Installing Cylinder Head Cover

NOTIFICATION 

Dirt and contamination 

• Risk of damage to units or components 
  1. → Protect components from dirt and contamination.
  2. → Clean or replace dirty components.

Information 

• The cylinder head cover must be installed within 5 minutes of applying the sealant. 
• The bead of sealant must not be thicker than the prescribed thickness. 
• Observe the use-by date of the sealant. 

1. Insert intake camshaft -1-  into the cylinder head.

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   Intake camshaft

   Information 

   The sealing faces must be dry and free of oil and grease.

2. Apply sealant -1-  to clean sealing face -Arrows-  .

   Sealant bead thickness: 2...3 mm.

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   Sealing agent for cylinder head cover

3. Insert outlet camshaft -1-  into the cylinder head cover.

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   Outlet camshaft

4. Install cylinder head cover -7-  .
   Fig 1: Cylinder Head Cover Screws Tightening Sequence

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   Cylinder head cover

   1. 4.1  Position cylinder head cover -7-  with outlet camshaft on the cylinder head.
   2. 4.2  Fit new screws -1 to 6-  and screw in hand-tight.
   3. 4.3  Tighten screws in the sequence -1 to 6-  .

      Initial tightening 8 Nm (6 ftlb.) 

      Final tightening + 90° 

5. Align intake camshaft -1-  and lock it.

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   Intake camshaft

   1. 5.1  Turn the T40266 - adapter-2-  in -direction of arrow A-  until the marking -3-  aligns with the T40271 - camshaft clamps/2-4-  .
   2. 5.2  Lock intake camshaft by pushing the T40271 -/2 camshaft clamp-4-  in -direction of arrow B-  .
6. Align and lock outlet camshaft -1-  .

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   Outlet camshaft

   1. 6.1  Turn the T40266 - adapter-2-  in -direction of arrow A-  until the marking -3-  aligns with the T40271 - camshaft clamps/2-4-  .
   2. 6.2  Lock outlet camshaft by pushing the T40271 -/1 camshaft clamp-4-  in -direction of arrow B-  .
7. Turn crankshaft to TDC position.
   1. 7.1  Turn crankshaft on the crankshaft pulley screw -Arrow- in - the running direction of the engine  to TDC position.
   2. 7.2  Unscrew screw for crankshaft pulley -Arrow-  and remove T10368 - pressure piece-1-  .
   3. 7.3  Pull off the sprocket.

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   Pressure piece on crankshaft sprocket

8. Secure tank vent valve -1-  with holder to cylinder head cover.

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   Tank vent valve

   1. 8.1  Position tank vent valve with holder.
   2. 8.2  Fit and tighten screws -3-  .

      > Tightening - torque 9 Nm (6.5 ftlb.) 

   3. 8.3  Clip in retaining clip -2-  .
9. Position engine wiring harness and clip cable duct -1-  onto holder -Arrows-  .

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   Cable duct

10. Push on and engage cable plug for tank vent valve -1-  .

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    Cable plug for tank vent valve

11. Push on and engage cable plug for temperature sensor -1-  .

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    Cable plug on temperature sensor

12. Push on and engage cable plugs -1, 2 and 3-  and clip in holder -4-  .

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    Cable plug

13. Push on and engage cable plug for hall sender for outlet camshaft -2-  .

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    Cable plug for hall sensor of outlet camshaft

14. Push on and engage the cable plug -1 and 2-  .

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    Cable plug for recirculating air valve and electronic adjuster