Valve Cover: Service and Repair
Removing cover for camshaft housing
Special tools
Removing cover for camshaft housing on cylinder bank 1-4
Note: The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5-8 and cylinder bank 1-4!
1. Remove left or right engine compartment cover.
2. Remove engine cover.
3. Detach the torque support. To do this unscrew the fastening screw on the torque converter bearing bracket.
Note: Place a cloth between design cover and secondary air pump to avoid scratching cover.
4. Detach the torque support on the body and swivel upwards.
5. Unscrew the 4 fastening screws on the ignition coil 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.
8. Remove torque arm bracket. To do so, undo the 4 fastening screws and remove bracket.
9. Disconnect the ignition coils. To do this, press the button on the plug and pull off the cable plug.
10. Undo ignition coils. To do this, unscrew the fastening screw on the valve cover.
11. Pull out the ignition coils.
12. Press together the plug connection for the positive crankcase ventilation on the camshaft housing cover and pull it off.
13. Pull off the cover cap and the cable plug for the hydraulic valve lying beneath it by pressing on wire clip -a- .
Note: Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to ensure they can be used again!
14. Remove wiring harness holders by pulling carefully on the holders. Lay wiring harness aside.
15. Remove wiring harness on sheetmetal holders on the camshaft housing cover.
Warning: Risk of damage to the position sensor on the camshafts trigger wheel!
Note: If the camshaft housing cover is not removed carefully, it can cause the trigger wheel on the position sensor at the rear on the camshaft to be bent out of shape!
Note: You are recommended to use a tool that has an addendum of less than 50 mm -A- (see special tool) to undo the rear fastening screw of the cylinder head cover close to the radiator tank.
16. Unscrew screws -1 to 19- (-16 and 19- were mounted on the torque support bracket) and lift the camshaft housing cover carefully at the back to avoid damaging the trigger wheel of the reference mark sender on the camshaft (this is located in the vicinity of screws 1 and 7) and then lift it off completely.
17. Turn the camshaft housing cover over and remove inner and outer seal for camshaft housing. Clean sealing surfaces on the camshaft housing cover and cylinder head.
Note: Always replace seals.
Installing cover for camshaft housing
Special tools
Installing cover for camshaft housing on cylinder bank 1-4
Note: The cover for the camshaft housing is removed and installed in the same way on cylinder bank 5-8 and cylinder bank 1-4!
Note: Always replace inner and outer seal for camshaft housing!
1. Thoroughly clean sealing surfaces on the camshaft housing cover and cylinder head.
2. Insert inner and outer seal in camshaft housing cover and apply a bead of DreiBond sealant to the lining between the cylinder head and timing chain cover on both sides.
Sealant beads on both sides
Warning: Risk of damage to the position sensor on the camshafts trigger wheel!
Note: If the camshaft cover is not fitted carefully, it can cause the trigger wheel on the position sensor at the rear on the camshaft to be bent out of shape!
3. Position the camshaft housing cover carefully; do not bend the trigger wheel of the position sensor on the camshaft when doing so.
4. Insert all ignition rod modules aligned in the corresponding camshaft housing cover.
5. Using the assembly sleeve 9701 press the sealing lip of the hydraulic valve over the hydraulic valve and align it.
Note: You are recommended to use a tool that has an addendum of less than 50 mm -A- to tighten the rear fastening screw of the cylinder head cover close to the radiator tank.
6. Position all fastening screws and tighten them to 10 Nm (7.5 ft. lbs.) in accordance with the correct tightening sequence. Screws 16 and 19 follow at a later stage with the torque support bracket.
7. Fit wiring harness on sheetmetal holders on the camshaft housing cover.
8. Fit wiring harness holder with new plastic clips. To do this, simply press on the wiring harness holder.
9. Connect the cable plug for the hydraulic valve and fit the cover cap.
10. Attach plug connection for the positive crankcase ventilation to the flange on the camshaft housing cover.
11. Tighten ignition coils to 10 Nm (7.5 ft. lbs.).
12. Disconnect ignition coil. To do this slide on the connector until it locks with an audible click.
13. Install bracket for torque arm. The M8 x 45 Torx screws are tightened on the upper screw points to 23 Nm (17 ft. lbs.). On the lower screw-mounting points (middle of valve cover) the M6 x 40 screws are first tightened to 5 Nm (3.5 ft. lbs.) and then to 10 Nm (7.5 ft. lbs.).
14. 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.
15. Press down the 2 rubber mounts on the support. The rubber mounts must be felt to engage.
16. Tighten the 4 fastening screws on the design cover to 3 - 3.5 ft. lbs.
17. Install secondary air pump with console.
18. Install engine cover.
19. Install right or left engine compartment cover.
Tightening torques