323001628 - 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 heater plug electrical connections.

	Description	Connector
1	Glow heater plugs	See A040 HEATER PLUGS

2. Detach 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 securing the cable duct to the cylinder head.6. Release electrical wiring (6a) from fastenings (6b) and move it aside. 1. Detach the fuel pressure sensor electrical connection.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

2. Detach the excess pressure sensor electrical connection.

	Description	Connector
2	Turbocharging 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

	Description	Connector
4	EGR solenoid	See L030 EGR SOLENOID VALVE

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

	Description	Connector
5	Integrated throttle body actuator	Vedere

6. Release electrical wiring (6a) from bands (6b) securing the air intake chamber and remove it. 1. Undo bolts (1a) and remove oil filter guard (1b).2. Undo connectors (2a) and remove turbocharger engine oil supply pipe (2b).3. Undo the bolts securing the engine oil return pipe from the turbocharger, crankcase side.4. Undo nuts (4a) and bolt (4b) securing the engine lifting bracket and remove exhaust manifold heat partition (4c). 1. Undo nuts (1a) and remove turbocharger (1b) complete with catalytic converter (1c). 1. Undo bolts (1a) and remove timing side rigid engine support (1b) complete with engine lifting bracket (1c). 1. Use a wrench in a clockwise direction on moving tensioner (1a) and remove auxiliary drivebelt (1b). 1. Undo bolt (1a) and remove auxiliary drivebelt moving tensioner (1b).2. Completely undo bolts (2a) loosened previously and remove crankshaft pulley (2b).3. Undo nuts (3a) and remove coolant pump (3b) complete with gasket. 1. Completely undo left hand thread bolt (1a) loosened previously and remove the pulley mounting flange on crankshaft (1b).Refer to    Op. 1004D40 ENGINE - POSITION ON STAND AND REMOVE 1. Undo bolts (1a) and remove intermediate driveshaft mount (1b). 1. Undo retaining bolt (1a) and remove engine oil dipstick tube (1b) assembly. - Rotate the engine through 180° on the overhaul stand.1. Undo bolts (1a) and remove mount (1b).2. Undo nuts (2a) and 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 bolts (1a) and remove crankcase oil sump buffeting bulkhead (1b). - Rotate the crankcase through 180° on the overhaul stand.1. Undo bolt (1a) and disconnect connector (1b) for the engine oil vapour recovery pipe from the timing cover. 1. Undo bolts (1a) and remove timing cover (1b) complete with engine oil suction head (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 crankshaft timing tool.

Tool	Description	Function	Validity
1870900300	Template	Crankshaft tuning	1.3 Multijet

1. Undo the timing driven pulley bolt.

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

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

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

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

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

4. Loosen the band and disconnect pipe (4a) from fuel manifold (4b).5. Undo bolts (5a) and remove mounting bracket (5b) complete with common rail (5c), fuel pressure regulator (5d) and fuel pressure sensor (5e). 1. Undo the injector fastening bracket nut.2. Keep washer (2a) and tapered washer (2b).3. Remove injectors (3a) from seats one at a time, using 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 injector/new injectors are being fitted, run the self-learning 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 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 cylinder head extension.

These dust seals are replaced each time they are dismantled.

1. Undo bolts (1a) and (1b) and remove cylinder head extension (1c) assembly.2. Remove the seal. 1. Unscrew the bolt securing the coolant/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 bolts (1a) and remove the coolant supply pipe to engine oil heat exchanger (1b). 1. Loosen the band and disconnect the E.G.R. pipe from the thermostat. 1. Undo bolts (1a) and remove cylinder head assembly (1b).2. Remove the cylinder head gasket.