Removing Cylinder Head Cover (Bank 1-2)

1. Remove heat shield.
   1. 1.1 Unscrew screws -1-  and remove heat shield -2-  .

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   Heat shield on cylinder bank 1-2

2. Remove engine carrier bracket, bank 1-2.

   > 103019 REMOVING AND INSTALLING ENGINE CARRIER (BRACKET)

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   1. 2.1 Unscrew screws -2 to 5-  and remove bracket.

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   Engine carrier bracket, bank 1-2

   1. Engine carrier bracket
   2. Screw, M8 x 35
   3. Screw, M8 x 45
   4. Screw, M8 x 110
   5. Screw, M8 x 125
3. Remove accessories and cable plugs on the cylinder head.
   • Disconnect cable plugs: ignition coils, hall senders, fuel injectors
   • Loosen ground line and unscrew screw
   • Unclipping wiring harness
   • Pull off positive crankcase ventilation line.
   • Remove ignition coils and unscrew screws
   • Disconnect fuel line at the fuel collection pipe (push union nut upwards)
   • Remove fuel collection pipe with fuel injectors (two screws)

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   Accessories on cylinder head, bank 1-2

   1. Cable plugs for ignition coils
   2. Cable plugs for hall senders
   3. Cable plugs for fuel injectors
   4. Ground cable (for ignition coils)
   5. Screw, M6
   6. Cable holder
   7. Positive crankcase ventilation line connection
   8. Ignition coils
   9. M6 screws for ignition coil
   10. Fuel collection pipe
   11. Union nut for fuel line
   12. Screws for fuel collection pipe
4. Remove holder for control valves.
   1. 4.1 Pull off cable plug -2-  .
   2. 4.2 Unscrew screws -3-  and hang holder -1-  with valves to the side.

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   Control valve holder on cylinder bank 1-2

5. Release and disconnect cable plug -1-  at the actuators -3-  for camshaft control.

   Actuators can remain installed if the cylinder head cover is removed for subsequent work  (e.g. for removing camshafts or fitting a new seal).

   When replacing the cylinder head covers, remove the actuators and replace the O-rings. 

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   Actuator for camshaft control

6. Unscrew screws on the cylinder head cover from the outside in.
   1. 6.1 Carefully guide the cylinder head cover past the fuel line and remove it.

      Be careful of the actuators for camshaft control during removal! 

   Fig 1: Cylinder Head Cover Screws Tightening Sequence - Cylinder 1-2

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   Tightening sequence for cylinder head cover, cylinder 1-2

7. Check seal for damage and replace it if necessary.
8. Clean sealing face on the cylinder head.

Removing cylinder head cover (bank 3-4) 

1. Remove heat shield.
   1. 1.1 Unscrew screws -2-  and slide heat shield -1-  down at the right.

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   Heat shield on cylinder bank 3-4

2. Remove engine carrier bracket.
   1. 2.1 Unscrew screws -2 to 5-  .

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   Bracket for engine mounting

   1. Bracket for engine mounting
   2. Screw, M8 x 35
   3. Screw, M8 x 45
   4. Screw, M8 x 110
   5. Screw, M8 x 125
3. Remove vent line -1-  for turbocharger oil supply.
   1. 3.1 Loosen cable clip -3-  on the holder and unclip cable for exhaust temperature sensor -4-  .
   2. 3.2 Unscrew screws -2-  .
   3. 3.3 Disconnect oil line and replace O-rings  .

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   Vent line for turbocharger oil supply, bank 3-4

4. Disconnect wire harness.
   1. 4.1 Pull off cable plugs for ignition coils -1-  , hall senders -2-  , electronic adjusters -3-  and actuators -4-  .

      Actuators can remain installed if the cylinder head cover is removed for subsequent work  (e.g. for removing camshafts or fitting a new seal).

      When replacing the cylinder head covers, remove the actuators and replace the O-rings. 

   2. 4.2 Loosen holder with exhaust temperature sensor connector -5-  and unscrew screw -6-  .
   3. 4.3 Disconnect ground cable -7-  and unscrew screw -8-  .

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   Wiring harness, cylinder bank 3-4

5. Disconnect or remove cable plugs and accessories.
   1. 5.1 Release and pull off cable plugs -1-  for fuel injectors.
   2. 5.2 Unclip wiring harness (2x) -2-  .
   3. 5.3 Remove fuel collection pipe -3-  : Unscrew and push up union nut -4-  and unscrew screws -5-  .
   4. 5.4 Remove ignition coils -6-  : Unscrew screws -7-  .

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   Cable plugs for fuel injectors and accessories, cylinder bank 3-4

6. Remove vacuum line and disconnect fuel line (low-pressure).
   1. 6.1 Vacuum line -1-  : Unscrew screws -3-  and disconnect line at the vacuum pump.
   2. 6.2 Fuel line -2-  : Unscrew screws, hang line to one side and secure with a tie-wrap. The fuel hose remains on the high-pressure pump.
   3. 6.3 Unscrew screw -5-  for oil line.

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   Vacuum and fuel line (low-pressure), bank 3-4

7. Remove vacuum pump.

   > 477619 REMOVING AND INSTALLING VACUUM PUMP .

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   Mounting for vacuum pump

   1. Vacuum pump
   2. M6 screws
8. Unscrew screws -2-  on the cylinder head cover -1-  from the outside in.
   1. 8.1 Carefully guide the cylinder head cover past the fuel line -3-  and remove it.

      Be careful of the actuators for camshaft control during removal! 

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   Screws for cylinder head cover, bank 3-4

9. Check seal for damage and replace it if necessary.
10. Clean sealing face on the cylinder head.