Cylinder head cover — removal and installation

Removing

1. Disconnect the wire terminal from the battery «masses» (-).

2. Remove the protective cover from the engine and disconnect the charge air pipeline 3 from the cylinder head cover by removing the hoses 1 and 2 fixed with clamps (see illustration).



3. Remove the intake manifold.

4. Remove the fuel injectors by disconnecting them with a special key, for example, HAZET 4550, high pressure fuel lines (see illustration). Unscrew the nozzles with a socket head by 27 mm. Mark the nozzles in order to subsequently install them in their original place. In addition, the plug of the fuel supply start sensor should be disconnected from the injector of cylinder No. 4.



5. Disconnect plug 4 from the boost air pressure regulator valve (see illustration).




6. Disconnect plug 3 camshaft position sensor (see illustration 2.5).

7. Disconnect the low pressure hose 2 from the T-piece (see illustration 2.5).

8. Unscrew bolts of fastening of an arm 1 of the pipeline of the conditioner by which it fastens to a cover of a head of the block of cylinders, and disconnect it (see illustration).



9. Disconnect hose 2 from cylinder head cover (see illustration 2.8).

10. Unscrew the outer bolts of the cylinder head cover, acting in sequence from 1 to 18 (see illustration).



11. Unscrew the inner bolts of the cylinder head cover, acting in sequence from 19 to 30 (see illustration).




12. Remove the cover, clean the sealing surfaces of the cover and cylinder head and remove the seal residues.

Installation

13. Apply black sealant to the mating surfaces at the points indicated by the arrows (see illustration).



14. Install a new head cover gasket.

15. Install the cover on the cylinder head and screw in the internal mounting bolts with a force of 10 Nm, acting in the reverse order of their unscrewing, i.e. from 30 to 19 (see illustration 2.11).

16. Screw in the outer mounting bolts with a force of 10 Nm, acting in the reverse order of their unscrewing, i.e. from 19 to 1 (see illustration 2.10).

Installation and fastening of the parts detached from the cylinder head postcard is carried out in the reverse order of removal.