Cylinder Head Cover (Valve Cover)

Removing and installing cylinder head cover (valve cover) on 4.8-liter DFI engines

Information

Component changes for model year 2009 as of October 2008

Information
Always read the information concerning modified tightening specifications and component changes relating to repairs provided for specific engine numbers in the Information section!

Preliminary work

1. Remove engine cover.
2. Remove oil mist separator.
3. Remove bar ignition modules.

Tools and materials

Tools

Information

Tool height

It is best to use a tool that has an head height of less than 50 mm -A- (see special tools) to loosen and tighten the rear fastening screw of the cylinder head cover close to the plenum panel.

Recommended special tools

Information

Component overview

Valve cover seals, cylinders 1 to 4

1 - Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2 - Oil cap
3 - Screw, M6 x 16
4 - Hall sender
5 - O-ring
6 - Valve cover seal
7 - Valve cover seal, inner
8 - Seal for hydraulic valve for camshaft control

Valve cover seals, cylinders 5 to 8

1 - Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2 - Hall sender
3 - Screw, M6 x 16
4 - O-ring
5 - Valve cover seal
6 - Valve cover seal, inner
7 - Seal for hydraulic valve for camshaft control

Tightening sequence for valve cover for cylinders 1 to 4

Tightening sequence for valve cover for cylinders 5 to 8

Bar ignition modules and valve cover, cylinder bank 1 to 4

1 - Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2 - Bar ignition module
3 - Screw for bar ignition module
4 - M6 screw
5 - Cap
6 - M8 screw
7 - Eyelet
8 - sheet metal holder
A - Direction of travel
- Not shown; design cover on bar ignition modules

Bar ignition modules and valve cover, cylinder bank 5 to 8

1 - Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2 - Eyelet
3 - M8 screw
4 - M6 screw
5 - Bar ignition module
6 - Screw for bar ignition module
7 - sheet metal holder
8 - Cap
A - Direction of travel
- Not shown; design cover on bar ignition modules

Removing cylinder head cover (valve cover)

Notice
Valve cover fitted and screwed on incorrectly
Incorrect installation position of hall sender with respect to the camshaft
Risk of engine damage
Fault entries in the DME control unit

- Align the valve cover carefully over the fitted ignition rod modules.

1. Pull off the cap and the cable plug for the hydraulic valve lying beneath it by pressing on the wire clip -a-.

Cap and cable plug of the hydraulic valve

2. Loosen the two ground points on the valve covers. -1-

Engine wire harness, timing case and valve cover

1 - Screw, M6 x 12
2 - Screw, M6 x 16

3. Disconnect cable plug for hall sender.

Information
Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to ensure they can be used again!

4. Remove wire harness holders by pulling carefully on the holders. The wire harness can be detached and lifted up carefully at the lugs. Lay wire harness aside.

Wire harness holder

Information
It is best to use a tool with a head height of less than 50 mm -A- (see Special tools) for loosening and tightening the rear fastening screw on the cylinder head cover close to the plenum panel.

Tool height

If you do not have a suitable tool, the side plenum panel must be removed and then refitted. To do this, remove cover of plenum panel. Remove plenum panel wall (shown on left). Release lambda sensor connector from the holder at the plenum panel wall -1-. Unclip cable -2-. Loosen PDCC reservoir from plenum panel, if fitted. Loosen three screws on the plenum panel -3-. Pull plenum panel up and off Install in reverse order.

When doing this, first fit seal on the body and spray with silicon spray

Plenum panel wall (shown on left)

5. Unscrew screws and carefully lift valve cover. Figure shows tightening sequence. Loosen holder for cylinder 5 wire harness and lay it to one side. -1-

Tightening sequence for valve cover for cylinders 1 to 4

Tightening sequence for valve cover for cylinders 5 to 8

Engine wire harness, generator

1 - Holder - see Valve cover
G - Cable clips

6. Turn the valve cover over and remove inner and outer seals. Clean sealing faces on valve cover and cylinder head.

Sealing faces on cylinder head

Information
Always replace seals.

