Left Cylinder Head Cover

Left Cylinder Head Cover

Special tools, testers and auxiliary items required

• Pry Lever - Rmv Outside Mirror (80 - 200)

Removing

- Carefully pull the engine cover - arrows - off the 4 bolts one after the other.






- Remove the upper section of the intake manifold.






- Remove the oil filler tube by lifting the strap - 1 - and turning the tuber counter-clockwise - arrow -.






- Remove electrical connectors from bracket and disconnect.






1. For catalyst temperature sensor 1 (G20) (orange) - only engines meeting emissions standard BIN 5

2. For exhaust gas temperature 3 (G495) (brown)


- Disconnect the glow plug connector for cylinders "4" and "5".

- Disconnect the electrical connectors - 1 through 4 -.






- Free up the wiring harness using the (80 - 200).

Vehicles Built through 05.10

- Free up the wiring on the cylinder head.

- Remove the bolts - 2 - and - 3 - and push the bracket - 1 - and - 4 - with the wiring harness to the side.






Vehicles built from 06.10

- Free up the electric wires on the cylinder head.

- Remove the bolts - arrows - and move the brackets - 1 - and - 2 - and wiring harness to the side.






All vehicles

- Mark the injector high pressure line for re-installing.

- Remove the high pressure lines by loosening the union nuts - 1 through 6 -.






- Remove the injectors.






- Loosen the cylinder head cover bolts - arrows - in a diagonal sequence.






- Remove the bolts and the cylinder head cover.

Installing

Install in reverse order of removal. Note the following:

• Tightening specifications, refer to => [ Cylinder Head Cover Overview ] Cylinder Head Cover Overview.

• Replace O-ring.

• Replace the cylinder head seal if it is damaged.

• Replace the cylinder head cover bolts when replacing the damaged seal.

- Clean the sealing surfaces; they must be free of oil and grease.

- Tighten cylinder head cover bolts. Refer to => [ Cylinder Head Cover, Tightening Specifications and Sequence ] Cylinder Head Cover Overview.

- Install the injectors, high pressure lines and upper section of the intake manifold.

- Fuel system, performing leak test. Refer to => [ Fuel System, Checking for Leaks ] Fuel System, Checking For Leaks.