Removing and Installing Engine Cover (Design Cover)

Removing and installing engine cover











Note:
^ A special paint is applied to the covers for reasons of appearance.
^ When the engine is washed, a minimum clearance of 50 cm must be maintained between the cleaning apparatus lance and the covers.
^ The covers are sensitive to scratching.
^ Small scratches in the coat of paint can be touched up with a special touch-up applicator.

Removing design cover of cylinder row 1-4

Note: Place a cloth between secondary air pump and design cover to avoid scratching the cover.

1. Remove engine compartment lining on the right side. To do this, loosen the 4 bayonet screws and the fastening screw on the windscreen washer reservoir.





2. Detach the torque support. To do this, unscrew the fastening screw on the torque support bracket and pull it out.





3. Detach the torque support on the body and swivel upwards.





4. Detach the secondary air pump from cylinder bank 1-4. To do this, unscrew the 3 fastening screws, pull the pump out of the holder and lay it aside.





5. Unscrew the 4 fastening screws on the design cover.





6. Remove design cover from the cylinder bank 1-4. Lift the cover slightly with both hands on the side pointing towards the intake system until it snaps out of the mounting bosses.





7. Lift the cover at the front edge and slide the ignition coil cover of the second cylinder out of the torque support bracket. Pull out cover to the front.

Installing design cover of cylinder bank 1-4

Note: Place a cloth between secondary air pump and design cover to avoid scratching the cover.





1. Slide the design cover of the cylinder bank 1-4 under the secondary air pump as shown in the picture and then slide the cover of the second ignition coil through underneath the torque support bracket.





2. Press down the 2 rubber mounts on the support. The rubber mounts must be felt to engage.





3. Tighten the 4 fastening screws on the ignition coils to 4 - 5 Nm (3.0 - 3.5 ft. lbs.).





4. Reinstall secondary air pump. Tighten the 3 fastening screws to 10 Nm (7.5 ft. lbs.).





5. Reinstall torque support. Install the fastening screw (M10 x 70) with a new fastening nut on the bracket. Tightening torque 60 Nm (44 ft. lbs.).
6. Tighten torque support fastening screw on the body (M10 x 20) to 60 Nm (44 ft. lbs.).
7. Install engine compartment cover on the right side. To do this, tighten the 4 screws and the fastening screw on the windshield washer reservoir.

Removing design cover of cylinder bank 5-8

Note: Place a cloth between secondary air pump and design cover to avoid scratching the cover.





1. Unscrew the 4 fastening screws on the design cover.





2. Remove design cover of cylinder bank 5-8. To do this, lift the cover slightly with both hands on the side pointing towards the intake system until it is released from its retainer.





3. Lift the front of the design cover and remove it.

Installing design cover of cylinder bank 5-8

Note: Place a cloth between secondary air pump and design cover to avoid scratching the cover.





1. Slide the cover under the secondary air pump.





2. Then press in the 2 rubber mounts on the holder. The rubber mounts must be felt to engage.





3. Tighten the 4 fastening screws on the ignition coils with 4 - 5 Nm (3.0 - 3.5 ft. lbs.).

Removing throttle body cover





1. Pull the cover of the throttle body vertically upwards.

Installing throttle body cover





1. Press the 4 rubber elements in the cover onto the 4 ball socket holders. The fastening elements must lock in firmly.





Tightening torques