Table of contents: Removal ↓ Installation ↓
Removal
Open the expansion tank cap.
Remove the front cross member.
Place a drip pan under the engine to collect the coolant.
Fig. 3.4–17. Location of threaded plugs for draining coolant from the cooling system
Unscrew the three threaded plugs and drain the coolant from the cooling system (see Fig. 3.4–17).
Fig. 3.4–19. Removing the engine casing
Remove the engine cover by pulling it upwards by the sides (see Fig. 3.4–19).
Remove the screws and the additional left cover in the engine compartment.
Loosen the clamps and disconnect the cooling system hoses near the high-pressure fuel pump.
Fig. 3.4–40. Cylinder head cover: 1 – cylinder head cover gasket; 2 – cylinder head cover; 3, 4 – sealing rings; 5 – bolt, 10 Nm; 6 – oil filler neck; 7 – seal; 8 – lid; 9 – bolt, 5 Nm; 10 – fuel supply line; 11 – high pressure fuel line; 12 – spring clamp; 13 – sealing ring; 14 – bolt, 10 Nm; 15 – fuel injector; 16 – sealing ring; 17 – bolt, 10 Nm; 18 – Hall sensor G40; 19 – sealing ring; 20 – bolt, 10 Nm; 21 – plug
Fig. 3.4–41. Location of bolts and connecting nuts for fastening pipelines to the fuel injection control unit (Rail element): 1 – end connecting nut; 2, 3 – bolts; 4, 5, 6, 7 – fuel line connecting nuts
Unscrew the end union nut 1 (Fig. 3.4–41).
Unscrew the connecting nuts of fuel lines 4–7.
Unscrew two bolts 2 and 3 and remove the fuel injection unit from the intake manifold.
Fig. 3.4–42. Location of vacuum hose (1), fuel return line clamps (2), and injector electrical connectors (3, 4, 5, 6, 7)
Disconnect the electrical connectors of injectors 3–7 (Fig. 3.4–42).
Disconnect vacuum hose 1.
Release the return fuel line 2 from the clamps and remove it.
Unscrew the oil filler cap.
Fig. 3.4–43. Location of the notch in the oil filler neck opening
Using the crankshaft pulley mounting bolt, turn the shaft until a recess is visible in the oil filler neck hole (Fig. 3.4–43).
Fig. 3.4–44. Location of fuel injector housing mounting bolts
Unscrew the injector housing mounting bolts, pull the housings up and turn 90° counterclockwise (Fig. 3.4–44).
Fig. 3.4–45. Location of fuel injector mounting bolts
Unscrew the exposed injector mounting bolts (Fig. 3.4–45).
Pull up and remove the injectors for cylinders 6 and 8.
When removing fuel injectors, you can use a lever.
Turn the crankshaft clockwise 180° and remove the injectors of cylinders 5 and 7.
Fig. 3.4–46. Location of cylinder head cover mounting bolts
Remove the bolts and the left cylinder head cover (Fig. 3.4–46).
Installation
Installation is carried out in the reverse order of removal, taking into account the following.
Replace the fuel return line seals.
Replace the cylinder head cover gasket if necessary.
Install the sealing half ring.
Degrease the surface under the cylinder head cover gasket.
Fig. 3.4–47. Places to apply sealant before installing the left cylinder head cover
Apply a thin, continuous layer of sealant to the semicircular surface (Fig. 3.4–47) at the end of the cylinder head.
Apply a 3 mm diameter layer of sealant to the outer camshaft covers in 5 mm long sections (see Fig. 3.4–47).
Tighten the cylinder head cover nuts gradually in a crosswise pattern.
Install the front cross member.
Fill the cooling system with coolant.
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