1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL - Alfa - 159 - eLearn

939010400 - 1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL

1. Loosen band (1a) securing oil vapour pipe (1b) to the separator.2. Undo the bolt fixing the oil vapour pipe to the intake chamber.

1. Undo bolt (1a) securing bracket (1b) which supports oil vapour pipe (1c) to the rigid return pipe to the water pump and remove it.

1. Undo nut (1a) and remove supply cable (1b) from the alternator.

1. Detach the electrical connection for the air conditioning compressor.

	Description	Connector
1	Air conditioning compressor engagement electro-magnet	See L020 AIR CONDITIONING COMPRESSOR ENGAGEMENT ELECTRO-MAGNET

2. Detach the electrical connection for the alternator.

	Description	Connector
2	Alternator	See A010 ALTERNATOR

1. Detach the electrical connection for the timing sensor.

	Description	Connector
1	Timing sensor	See K047 TIMING SENSOR

1. Detach the electrical connections for the injectors.

	Description	Connector
1	Injector	See N070 INJECTOR

2. Undo bolts (2a) and move channel (2b) to one side.

1. Detach the electrical connection for the pressure regulator on the single fuel manifold.

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

2. Detach the electrical connections for the spark plugs.

	Description	Connector
2	Heater plugs	See A040 HEATER PLUGS

3. Detach the electrical connection for the pressure relief sensor.

	Description	Connector
3	Supercharging sensor	See K082 SUPERCHARGING SENSOR

1. Detach the electrical connection for the fuel pressure sensor.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

1. Detach the electrical connection for the air temperature sensor.

	Description	Connector
1	Engine temperature sending unit	See K036 ENGINE COOLANT TEMPERATURE SENSOR/SENDER UNIT

2. Detach the electrical connection for the throttle casing.

	Description	Connector
2	Integrated throttle casing actuator	See N075 THROTTLE BODY ACTUATOR

1. Detach the electrical connection for the swirl solenoid.

	Description	Connector
1	Flow modifier solenoid valve	See L064 FLOW MODIFYING SOLENOID VALVE

1. Detach the electrical connection for the rpm sensor.

	Description	Connector
1	Rpm sensor	See K046 RPM SENSOR

1. Detach the electrical connection for the engine oil level sensor.

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

1. Detach the electrical connection for the engine oil pressure switch.

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

1. Detach the electrical connection for the fuel flow regulator on the pressure pump.

	Description	Connector
1	Fuel pressure regulator	See N077 FUEL PRESSURE REGULATOR

1. Detach the electrical connection for the E.G.R. command solenoid.

	Description	Connector
1	EGR solenoid valve	See L030 EGR SOLENOID VALVE

- Open the various wiring retaining clips and remove from the engine.

1. Using tool (1a), release automatic tensioner (1b) on auxiliary drivebelt (1c) and remove it.

Tool	Description	Function	Validity
1860966000	Spanner	Loosen the single engine components drive belt tension	2.4 JTD 20V

1. Undo bolts (1a) and remove auxiliary drivebelt automatic tensioner (1b).

1. Undo bolts (1a) securing air conditioning compressor (1b) and remove it along with alternator drive belt (1c)

1. Undo bolt (1a) securing guard (1b) and remove it.2. Undo bolts (2a) and remove alternator (2b).

1. Undo bolts (1a) and remove mounting (1b) complete with hydraulically assisted steering pump.

1. Undo bolts (1a) and remove turbocharger rigid air inlet hose (1b).- Remove the gasket.2. Undo fastenings (2a) and remove heat shield (2b) from the turbocharger manifold unit.

1. Undo bolts (1a) and disconnect turbocharger lubrication oil outlet pipe (1b) from the sump.- Open the retaining tabs and remove the gasket.

1. Undo connector (1a) and disconnect turbocharger lubrication oil supply pipe (1b) from the crankcase.

1. Undo the nut securing the precatalyzer mounting bracket intermediate fastening.2. Loosen the fastening collar for the exhaust gas flexible coupling to the heat exchanger.3. Undo nuts (3a) and remove exhaust manifold (3b) complete with turbocharger (3c) and precatalyzer (3d).- Remove the exhaust manifold gasket.

1. Undo bolts (1a) and remove timing belt guard (1b).2. Undo bolts (2a) and remove timing side rigid engine support (2b).

1. Undo bolts (1a) and remove auxiliary drivebelt pulley (1b).

1. Undo nut (1a) of mobile tensioner (1b) to loosen and then remove the timing drive belt (1b).

1. Disconnect the two flexible pipes from the vacuum tank.2. Disconnect the flexible pipe from the vacuum.3. Undo the bolts securing the rigid vacuum pipes and remove them.

1. Loosen the connectors and remove the single fuel manifold rigid supply pipe.2. Loosen the connectors and remove the injectors fuel supply pipe.3. Loosen the band and disconnect the return pipe from the single fuel manifold, return manifold side.4. Undo bolts (4a) and remove single fuel manifold (4b).5. Disconnect the fuel return pipe for the injectors from the return manifold and remove it.

1. Undo the injector bracket retaining nuts.2. Remove injectors (2a) complete with brackets, using tool (2b).

If a new injector/new injectors are fitted:- determine the identification code stamped on the top surface;- check, using an Examiner, that the new injector(s) is (are) recognised by the engine management control unit.

Start the removal beginning with the injector for the first cylinder and continue with the injectors for the second, third, fourth and fifth cylinders.

Tool	Description	Function	Validity
1870897300	Extractor	Removing injectors	1.9 JTD 8V1.9 JTD 16V2.4 JTD 20V

1. Loosen the collar and disconnect the engine oil vapour pipe from the engine oil inlet opening.2. Undo bolts (2a) and remove upper cylinder head (2b).

1. Undo bolts (1a) and remove timing belt side guard (1b).

1. Loosen the band and disconnect the exhaust pipe for oil condensed in the sump.2. Loosen the band and disconnect the oil exhaust pipe from the oil filter.3. Loosen the band and disconnect the oil vapour intake pipe from the engine block.

1. Undo bolts (1a) and remove the bracket complete with oil vapour separator (1b) and piping.

1. Undo nuts (1a) and remove vacuum tank (1b).

1. Disconnect the swirl valves control arm.2. Undo bolts (2a) and remove swirl valves control mechanism (2b).

1. Loosen the band and disconnect the pressure pump flexible fuel return pipe, return manifold side.

1. Fit the mounting bracket on the cylinder head.

Tool	Description	Function	Validity
1860470000	Support	Overhaul cylinder head

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

1. Undo bolts (1a) and remove engine oil dipstick tube (1b).

1. Undo the bolt securing the oil pipe support bracket to the sump.2. Undo bolts (2a) and remove oil pipes (2b) from the oil filter mounting.- Remove the O-rings.

1. Undo bolts (1a) and remove oil filter mount (1b).2. Remove the O-rings.

1. Undo bolts (1a) and remove pressure pump mount (1b) complete with pump.

1. Undo the bolts fixing the oil sump to the engine block, using the tool.

Tool	Description	Function	Validity
1860834000	Spanner	Loosen/ tighten front and rear crankcase sump bolts	2.4 JTD 20V

2. Undo the bolts securing the oil sump to the crankcase front and rear covers, using the tool.

Tool	Description	Function	Validity
1860833000	Spanner	Loosen/ tighten the bolts securing the crankcase sump, timing side and gearbox side	1.9 JTD 8V2.4 JTD 20V

3. Cut the oil sump sealant using the tool.

Tool	Description	Function	Validity
1870718000	Blade	Cut the crankcase sump sealant

4. Remove the oil sump.