Installing cylinder head cover (valve cover)

Installing cylinder head cover (valve cover) (up to October 2008)

Information
Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to ensure they can be used again!

1. Clean sealing faces on valve cover and cylinder head thoroughly.

Cylinder head

Information
Always replace seals.

2. Fit inner and outer seals in the valve cover -6 and 7-/-5 and 6- and apply a bead of Silikon 2210 Drei Bond sealant (000.043.204.58, status 02/06) to the lining between the cylinder head and timing chain cover on both sides.

Valve cover seals, cylinders 1 to 4

1 - Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2 - Oil cap
3 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Hall sender
5 - O-ring
6 - Valve cover seal
7 - Valve cover seal, inner
8 - Seal for hydraulic valve for camshaft adjustment

Valve cover seals, cylinders 5 to 8

1 - Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2 - Hall sender
3 - Screw, M6 x 16 - Tightening torque: 10 Nm (7.5 ftlb.)
4 - O-ring
5 - Valve cover seal
6 - Valve cover seal, inner
7 - Seal for hydraulic valve for camshaft adjustment

Applying sealant to timing-case cover and cylinder head

Sealant beads on both sides

3. Place valve cover carefully in position.

Notice
Valve cover fitted and screwed on incorrectly
Incorrect installation position of hall sender with respect to the camshaft
Risk of engine damage
Fault entries in the DME control unit

- Align the valve cover carefully over the fitted ignition rod modules.

4. Fit all bar ignition modules aligned into the corresponding valve cover.

Fitting bar ignition modules

Information

Tool height

It is best to use a tool with a head height of less than 50 mm -A- (see Special tools) for loosening and tightening the rear fastening screw on the cylinder head cover close to the plenum panel.
If you do not have a suitable tool, the side plenum panel must be removed and then refitted. To do this, remove cover of plenum panel. Remove plenum panel wall (shown on left). Release lambda sensor connector from the holder at the plenum panel wall -1-. Unclip cable -2-. Loosen PDCC reservoir from plenum panel, if fitted. Loosen three screws on the plenum panel -3-. Pull plenum panel up and off Install in reverse order.

When doing this, first fit seal on the body and spray with silicon spray

Plenum panel wall (shown on left)

5. Fit all M6 and M8 fastening screws (torque support and eyelets) according to specifications.

Tightening sequence for valve cover for cylinders 1 to 4

Tightening sequence for valve cover for cylinders 5 to 8

Bar ignition modules and valve cover, cylinder bank 1 to 4

1 - Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2 - Bar ignition module
3 - Bar ignition module screw - Tightening torque: 10 Nm (7.5 ftlb.)
4 - Screw, M6 Tightening torque: 13 Nm (9.5 ftlb.)
5 - Cap
6 - Screw, M8 Tightening torque: 23 Nm (17 ftlb.)
7 - Eyelet - Tightening torque: 23 Nm (17 ftlb.)
8 - sheet metal holder
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)

Bar ignition modules and valve cover, cylinder bank 5 to 8

1 - Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2 - Eyelet
3 - Screw, M8 Tightening torque: 23 Nm (17 ftlb.)
4 - Screw, M6 Tightening torque: 13 Nm (9.5 ftlb.)
5 - Bar ignition module
6 - Bar ignition module screw - Tightening torque: 10 Nm (7.5 ftlb.)
7 - sheet metal holder
8 - Cap
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)

6. Fit wire harness holder. To do this, press on the wire harness holder.

Wire harness holder

7. Connect the cable plug for the hydraulic valve and fit the cap.

Cable plug

8. Fit the two ground points on the valve covers. -1-

Engine wire harness, timing case and valve cover

1 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Screw, M6 x 16

9. Connect cable plug for hall sender.

Installing cylinder head cover (valve cover) (as of October 2008)

Information
Plastic clips can be damaged once the wiring harness holder has been undone and must be checked to ensure they can be used again!

