description	Connector
2	Supercharging sensor	See K082 TURBOCHARGING SENSOR

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

	Description	Connector
3	Fuel pressure regulator	See N77 FUEL PRESSURE REGULATOR ( ENGINE )

4. Disconnect the electrical connection for the EGR solenoid valve.

	Description	Connector
4	EGR solenoid valve	See L30 EGR SOLENOID VALVE ( ENGINE )

5. Release the electrical wiring (5a) from the bands (5b) securing the air intake chamber and remove it. Remove the protective strips on the oil filter and the engine oil heat exchanger.1. Undo the bolts securing the engine oil return pipe from the turbocharger, crankcase side.2. Undo the connectors (2a) and remove the turbocharger engine oil supply pipe (2b). 1. Undo the bolts (1a) and the nut (1b) and remove the exhaust manifold heat shield (1c) complete with engine lifting bracket (1d).2. Undo the bolt securing the engine oil heat exchanger coolant supply pipe to the engine block.3. Undo the bolts (3a), loosen the band (3b) and remove the engine oil heat exchanger coolant supply pipe (3c) complete with gasket. 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 an anti-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).    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE. Undo the bolts and remove the intermediate driveshaft support.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.

	Description	Code
3	Blade	1.870.718.000

4. Remove the crankcase sump. 1. Undo the bolts (1a) and remove the crankcase oil sump partition (1b). Rotate the engine 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    Op. 1004d10 POWER UNIT (MANUAL GEARBOX), REMOVED, REMOVE AND RE-BUILD

	Description	Code
1b	Template	1.871.000.900

1. Fit the camshaft timing adjustment tool.

	Description	Code
1b	Template	1.870.900.300

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. Remove the timing driven pulley (1a) together with the chain (1b) and the timing drive pulley (1c).2. Undo the bolts (2a) and remove the timing chain fixed plate (2b).3. Undo the pin (3a) and remove the timing chain fixed plate (3b). 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 pipes 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 return pipe from the pressure pump to the fuel manifold, pressure pump side.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.

	Description	Code
3b	Extractor	1.870.900.700

	Description	Code
3c	Extractor	1.870.739.000

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. Undo the bolts (1a) and remove the cylinder head assembly (1b).2. Remove the cylinder head gasket.