21.1. Left cylinder head cover installation details:
1 - Cover gasket 2;
2 - Cylinder head cover;
3 - Bolt with seal, 9 Nm;
4, 12, 20 - O-ring, subject to replacement;
5 - Oil filler neck;
6, 7 Gasket;
8 - Neck cover 5;
9 - Nut;
10 - High pressure hose: mark before disconnecting to avoid confusion when connecting: do not change the bends of the hoses;
11 - Return fuel line;
13 - Bolt;
14 - Holder;
15, 18 - Bolt, 5 Nm;
16, 19 - Electrical wiring bracket;
17 - Nozzle;
21 - Copper seal, must be replaced.
Left cylinder head cover
2. Remove the upper engine cover (see Section 19 of Chapter 1).
3. Remove the upper section of the intake manifold (see Chapter 4).
4. Remove the oil filler neck. To do this, lift its latch, turn it counterclockwise and pull out the neck (see illustration 11.1e).
5. Remove the electrical wiring connectors from the bracket and disconnect them (see illustration 15.39): (1) - sensor No. 1 "G20" of the catalytic converter temperature (orange, only on BIN5 engines) and (2) - sensor No. 3 "G495" exhaust gas temperature (brown).
6. Disconnect the glow plug wiring connectors for cylinders #4 and #5. Disconnect the connectors (1-4 in the illustration) and move the wiring to the side.
21.6. Electrical wiring connectors.
7. On models before 05.2010, remove the cylinder head wiring and unscrew the bolts (2 and 3 in the illustration) and move the brackets (1 and 4) together with the wiring to the side.
21.7. Fastening electrical wiring brackets (models before 05.2010.).
8. On models from 06.2010, remove the cylinder head wiring and unscrew the bolts (arrows in the illustration) and move the brackets (1 and 2) together with the wiring to the side.
21.8. Fastening electrical wiring brackets (models from 06.2010.).
9. Mark the high pressure fuel pipes installed between the fuel distribution line and the injectors so that they can be installed in their original places, then unscrew the union nuts and remove the pipes. Remove the injectors for the corresponding cylinder bank.
10. Loosen the bolts (see illustration 11.5) in a diagonal order, then completely unscrew them and remove the cylinder head cover.
11. Installation is carried out in reverse order. Use new gaskets and O-rings. If the seals on the bolts are damaged, replace the bolts together with the seals. Tighten the cover mounting bolts diagonally in several passes, with a final torque of 9 Nm.
Right cylinder head cover
12. Remove the upper engine cover (see Section 19 of Chapter 1) and the air cleaner filter element (see Section 16 of Chapter 1).
13. Remove the electrical wiring connector from the bracket and disconnect it (see illustration 4.25). Then unscrew the bracket mounting bolt on the cylinder head cover.
14. Disconnect the glow plug connector for cylinder #1. Disconnect the connectors (1 in illustration 11.4) and move the wiring to the side.
Note: Connector #4 is not available on models from 06.2010.
15. Remove the electrical wiring from the cylinder head cover. Remove the bolt (1 in illustration 19.9) and move the bracket (2) together with the wiring to the side.
16. Mark the high pressure fuel tubes installed between the fuel distribution line and the injectors so that they can be installed in their original places, then loosen the union nuts and remove the tubes (see Chapter 4).
17. Remove the fuel pressure holding valve from the holder and set it aside without disconnecting the fuel hoses. Remove the bracket for this valve.
21.17. Fuel pressure holding valve.
18. Remove the injectors of the corresponding cylinder bank (see Chapter 4).
19. Follow the steps described in paragraphs 10-11.
Cylinder head
20. Drain the coolant (see Chapter 3).
21. Remove the appropriate upper timing chain from the camshaft only (see section 20).
22. Remove the upper section of the intake manifold (see Chapter 4).
23. Remove the corresponding cylinder head cover (see subsection above). When working on the left cylinder head, perform the steps described in paragraphs 24-29, and when working on the right cylinder head, perform the steps described in paragraphs 30-36. Then perform the steps described in paragraphs 19-26 Section 11.
24. Remove the upper left coolant pipe (see Chapter 3).
25. Remove the fuel injection pump drive toothed belt and its tensioner (see Chapter 4). Remove the camshaft timing gear (see paragraphs 9-10 of Section 11).
26. Follow the steps described in paragraphs 32-35 of Section 11.
27. Disconnect the connector (1 in the illustration) activator No. 2 "V275" of the intake manifold flap (4).
21.27. Connector (1) of activator No. 2 of the intake manifold flap (4).
28. On models from 06.2010, pinch the power steering fluid hose (1 in illustration 15.5) clamp No. 3094, unscrew the bolts (2) and move the tube back. Plug any open lines and fittings.
29. Loosen the clamp (arrow in the illustration) and disconnect the EGR pipe (1).
21.29. EGR pipe clamp (arrow) (1).
30. Remove the right intermediate exhaust pipe (see Chapter 4) and the upper right coolant pipe (see Chapter 3).
31. Remove the bolts (arrows in illustration 11.34) and remove the fuel injection pump protective plate. Then, unscrew the union nuts (1 and 4), move the high-pressure fuel line aside, and remove it.
32. Remove the bolts (1 and 2 in illustration 11.39) lifting eye and the "V400" EGR cooler pump. Move the wiring (arrow) to the side.
33. Loosen the clamp (arrow in the illustration) and disconnect the coolant line.
21.33. Coolant hose clamp.
Disconnect the glow plug connectors for cylinders #2 and #3.
34. Disconnect the connector (1 in the illustration) activator "V157" of the intake manifold flap.
21.34. Connector (1) of the intake manifold flap actuator.
35. Remove the orange connector from the bracket and disconnect it (1 in the illustration) eGR temperature sensor "G98".
21.35. Connector (2) of the EGR temperature sensor "G39".
36. Remove the bolts (arrows in illustration 11.43) and move the fuel rail to the side without disconnecting the fuel lines.
37. Follow the steps in paragraphs 19-26 Section 11.
(The original article is available on the online resource: «AUDIMANUAL.ru»)