Installing cylinder head cover

Bolts of the cylinder head cover 

Fig 1: Cylinder Head Cover Bolts Tightening Sequence

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• There must be no oil or grease on sealing surface (1)  .

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• Replace the seals (1)  .

  Parts:  Seals

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• Insert and install the cylinder head cover (1)  .

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• Make sure that the cylinder head cover (1)  is correctly installed in the marked  area on the high pressure pump bracket (2)  .

  The cylinder head cover (1)  must not be in the marked  area on the high pressure pump bracket (2)  .

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• Position the cylinder head cover (A)  .
• Make sure that the cylinder head cover (A)  does not touch the high pressure pump bracket!
• Tighten all screws in the sequence (1)  to (21)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Cylinder head cover to cylinder head
  M6X30	Joining torque	8 Nm

  Fig 2: Cylinder Head Cover Screws Tightening Sequence

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• Tighten all screws in the sequence (1)  to (21)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Cylinder head cover to cylinder head
  M6X30	tightening torque	11 Nm

• Insert and install the engine ventilation line (2)  .
• Ensure that locks (1)  engage audibly.

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• Feed in and install the wiring harness section (1)  for sensor system 2.
• Make sure that the locks (arrows) engage audibly.

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• Insert and position the holders (4)  .
• Tighten down screws (3)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Auxiliary coolant pump holder to cylinder head
  M6	tightening torque	7 Nm

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• Thread in ground cable (2)  and install.
• Tighten nut (1)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Standard screw connection M6
  M6	Tightening torque	8 Nm

• Connect and lock the connector (1)  to the exhaust camshaft sensor.
• Make sure the connector (1)  engages audibly on the exhaust camshaft sensor.
• Secure clamps (2)  .

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  NOTE: The following step(s) must be performed if the listed component(s) is/are installed.
• Feed in and install the differential pressure sensor (3)  .
• Tighten down screw (2)  .
  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Differential pressure sensor to holder
  TS6X18	Tightening torque	3.5 Nm

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• Connect and lock the connector (1)  .
• Make sure the connector (1)  engages audibly.
  CAUTION: Improper routing of the positive battery cable. 
  Risk of short circuits! 

  • Route the positive battery cable without abrasions and do not trap.
• Feed in the bracket (2)  of positive battery cable and install.
• Tighten down screws (1)  .

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  TIGHTENING TORQUE SPECIFICATIONS
  
  

  Holder, positive battery cable to cylinder head cover
  6X18	Tightening torque	6 Nm

• Secure clamps (1)  .

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• Secure clamps (1)  .

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• Connect and lock the connector (1)  on the intake camshaft sensor.
• Make sure the connector (1)  engages audibly.
• Secure clamps (2)  .

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Follow-up work 

• Refer to INSTALLING BOTH ACTUATORS .
• Refer to PREPARING THE INJECTORS FOR INSTALLATION .
• Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 4 TO 6 .
• Refer to INSTALLING THE HIGH-PRESSURE RAIL WITH INJECTORS OF THE CYLINDERS 1 TO 3 .
• Refer to INSTALLING HIGH PRESSURE PUMP .
• Refer to INSTALLING FUEL DELIVERY LINE .
• Refer to INSTALLING THE HIGH-PRESSURE LINE BETWEEN THE HIGH-PRESSURE PUMP AND THE HIGH-PRESSURE RAIL .
• Refer to INSTALLING ALL IGNITION COILS .
• Refer to INSTALLING ACOUSTIC COVER AT REAR .
• Refer to INSTALLING THE CENTER COWL UPPER PART .
• Refer to INSTALLING TENSION STRUT ON SHOCK TOWER .
• Refer to INSTALLING WINDSHIELD PANEL COVER .
• Refer to INSTALLING LEFT AND RIGHT WIPER ARM .
• Refer to INSTALLING THE REAR RIGHT ENGINE COMPARTMENT COVER .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT ON THE REAR LEFT .
• Refer to INSTALLING THE FRONT HOOD SEAL AT THE REAR .
• Refer to INSTALLING FAN COWL .
• Refer to INSTALLING THE REAR TOP CROSS CONNECTION .
• Refer to INSTALLING FRONT CROSS CONNECTION (FRONT-END STRUT REMOVED) .
• Refer to INSTALLING THE RESONATOR WITH THE TOP CLEAN AIR PIPE .
• Refer to INSTALLING THE INTAKE FILTER HOUSING (TENSION STRUT REMOVED ON SHOCK TOWER) .
• Refer to INSTALLING BOTH FRONT-END STRUTS .
• Refer to INSTALLING THE COVER OF THE ENGINE COMPARTMENT CENTER .
• Refer to CONNECTING ALL BATTERY GROUND LEADS .
• Refer to INSTALLING ACOUSTIC COVER .
• Refer to TAKING HOOD OUT OF THE SERVICE POSITION .