Removing the cylinder head cover

WARNING: High-voltage system.
The high-voltage system operates on the basis of hazardous, electrical voltage and high currents. Mortal hazard through electric shock!

All work on the high-voltage system may only be carried out by specially trained and technically experienced personnel.
For additional information see: SAFETY INSTRUCTIONS ON HANDLING HYBRID CARS .
For additional information see: NOTES ON REPAIR OF HIGH-VOLTAGE BATTERY UNIT .

WARNING: Hot surfaces.
Risk of burning!

Perform all work only on components that have cooled down.

WARNING: Working on fuel system.
Risk of fire! Danger of explosion!

When working on the fuel system, make sure the workstation has sufficient ventilation, e.g., by means of extraction.
Tightly seal off open lines and connections; collect any leakage fuel directly at the point of exit.
No fire, sparks, open flames or smoking.

Preliminary work

Remove right flap in luggage compartment TRIM PANEL
De-energize the HIGH-VOLTAGE SYSTEM
CHECK that no voltage is applied.
Disconnect the (starter unit battery) negative BATTERY CABLE
Remove trunk battery COVER
Disconnect the (starter unit battery) negative BATTERY CABLE .
Bring front compartment lid in the SERVICE POSITION
Remove the ACOUSTIC COVER
Remove the rear left engine compartment COVER
Remove the rear right engine compartment COVER .
Remove the hood rear SEAL .
Remove left and right WIPER ARM .
Remove the cowl COVER .
Remove the left and right shock tower TENSION STRUT .
Remove the upper part FIREWALL .
Release the EME HIGH-VOLTAGE CABLES .
Remove the bottom second FIREWALL .
Remove rear ACOUSTIC COVER .
Remove RESONATOR .
Remove the front engine ACOUSTIC COVER .
Remove the cylinder head cover ACOUSTIC COVER .
Remove the IGNITION COIL .
Remove the HIGH PRESSURE LINE between the high pressure pump and the rail.
Remove the RAIL with injectors.
Remove FUEL DELIVERY LINE .
Remove HIGH PRESSURE PUMP .
Remove both ACTUATORS .

CAUTION: On releasing high pressure line, fuel may emerge at high speed.
Injury hazard!

Wear suitable personal protective equipment.
Before performing any installation work, allow cooling system to cool down to less than 40°C.
Note warnings on cylinder head cover.

NOTE: TECHNICAL INFORMATION
Collect and dispose of emerging fluids. Observe country-specific waste disposal regulations.

Bolts of the cylinder head cover

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1 Bolts of the cylinder head cover

15 Cylinder head cover

NOTE: RISK OF DAMAGE
Damage to wires when disconnecting connectors and plug connections.
Sheared wires can cause a short circuit.

Do not pull on wires when disconnecting connectors and plug connections.

Unlock the locks (1).
Feed the engine ventilation line (2) out and set it aside.

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Unlock the plug connection (1) on the intake camshaft sensor and disconnect.
Loosen screw (2).
Feed out the wiring harness section (3) for sensor system 1 and place to one side.

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Unlock the plug connection (1) on the exhaust camshaft sensor and disconnect.
Unlock and loosen clamp (2).

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Unlock and detach the locks (arrows).
Feed out the wiring harness section (1) for sensor system 2 and place to one side.

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Unlock plug connection (1) and disconnect.
Feed out the differential pressure sensor (2) from the holder (3) and place to one side.

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Loosen screws (1).
Feed out the bracket (2) of the positive battery cable and set it aside.

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Feed wiring harness section (1) for sensor system 2 out of guides (2), and place to side.

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Loosen clamp (1).

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Loosen clamp (1).
Feed out the wiring harness section (2) for the injectors and ignition coils and set aside.

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Loosen screws in the order (15) to (1).
Feed out and remove the cylinder head cover (A).

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