244000625 - 1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL

See in Op. 1004D401.- Disconnect the electrical connections for the injection wiring.

	Description	Connector
.	Injector	N070A

	Description	Connector
.	Injector	N070B

	Description	Connector
.	Injector	N070C

	Description	Connector
.	Injector	N070D

	Description	Connector
.	Timing sensor	K047

	Description	Connector
.	Fuel pressure sensor	K083

	Description	Connector
.	Coolant temperature sending unit (for instrument panel)	K035

	Description	Connector
.	Engine coolant temperature sensor/sender unit	K036

	Description	Connector
.	Rpm sensor	K046

	Description	Connector
.	Fuel pressure regulator	N077

- Disconnect the glow plug connections.

	Description	Connector
.	Heater plugs	A040A

	Description	Connector
.	Heater plugs	A040B

	Description	Connector
.	Heater plugs	A040C

	Description	Connector
.	Heater plugs	A040D

- Remove the injection wiring and the glow plug wiring.1. Press connectors (1a), undo clips (1b) and disconnect the fuel recirculation pipe from the injectors.2. Prise off the fuel recirculation pipe. 1. Unscrew the glow plugs and remove. 1. Unscrew the connectors and remove the pipes from the fuel manifold to the injectors.2. Unscrew the connectors and remove the pipe from fuel manifold to pressure pump.3. Undo connector (3a) and disconnect the fuel return pipe.4. Undo bolts (4a) and remove fuel manifold (4b). 1. Undo bolts (1a) and remove fuel vapour separator cover (1b). 1. Undo nuts (1a) and remove bracket (1b) supporting the cold air intake pipe to the turbocharger. 1. Undo bolts (1a) and remove brackets (1b) for the injectors.2. Use appropriate tools (2a) and (2b) to remove injectors (2c) with seal.

	Description	Code	Function
2a	Extractor	1.870.850.000	Injector removal

	Description	Code	Function
2b	Mallet	1.840.206.001	Injector removal

1. Fit the flywheel locking tool.

	Description	Code	Function
1	Counter-torque	1.860.846.000	Flywheel lock

1. Undo the bolts (1a) and remove the crankshaft pulley (1b). 1. Undo the bolts (1a) and remove the timing cover (1b). 1. Loosen the tensioner screw.2. Remove the timing belt.

If the mileage for the belt is more than 25,000 km, it must be replaced irrespective of its appearance or wear. If it is not being replaced, remember that the replacement interval for the timing belt and automatic tensioner as set out in the maintenance programme is every 240,000 km or 5 years.

1. Undo the retaining bolts.2. Remove the head extension.3. Remove the seal. 1. Undo retaining bolt (1a) and remove the engine oil dipstick tube (1b).2. Remove the bands and disconnect the connector from thermostat (2a) and the connector from engine oil heat exchanger (2b).3. Undo bolts (3a) and remove pipe (3b) from thermostat to radiator and pipe (3cv) from engine oil heat exchanger to radiator. 1. Undo bolts (1a) and place fuel manifold (4b) to one side. 1. Undo bolts (1a) and remove engine coolant filler pipe (1b) complete with sealing ring (1c). 1. Remove rockers (1a) complete with return springs (1b) and tappets (1c). 1. Undo bolts (1a) and remove cylinder head (1b) complete with heat exchanger for EGR (1c), intake manifold (1d) and thermostat (1e).- Remove the cylinder head gasket. - Turn the engine on the overhaul stand.1. Undo bolts (1a) and remove the engine block sump.