Overhaul

WM 158219 Removing and installing cylinder head cover (valve cover) on 4.8-litre DFI engines

Tools

Technical values

Preliminary work

1. Remove engine cover. => 108319 Removing and installing engine cover (design cover) on DFI engines - section on "Removing".
2. Remove oil mist separator. => 105519 Removing and installing oil mist separator on 4.8-litre DFI engines - section on "Removing"
3. Remove bar ignition modules. => 282020 Removing and installing DFI bar ignition modules - section on "Removing"

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

Valve cover seals, cylinders 5 to 8

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

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

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

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. => 664419 Removing and installing cowl panel cover - section on "Removing". 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 => 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

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 => Applying sealant to timing-case cover and cylinder head.

Valve cover seals, cylinders 1 to 4

Valve cover seals, cylinders 5 to 8

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

- 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.

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

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

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

9. Connect cable plug for hall sender.

Subsequent work

1. Fit bar ignition modules. => 282020 Removing and installing DFI bar ignition modules - section on "Installing"
2. Install oil mist separator. => 105519 Removing and installing oil mist separator on 4.8-litre DFI engines - section on "Installing"
3. Install engine cover. => 108319 Removing and installing engine cover (design cover) on DFI engines - section on "Installing".