Installing Cylinder Head Cover (Valve Cover) (Up To October 2008)

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! 

1. Clean sealing faces on valve cover and cylinder head thoroughly.
   Fig 1: Identifying Cylinder Head

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   Information 

   • Always replace seals  .
2. Fit inner and outer seals in the valve cover -6 and 7-  /-5 and 6-  and apply a bead of Silikon 2210 Drei Bond sealant (000.043.204.58, status 02/06) to the lining between the cylinder head and timing chain cover on both sides.
   Fig 2: Exploded View Of Valve Cover Seals (Cylinders 1 To 4)

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   1. Valve cover for cylinders 1 to 4 (align over bar ignition modules)
   2. Oil cap
   3. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   4. Hall sender
   5. O-ring
   6. Valve cover seal
   7. Valve cover seal, inner
   8. Seal for hydraulic valve for camshaft adjustment
      Fig 3: Exploded View Of Valve Cover Seals (Cylinders 5 To 8)

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   1. Valve cover for cylinders 5 to 8 (align over bar ignition modules)
   2. Hall sender
   3. Screw, M6 x 16 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   4. O-ring
   5. Valve cover seal
   6. Valve cover seal, inner
   7. Seal for hydraulic valve for camshaft adjustment
   Fig 4: Applying Sealant To Timing-Case Cover And Cylinder Head

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   Fig 5: Identifying Sealant Beads Applying Area On Timing-Case Cover

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3. Place valve cover carefully in position.
   NOTE: Valve 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

   → Align the valve cover carefully over the fitted ignition rod modules.

4. Fit all bar ignition modules aligned into the corresponding valve cover.
   Fig 6: Fitting Bar Ignition Modules

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   Information 

   • It is best to use a tool with a head height of less than 50 mm -A- (see  SPECIAL TOOLS  ) for loosening and tightening the rear fastening screw on the cylinder head cover close to the plenum panel  .
     Fig 7: Identifying Tool Height

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   • If you do not have a suitable tool, the side plenum panel must be removed and then refitted. To do this, remove cover of plenum panel. →  Removing cowl panel cover  . Remove plenum panel wall (shown on left). Release lambda sensor connector from the holder at the plenum panel wall -1-  . Unclip cable -2-  . Loosen PDCC reservoir from plenum panel, if fitted. Loosen three screws on the plenum panel -3-  . Pull plenum panel up and off. Install in reverse order. When doing this, first fit seal on the body and spray with silicon spray  .
     Fig 8: Identifying Plenum Panel Wall

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5. Fit all M6 and M8 fastening screws (torque support and eyelets) according to specifications.
   Fig 9: Identifying Valve Cover Screws Tightening Sequence (Cylinders 1 To 4)

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   Fig 10: Identifying Valve Cover Screws Tightening Sequence (Cylinders 5 To 8)

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   Fig 11: Exploded View Of Bar Ignition Modules And Valve Cover (Cylinder Bank 1 To 4)

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   1. Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
   2. Bar ignition module
   3. Bar ignition module screw → Tightening torque: 10 Nm (7.5 ft lbs.) 
   4. Screw, M6 → Tightening torque: 13 Nm (9.5 ft lbs.) 
   5. Cap
   6. Screw, M8 → Tightening torque: 23 Nm (17 ft lbs.) 
   7. Eyelet → Tightening torque: 23 Nm (17 ft lbs.) 
   8. Sheetmetal holder
   1. Direction of travel
      • Not shown; design cover on bar ignition modules → Tightening torque: 4.4 Nm (3.0 ft lbs.) 
        Fig 12: Exploded View Of Bar Ignition Modules And Valve Cover (Cylinder Bank 5 To 8)

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   1. Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
   2. Eyelet
   3. Screw, M8 → Tightening torque: 23 Nm (17 ft lbs.) 
   4. Screw, M6 → Tightening torque: 13 Nm (9.5 ft lbs.) 
   5. Bar ignition module
   6. Bar ignition module screw → Tightening torque: 10 Nm (7.5 ft lbs.) 
   7. Sheetmetal holder
   8. Cap
   1. Direction of travel
      • Not shown; design cover on bar ignition modules → Tightening torque: 4.4 Nm (3.0 ft lbs.) 
6. Fit wire harness holder. To do this, press on the wire harness holder.
   Fig 13: Fitting Wire Harness Holder

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7. Connect the cable plug for the hydraulic valve and fit the cap.
   Fig 14: Locating Cable Plug

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8. Fit the two ground points on the valve covers. -1- 
   Fig 15: Identifying Engine Wire Harness, Timing Case And Valve Cover

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   1. Screw, M6 x 12 → Tightening torque: 10 Nm (7.5 ft lbs.) 
   2. Screw, M6 x 16
9. Connect cable plug for hall sender.