Right Cylinder Head Cover, Removing And Installing

WARNING: This page is about a different variant/trim than selected.

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 air filter. Refer to AIR FILTER .

-- Remove the connector -arrow- from the bracket and disconnect it.

Fig 2: Connector

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-- Remove the connector bracket screw on the cylinder head cover.

-- Disconnect cylinder "1" glow plug connector.

Fig 3: Identifying Connectors -1 Through 7-

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-- Disconnect the connectors -1 through 7- and free up the wiring harness using the Pry Lever 80-200.

NOTE:

-4- not on vehicles built from 06.10.

-- Free up the wiring harness on the cylinder head cover using the Pry Lever 80-200.

Fig 4: Identifying Bolt -1-, Bracket -2-, And Wiring Harness

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-- Remove the bolt -1- and move the bracket -2- and wiring harness to the side.

NOTE:

Ignore -arrows-.

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

Fig 5: Identifying High Pressure Lines And Union Nuts -1 Through 6-

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

-- Remove the pressure retention valve -arrow- from the bracket with the fuel hoses still connected and move it to the side.

Fig 6: Identifying Pressure Retention Valve -Arrow- And Bracket With Fuel Hoses

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-- Remove the pressure retention valve bracket.

-- Remove the injectors. Refer to INJECTOR .

Fig 7: Identifying Puller T10055 With Adapter T10055/1

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

Fig 8: 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 .

NOTE:

Replace the cylinder head seal if it is damaged.

Replace the cylinder head cover bolts when replacing the damaged seal.

The hose connections as well as the air guide pipes and hoses must be free of oil and grease before Installation.

Secure all hose connections with hose clamps of the same type as those equipped by the factory.

-- 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 air filter. Refer to INJECTOR , HIGH PRESSURE LINES, INSTALLING and AIR FILTER, REMOVING AND INSTALLING .

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