Valve Cover: Service and Repair
WM 158219 Removing and installing cylinder head cover
Tools
Preliminary work
Information
The repair procedure is carried out at the same time for both cylinder head covers.
1. Remove engine cover. -> 108319 Removing and installing engine cover (design cover) - section on "Removing" 108319 Removing and installing engine cover (design cover)..
2. Remove bar ignition modules. -> 282020 Removing and installing bar ignition modules - section on "Removing" Service and Repair
3. Remove oil separator for cylinders 5 to 8. -> 105519 Removing and installing oil separator - section on "Removing" Service and Repair
4. Disconnect ground strap for cylinders 5 to 8 from the battery. -> 9X00IN Work instructions after disconnecting the battery Testing and Inspection and loosen the B+ transfer point and set the cables aside => Fastening screw on B+ line.
Fastening screw on B+ line
5. Remove the relevant cross panel at the left or right. -> 508119 Removing and installing cross panel - section on "Removing" Service and Repair
Tools and materials
Tools
Information
- It is best to use a tool that has an head height of < 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
The following tool can also be used (particularly for aluminium screws with an inner pin) =>
- Flexible-head socket wrench, a/f 8 9824
- Flexible-head socket wrench, a/f 10 9824/1
- Torx Micro Bit T30 9824/2
- Torx Micro Bit T45 9824/3
Recommended special tools
Information
Component overview
Valve cover for seals, cylinders 1 to 4
Valve cover for seals, cylinders 5 to 8
Bar ignition modules and valve cover, cylinders 1 to 4
Bar ignition modules and valve cover, cylinder bank 5 to 8
Removing cylinder head 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.
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!
Information
- Always replace seals.
1. Remove hose for positive crankcase ventilation. => Positive crankcase ventilation hose
Positive crankcase ventilation hose
2. Remove cover on solenoid valve for camshaft adjustment -A- and release and pull off the connector lying underneath -B-.
Solenoid valve for camshaft
3. Release and unplug connector for valve lift adjustment at cylinder 4. => Connector for valve lift adjustment
Connector for valve lift adjustment
4. Release wiring harness for bar ignition modules from the bracket -A- and remove fastening screws on the ground straps underneath -B-.
Wiring harness for bar ignition modules
5. Release and unplug connector for camshaft hall sender. => Camshaft hall sender connector
Camshaft hall sender connector
6. Remove B+ wiring harness on cylinders 5 to 8 and camshaft hall sender connector.
Fastening screw on wiring harness
6.1. Remove fastening screw -A- on B+ wiring harness holder at the cylinder head cover.
6.2. Remove fastening screw -B- on B+ wiring harness holder at the engine retaining eyelet.
6.3. Lay the wiring harness aside.
6.4. Release and unplug connector for camshaft hall sender -C-.
7. Unscrew and remove fastening screws for engine retaining eyelet. => Engine retaining eyelet, cylinders 1 - 4 and => Engine retaining eyelet, cylinders 5 - 8
Engine retaining eyelet, cylinders 1 - 4
Engine retaining eyelet, cylinders 5 - 8
8. Remove fastening screw on wiring harness holder for cylinder 5 and remove the holder. => Holder for wiring harness
Holder for wiring harness
9. Unscrew fastening screws -1 to 13- on the cylinder head cover in the opposite sequence.
Fastening screws on cylinder head cover for cylinders 1 to 4
10. Lift up cylinder head cover at a slant -A- , remove it towards the front -B- and set it down on a clean surface. Carefully pull cylinder head cover through under the cables at cylinders 5 to 8 => Cylinder head cover - cylinders 5 to 8.
Cylinder head cover - cylinders 1 to 4
Cylinder head cover - cylinders 5 to 8
Installing cylinder head 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!
Information
- The eyelets must not be inadvertently secured using aluminium screws! => Aluminium screws would break and the suspended engine would fall down!
Information
- The tightening specifications for the basic engine are stored centrally. -> 1001IN Tightening torques, tightening sequences, assembly overviews [1][2]Specifications. Tightening torques and assembly instructions for other assemblies (e.g. chassis, electrics, transmission or body) or for peripheral engine equipment can be found in the corresponding documents.
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 Silicon 2210 three 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-case 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
5. Fit all M6 and M8 fastening screws (torque support and eyelets) according to specifications.
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 two ground points.
9. Connect cable plug for hall sender.
10. Fit the relevant air-cleaner box cover at the left or right.
11. Carry out remaining work.
Subsequent work
1. Install the relevant cross panel at the left or right. -> 508119 Removing and installing cross panel - section on "Installing" Service and Repair
2. Fit bar ignition modules. -> 282020 Removing and installing bar ignition modules - section on "Installing" Service and Repair
3. Install oil separator. -> 105519 Removing and installing oil separator - section on "Installing" Service and Repair
4. Install the engine cover. -> 108319 Removing and installing engine cover (design cover) - section on "Installing" 108319 Removing and installing engine cover (design cover)..
5. Connect the battery if necessary.