Installing Cylinder Head Cover

Information 

• Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to ensure they can be used again! 

Information 

• The eyelets must not be inadvertently secured using aluminium screws! => Aluminium screws would break off and the suspended engine would fall down! 

Information 

The tightening specifications for the basic engine are stored centrally.

> TECHNICAL VALUES

/

> 2X00IN TECHNICAL VALUES

or

> WM, 1001IN TIGHTENING TORQUES, TIGHTENING SEQUENCES, ASSEMBLY OVERVIEWS FOR ENGINE

Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.

1. Clean sealing faces on cylinder head cover and cylinder head thoroughly.

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   Cylinder head

   Information 

   • Always replace seals. 
2. Fit inner and outer seals in the cylinder head cover -6 and 7-  /-5 and 6-  and apply an additional small bead of Silikon 2210 Drei Bond sealant (000.043.204.58, status 12/08, may still be used in this restricted area provided there is no contact with aluminium screws) to the lining between the cylinder head and chain housing cover on both sides > Applying sealant to chain housing cover and cylinder head  .
   Fig 1: Cylinder-Head Cover Gaskets Components Location - Cylinder 1 To 4

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   Cylinder-head cover gaskets, cyl. 1 to 4

   1	Cylinder head cover for cylinders 1 to 4 (align over bar ignition modules)
   2	Oil cap
   3	Aluminium screw  , M6 x 20; hall sender (phase sensor); always use new aluminium screws
   4	Hall sender
   5	O-ring
   6	Cylinder-head cover gasket
   7	Cylinder-head cover gasket, inner
   8	Seal for hydraulic valve for camshaft control

   Fig 2: Cylinder-Head Cover Gaskets Components Location - Cylinder 5 To 8

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   Cylinder-head cover gaskets, cyl. 5 to 8

   1	Cylinder head cover for cylinders 5 to 8 (align over bar ignition modules)
   2	Hall sender
   3	Aluminium screw  , M6 x 20; hall sender (phase sensor); always use new aluminium screws
   4	O-ring
   5	Cylinder-head cover gasket
   6	Cylinder-head cover gasket, inner
   7	Seal for hydraulic valve for camshaft control

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   Applying sealant to chain housing cover and cylinder head

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   Sealant beads on both sides

3. Carefully position the cylinder head cover.
   NOTE: NOTIFICATION 
   Cylinder head cover fitted and screwed on incorrectly 

   • Incorrect installation position of hall sender with respect to the camshaft 
   • Risk of engine damage 
   • Fault entries in the DME control unit 

     → The cylinder head cover must be aligned carefully over the fitted bar ignition modules.

4. Fit all bar ignition modules aligned into the corresponding cylinder head cover.

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   Fitting bar ignition modules

5. Fit all M6 and M8 fastening screws (torque support and eyelets) according to specifications.
   Fig 3: Bar Ignition Modules And Cylinder Head Cover Components Location - Cylinder Bank 1 To 4

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   Bar ignition modules and cylinder head cover for cylinder bank 1 to 4

   1	Cylinder head cover for cylinder bank 1 to 4 (align over bar ignition modules)
   2	Bar ignition module
   3	Aluminium screw  , M6 x 20; bar ignition module; always use new aluminium screws
   4	Aluminium screw  , M6 x 30; always use new aluminium screws
   5	Cap
   6	Aluminium screw  , M8 x 35 (on torque support); always use new aluminium screws; steel screw  on eyelet!
   7	Eyelet (with steel screw  )
   8	Sheetmetal holder
   A	Direction of travel Not shown; design cover on bar ignition modules

   Fig 4: Bar Ignition Modules And Cylinder Head Cover Components Location - Cylinder Bank 5 To 8

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   Bar ignition modules and cylinder head cover for cylinder bank 5 to 8

   1	Cylinder head cover for cylinder bank 5 to 8 (align over bar ignition modules)
   2	Eyelet
   3	Eyelet (with steel screw)
   4	Aluminium screw  , M6 x 30; always use new aluminium screws
   5	Bar ignition module
   6	Aluminium screw  , M6 x 20; bar ignition module; always use new aluminium screws
   7	Sheetmetal holder
   8	Cap
   A	Direction of travel Not shown; design cover on bar ignition modules

6. Fit wire harness holder. To do this, press on the wire harness holder.

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   Wire harness holder

7. Connect the cable plug for the hydraulic valve and fit the cap.

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   Cable plug

8. Fit two ground points.
9. Connect cable plug for hall sender.
10. Fit the relevant air-cleaner box cover at the left or right.
11. Carry out remaining work.