Replacing Cylinder-Head Gasket (Valve Cover Seal)

WM 158219 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

Preliminary work

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

Tools and materials

Tools

Information:
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.

Tool height

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 - 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 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 - 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 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 - 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 - Sheetmetal 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 - Sheetmetal holder
8 - Cap
A - Direction of travel
- Not shown; design cover on bar ignition modules - Tightening torque: 4.4 Nm (3.0 ftlb.)

Removing cylinder head cover (valve cover)

Removing cylinder head cover (valve cover)

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

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

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/off). 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. Unscrew screws and carefully lift valve cover. Figure shows tightening sequence Tightening sequence for valve cover for cylinders 1 to 4 - Tightening sequence for valve cover for cylinders 5 to 8 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)

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.

Applying sealant to timing-case cover and cylinder head

Sealant beads on both sides

3. Place valve cover carefully in position.

Caution:
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:
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

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

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 - Tightening torque: 10 Nm (7.5 ftlb.)

9. Connect cable plug for hall sender.

Subsequent work

Subsequent work

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