Removing
1. Unscrew the screws and remove the plastic protective cover from the top of the head cover.
2. Loosen the clamp and disconnect the crankcase ventilation hose.
3. On turbo engines, loosen the clamp holding the metal pipe to the turbocharger and the clamp holding the intake port to the manifold. Unscrew the two bolts and remove the tube assembly from the engine along with the O-ring that is installed between the tube and the turbocharger.
4. Now disconnect the fuel supply hoses from the right end of the head cover and disconnect the wires from the glow plugs. Remove the bolt securing the intake manifold wiring harness to the head cover.
5. Unscrew the bolts and remove the head cover (bolt is indicated by an arrow).
Places for applying sealant to the cylinder head cover
Places of application of sealant are indicated by arrows.
Installation
1. Check that the mating surfaces of the head cover and cylinder head are clean and dry. Install the gasket on the cylinder head cover.
2. Install the sealing washers in the sockets under the bolts of the head cover.
3. Apply a thin layer of sealant to the cylindrical surface (arrow) on the left side of the head cover and cylinder head.
4. Install the head cover and tighten the mounting bolts to the specified torque.
5. Connect the fuel supply hoses and electrical connectors and connect the crankcase breather hose.
6. On turbo models, install the intake port using a new O-ring.
7. Install the protective plastic cover on the head cover and secure with screws.
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