1004E10 ENGINE, REMOVED - REMOVE CYLINDER HEAD AND OIL SUMP FOR INSPECTION - INCLUDES POSITIONING ON STAND AND REMOVAL
Engines: 2.3 JTD 16V, 2.8 JTD 8V
Engines: 2.3 JTD 16V
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.
Engines: 2.3 JTD 16V
1. Unscrew the glow plugs and remove.
Engines: 2.3 JTD 16V
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 nuts (1a) and remove bracket (1b) supporting the cold air intake pipe to the turbocharger.
Engines: 2.3 JTD 16V
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
Engines: 2.3 JTD 16V
1. Fit the flywheel locking tool.
Description
Code
Function
1
Counter-torque
1.860.846.000
Flywheel lock
Engines: 2.3 JTD 16V
1. Undo the bolts (1a) and remove the crankshaft pulley (1b).
Engines: 2.3 JTD 16V
1. Undo the bolts (1a) and remove the timing cover (1b).
Engines: 2.3 JTD 16V
1. Loosen the tensioner screw.2. Remove the timing belt.
Engines: 2.3 JTD 16V
1. Undo the retaining bolts.2. Remove the head extension.3. Remove the seal.
Engines: 2.3 JTD 16V
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.
Engines: 2.3 JTD 16V
1. Undo bolts (1a) and place fuel manifold (4b) to one side.
Engines: 2.3 JTD 16V
1. Undo bolts (1a) and remove engine coolant filler pipe (1b) complete with sealing ring (1c).
Engines: 2.3 JTD 16V
1. Remove rockers (1a) complete with return springs (1b) and tappets (1c).
Engines: 2.3 JTD 16V
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.
Engines: 2.3 JTD 16V
- Turn the engine on the overhaul stand.1. Undo bolts (1a) and remove the engine block sump.
Engines: 2.8 JTD 8V
See in Op. 1004D401. Release the fastening springs and remove the injector cover.2. Disconnect the electrical connections for the timing sensor (2a), pressure pump piston III exclusion (2b), coolant temperature (2c), airintake temperature (2d), injectors (2e), engine rpm sensor (2f).3. Remove the bracket together with the wiring.
Engines: 2.8 JTD 8V
1. Disconnect the thermal starter fuel pipe connector from the fuel manifold.2. Undo the fixing nuts (2a) and disconnect the intake manifold (2b).
Engines: 2.8 JTD 8V
- Fit the tool.
Description
Code
Function
.
Counter-torque
1.860.741.000
Tool for preventing crankshaft rotation
Engines: 2.8 JTD 8V
1. Undo the centre fixing bolt.2. Remove the engine components drive pulley.- Remove the tool.
Description
Code
Function
.
Counter-torque
1.860.741.000
Tool for preventing crankshaft rotation
Engines: 2.8 JTD 8V
1. Remove the lubricant filler cap.2. Undo the bolts (2a) and remove the upper timing drive belt cover (2b).3. Undo the bolts (3a) and remove the intermediate timing drive belt cover (2b).4. Undo the bolts (4a) and remove the lower timing drive belt cover (4b).
Engines: 2.8 JTD 8V
1. Loosen the belt tensioner fixing bolt.2. Remove the timing belt.3. Undo the fixing bolts (3a) and remove the fixed pulley (3b) and the guard (3c) underneath.
Engines: 2.8 JTD 8V
1. Undo the fixing bolt (1a) and remove the engine oil dipstick assembly (1b).2. Disconnect the pressure pump side connector for the supply pipe from the pressure pump to the manifold using a suitable spanner.3. Disconnect the manifold side connector for the supply pipe from the pressure pump to the manifold using a suitable spanner.4. Remove the pipe from the fuel supply connector to the pressure pump.
Engines: 2.8 JTD 8V
1. Remove the fuel return pipe from the injectors.2. Undo the manifold side connectors for the pipes from the fuel manifold to the injectors using a suitable spanner.3. Undo the injector side connectors for the pipes from the fuel manifold to the injectors using a suitable spanner.
Engines: 2.8 JTD 8V
1. Undo the bolts (1a) and remove the brackets (1b) for the injectors.2. Remove the injectors (2a) complete with gasket (2b).3. Remove the injector bracket support pads.
Engines: 2.8 JTD 8V
1. Undo the fixing bolts (1a) and remove the cylinder head cover (1b) complete with gasket.2. Undo the short bolts (2a) fixing the cylinder head, then undo the long cylinder head fixing bolts (2b).3. Remove the cylinder head assembly.4. Remove the cylinder head gasket.
Engines: 2.8 JTD 8V
- Rotate the engine through 180° on the overhaul stand.1. Undo the bolts fixing the crankcase sump.2. Cut the sealant using the tool.
