Note. The procedures are shown using the left cylinder head cover as an example. The operations for the right cylinder head cover are similar.
Removing
1. Remove the catalytic converter from the turbocharger.
2. Remove the upper intake manifold.
3. Remove the secondary air outlet.
4. Disconnect the forced crankcase ventilation pipe (1) from the oil dipstick tube and cylinder head cover (8).
5. Disconnect the wiring harness connectors and unscrew the fasteners, then remove the engine wiring harness (2). Tightening torque during installation: 20 Nm.
6. Loosen the bolt (3) securing the secondary air control valve. Tightening torque during installation: 65 Nm.
7. Remove the three mounting bolts (4) and remove the secondary air control valve (5). Tightening torque during installation: 10 Nm.
Note. Use a new gasket when installing the secondary air check valve.
8. Unscrew the two mounting bolts (6) and remove the engine lashing eye (7). Tightening torque during installation: 65 Nm.
9. Loosen the bolts (1) and remove ignition coils (2).
10. Remove 13 mounting bolts (1) and remove the left cylinder head cover (2).
11. Remove and discard bushings with cylinder head cover bolts.
Installation
1. Install the EN 46101 guides on the spark plug tubes of the left cylinder head.
2. Install new cylinder head cover bushings before installing bolts.
3. Clean the contact surfaces on the cylinder head with a clean, lint-free cloth.
4. Place a bead of sealant with a diameter of 4 mm and a length of 8 mm on the joint line of the front engine cover (1).
5. Install cylinder head cover (2).
6. Make 13 bolts (1) cylinder head covers.
7. Tighten the 13 cylinder head cover bolts in the sequence shown in two passes to 10 Nm.
8. Remove the EN 46101 guides from the spark plug tubes.
9. Install new spark plugs in the cylinder head and tighten to 20 Nm.
10. Install ignition coils (2) and tighten the mounting bolts (1) torque 10 Nm.
11. Install the remaining components in the reverse order of removal.
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