939010400 - 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. Undo the bolts and remove the power unit rigid support, timing side. 1. Adjust the belt tensioner to loosen and then remove the engine components drive belt. 1. Undo the nut and remove the wiring from the alternator. 1. Undo the bolt (1a), the bolt (1b) fastening the alternator (1c) and remove it from the support. 1. Undo the bolts (1a) and remove the alternator mounting (1b) from the engine crankcase. 1. Undo the bolts (1a) and remove the right front engine lifting bracket (1b). 1. Undo the bolts (1a) and remove the power steering pump (1b) from the support. 1. Undo the bolts (1a) and remove the power steering pump support (1b). 1. Disconnect 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. Undo the bolts (2a) and remove the air conditioning compressor (2b) from the mounting. 1. Undo the bolts (1a) and remove the air conditioner compressor mounting (1b). 1. Undo the bolts (1a) and remove the left front engine lifting bracket (1b). 1. Disconnect the electrical connection for the pressure regulator on the pressure pump.

	Description	Connector
1	Fuel pressure regulator	See N077 FUEL PRESSURE REGULATOR

1. Disconnect the electrical connection for the fuel pressure sensor on the fuel manifold pipe.

	Description	Connector
1	Fuel pressure sensor	See K083 FUEL PRESSURE SENSOR

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

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

2. Disconnect the electrical connection for the shut-off solenoid valve.

	Description	Connector
2

1. Disconnect the electrical connection for the absolute pressure sensor.

	Description	Connector
1	Absolute pressure sensor	See K048 ABSOLUTE PRESSURE SENSOR

1. Disconnect the rapid connectors (1a) and remove the engine oil vapour recovery pipe (1b).2. Undo the bolt (2a) and disconnect the earth lead (2b).3. Disconnect the electrical connections for the right cylinder head ignition coils.

	Description	Connector
3	Ignition coil	See A030 IGNITION COIL

4. Release the fastening clips and remove the cable duct. 1. Undo the bolts (1a) and remove the bracket (1b) fastening the electrical wiring.2. Disconnect the electrical connection for the right detonation sensor.

	Description	Connector
2	Detonation sensor - 2	See K050 DETONATION SENSOR

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

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

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

	Description	Connector
2	Rpm sensor	See K046 RPM SENSOR

1. Disconnect the electrical connections for the left cylinder head ignition coils.

	Description	Connector
1	Ignition coil	See A030 IGNITION COIL

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. Undo the bolt (2a) and disconnect the earth lead (2b). 1. Disconnect the electrical connection for the left detonation sensor.

	Description	Connector
1	Detonation sensor - 2	See K051 DETONATION SENSOR - 2

2. Disconnect the electrical connection for the engine oil pressure warning light switch.

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

1. Disconnect the intermediate couplings for the engine electrical wiring. 1. Disconnect the electrical connections for the left cylinder head phase transformer solenoids.

	Description	Connector
1	Inlet side phase transformer solenoid valve	See N092 PHASE SHIFTER SOLENOID VALVE ON INTAKE SIDE

	Description	Connector
1	Exhaust side phase transformer solenoid valve	See N093 PHASE SHIFTER SOLENOID VALVE ON EXHAUST SIDE

2. Disconnect the electrical connections for the left cylinder head cam angle sensors.

	Description	Connector
2	Timing sensor	See K047 TIMING SENSOR

1. Disconnect the electrical connections for the right cylinder head phase transformer solenoids.

	Description	Connector
1	Inlet side phase transformer solenoid valve	See N092 PHASE SHIFTER SOLENOID VALVE ON INTAKE SIDE

	Description	Connector
1	Exhaust side phase transformer solenoid valve	See N093 PHASE SHIFTER SOLENOID VALVE ON EXHAUST SIDE