1. Clean sealing faces on valve cover and cylinder head thoroughly.

Cylinder head

Information
Always replace seals.

2. Fit inner and outer seals in the valve cover -6 and 7-/-5 and 6- and apply an additional small bead of Silikon 2210 Drei Bond sealant (000.043.204.58, status 12/08, may still be used in this restricted area provided there is no contact with aluminium screws) to the lining between the cylinder head and timing chain cover on both sides.

Valve cover seals, cylinders 1 to 4

1 - Valve cover for cylinders 1 to 4 (align over bar ignition modules)
2 - Oil cap
3 - Aluminium screw, M6 x 20; hall sender (phase sensor); always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - Hall sender
5 - O-ring
6 - Valve cover seal
7 - Valve cover seal, inner
8 - Seal for hydraulic valve for camshaft control

Valve cover seals, cylinders 5 to 8

1 - Valve cover for cylinders 5 to 8 (align over bar ignition modules)
2 - Hall sender
3 - Aluminium screw, M6 x 20; hall sender (phase sensor); always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - O-ring
5 - Valve cover seal
6 - Valve cover seal, inner
7 - Seal for hydraulic valve for camshaft control

Applying sealant to timing-case cover and cylinder head

Fitting bar ignition modules

Information

Plenum panel wall (shown on left)

If you do not have a suitable tool, the side plenum panel must be removed and then refitted. To do this, remove cover of plenum panel. Remove plenum panel wall (shown on left) Release lambda sensor connector from the holder at the plenum panel wall -1-. Unclip cable -2-. Loosen PDCC reservoir from plenum panel, if fitted. Loosen three screws on the plenum panel -3-. Pull plenum panel up and off Install in reverse order. When doing this, first fit seal on the body and spray with silicon spray

5. Fit all M6 and M8 fastening screws (torque support and eyelets) according to specifications.

Tightening sequence for valve cover for cylinders 1 to 4

Tightening sequence for valve cover for cylinders 5 to 8

Bar ignition modules and valve cover, cylinder bank 1 to 4

1 - Valve cover for cylinder bank 1 to 4 (align over bar ignition modules)
2 - Bar ignition module
3 - Aluminium screw, M6 x 20; bar ignition module; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
4 - Aluminium screw, M6 x 30; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
5 - Cap
6 - Aluminium screw, M8 x 35 (on torque support); always use new aluminium screws; - Initial tightening: 10 Nm (7.5 ftlb.) and - Final tightening: 90 degrees Steel screw on eyelet!
7 - Eyelet (with steel screw) - Tightening torque: 23 Nm (17 ftlb.)
8 - sheet metal holder
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)

Bar ignition modules and valve cover, cylinder bank 5 to 8

1 - Valve cover for cylinder bank 5 to 8 (align over bar ignition modules)
2 - Eyelet
3 - Eyelet (with steel screw) - Tightening torque: 23 Nm (17 ftlb.)
4 - Aluminium screw, M6 x 30; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
5 - Bar ignition module
6 - Aluminium screw, M6 x 20; bar ignition module; always use new aluminium screws; - Initial tightening: 4 Nm (3 ftlb.) and - Final tightening: 90 degrees
7 - sheet metal holder
8 - Cap
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)

6. Fit wire harness holder. To do this, press on the wire harness holder.

Wire harness holder

7. Connect the cable plug for the hydraulic valve and fit the cap.

Cable plug

8. Fit the two ground points on the valve covers. -1-

Engine wire harness, timing case and valve cover

1 - Screw, M6 x 12 - Tightening torque: 10 Nm (7.5 ftlb.)
2 - Screw, M6 x 16

9. Connect cable plug for hall sender.

Subsequent work

1. Fit bar ignition modules.
2. Install oil mist separator.
3. Install engine cover.