Left Cylinder Head Cover, Removing And Installing

Special tools and workshop equipment required 

• Pry Lever 80-200

Removal 

Fig 1: Identifying Engine Cover -Arrows-

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-- Carefully pull the engine cover off the 4 bolts one after the other -arrows-.

-- Remove the intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

Fig 2: Identifying Bolts -Arrows-

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-- Remove the oil filler tube by lifting the strap -1- and turning the tuber counter-clockwise -arrow-.

Fig 3: Identifying Tab -1- And Position To Turn Oil Filler Tube (Counterclockwise -Arrow-)

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-- Remove electrical connectors from bracket and disconnect.

Fig 4: Electrical Connectors

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1. For Catalyst Temperature Sensor 1 -G20- (Orange) - Only Engines Meeting Emissions Standard BIN 5
2. For Exhaust Gas Temperature Sensor 3 -G495- (Brown)

-- Disconnect the glow plug connector for cylinders "4" and "5".

Fig 5: Identifying Electrical Connectors -1 Through 4-

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-- Disconnect the connectors -1 through 4-.

-- Free up the wiring harness using Pry Lever 80-200.

Vehicles through 05/2010: 

Fig 6: Identifying Bolts -Arrows- And Brackets -1- And -2-

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-- Free up the wiring on the cylinder head.

-- Remove the bolts -2- and -3- and push the bracket -1- and -4- with the wiring harness to the side.

Vehicles from 06/2010: 

Fig 7: Identifying Bolts -Arrows-, Brackets -1- And -2-, And Wiring Harness

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-- Free up the electric wires on the cylinder head.

-- Remove the bolts -arrows- and move the brackets -1- and -2- and wiring harness to the side.

All Vehicles: 

Fig 8: Identifying High Pressure Line Union Nuts -1 Through 6-

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-- Mark the injector high pressure line for re-Installation.

-- Remove the high pressure lines by loosening the union nuts -1 through 6-. .

-- Remove the injectors. Refer to INJECTOR .

Fig 9: Identifying Puller T10055 With Adapter T10055/1

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-- Loosen the cylinder head cover bolts -arrows- in a diagonal sequence.

Fig 10: Cylinder Head Cover Bolts

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-- Remove the bolts and the cylinder head cover.

Installation 

Install in reverse order of removal. Note the following:

• Tightening specification. Refer to CYLINDER HEAD COVER OVERVIEW .

-- Clean the sealing surfaces; they must be free of oil and grease.

-- Tighten cylinder head cover bolts, refer to Figure.

-- Install the injectors, high pressure lines and intake manifold upper section. Refer to INTAKE MANIFOLD UPPER SECTION, REMOVING AND INSTALLING .

-- Perform a leak test on the fuel system. Refer to FUEL SYSTEM LEAK TEST .