2. Disconnect the electrical connections for the right cylinder head cam angle sensors.

	Description	Connector
2	Timing sensor	See K047 TIMING SENSOR

3. Disconnect the electrical connection for the throttle casing.

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

4. Undo the bolt (4a) and disconnect the earth lead (4b).5. Remove the engine wiring. 1. Undo the bolts (1a) and remove the air chamber assembly (1b).- Remove the seals. 1. Undo the bolts (1a) and remove the ignition coils (1b).2. Undo the bolts (2a) and remove the tappet covers (2b) complete with gaskets. - Unscrew the spark plugs and remove them.1. Undo the connectors (1a) and remove the high pressure pipe (1b) connecting the left and right fuel manifold pipes.2. Undo the bolt fixing the pipe mounting bracket to the right cylinder head. 1. Release the intermediate couplings for the engine electrical wiring from the mounting bracket.2. Undo the bolt (2a) and remove the mounting bracket (2b).3. Undo the bolts (3a) and remove the water pump rigid inlet pipe (3b) complete with gaskets. 1. Fit the tool to be used for counter-torque for the bolt fixing the services pulley on the crankshaft.

Tool	Description	Function	Validity
1860815000	Flange	Loosen/ tighten the bolt fixing the services pulley on the crankshaft	3.2 JTS

1. Undo the bolt fixing the services pulley on the crankshaft, using a spanner on the tool fitted previously for counter-torque. 1. Using a universal extrator (1a) and reaction disc (1b), remove the services pulley on the crankshaft (1c).

Tool	Description	Function	Validity
1845028000	Reaction disc	Removing services pulley on crankshaft	3.2 JTS

1. Undo the bolts (1a) and remove the engine components single belt moving tensioner (1b). - Undo the bolts fixing the water pump pulley using the tool for counter-torque.

Tool	Description	Function	Validity
1870815000	Counter-torque	Loosen/ tighten the nut fixing the right front wheel hub to the driveshaftLoosen/ tighten bolts securing the water pump

- Remove the water pump pulley.- Remove the spacer. 1. Undo the bolts (1a) and remove the phase transformer solenoids (1b) from the left and right cylinder heads. 1. Undo the bolts (1a) and remove the engine front cover (1b) complete with oil seal (1c) water pump and cam angle sensors.

Using a suitable tool, cut the sealant between the engine and the engine front cover.

- Working at the bench, remove the oil seal from the engine front cover.

Take care not to damage the oil seal seal during its removal.

1. Undo the bolts (1a) and remove the hydraulic tensioner (1b) for the right cylinder head secondary timing chain.2. Undo the bolt (2a) and remove the moving pad (2b).3. Undo the bolts (3a) and remove the fixed pad (3b).4. Remove the right cylinder head secondary timing chain. 1. Undo the bolts (1a) and remove the primary timing chain hydraulic tensioner (1b).2. Undo the bolts (2a) and remove the fixed pad (2b) and the lower pad.3. Remove the primary timing chain. 1. Undo the bolts (1a) and remove the hydraulic tensioner (1b) for the left cylinder head secondary timing chain.2. Undo the bolt (2a) and remove the moving pad (2b).3. Undo the bolts (3a) and remove the fixed pad (3b).4. Remove the left cylinder head secondary timing chain. 1. Release the engine oil dipstick and remove it.2. Undo the bolt (2a) and remove the engine oil dipstick tube (2b). 1. Undo the bolts (1a) and remove the phase transformers (1b) for the left cylinder head.

Use a spanner on the hexagonal bolts on the camshafts to create counter-torque.

IN (inlet) and EX (exhaust) are stamped on the phase transformers identifying the fitting side.

1. Undo the bolts (1a), (1b) and remove the left cylinder head.- Remove the left cylinder head gasket.- Remove the locating pins. 1. Undo the bolts and remove the right cylinder head.- Remove the right cylinder head gasket.- Remove the locating pins. - Rotate the engine through 180 ° on the overhaul stand.1. Undo the bolts (1a) and remove the engine oil filter and heat exchanger mounting (1b).- Remove the gasket. 1. Undo the bolts fixing the engine oil sump.- Cut the crankcase sump sealant using the tool.

Tool	Description	Function	Validity
1870718000	Blade	Cut the crankcase sump sealant

2. Remove the crankcase sump using leverage at the points shown by the arrows in the diagram.- Remove the locating pins.