Table of contents: Removal 🠇 Refitting 🠇
Removal
1. Disconnect the breather hose from the lefthand end of the cylinder head cover.
2. Remove the upper timing belt cover as described in Section 5.
3. Unscrew the eight retaining bolts in a spiral sequence starting from the outside. Note their correct fitted locations, as they are of two different lengths. Recover the washers from the bolts/cover (see illustrations).
4.3a. Unscrew the eight retaining bolts (arrowed)...
4.3b.... and remove them along with their washers
4. Lift the cover away from the engine (see illustration), and recover the rubber seal.
4.4. Lift the cover away from the engine and recover the seal
Examine the seal for signs of damage and deterioration, and if necessary, renew it.
Refitting
5. Carefully clean the cylinder head and cover mating surfaces, and remove all traces of oil.
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6. Fit the rubber seal to the cylinder head cover groove, ensuring that it is correctly located along its entire length (see illustration).
4.6. Ensure that the rubber seal is correctly located in the cover groove prior to refitting
7. Carefully refit the cylinder head cover to the engine, taking great care not to displace the rubber seal.
8. Install the retaining bolts and washers, and tighten them to the specified torque setting. On TUD 5 engines, initially screw the bolts through to the head in the following order 8-5-7-6-4-1-3-2 (see illustration). Then pretighten them (to the specified torque), in numerical sequence (1 through to 8) and then finally complete by tightening to the specified torque, again in numerical sequence.
4.8. Cylinder head cover tightening sequence (TUD 5 engine)
9. Refit the upper timing belt cover as described in Section 5.
10. Reconnect the breather hose to the cylinder head cover, and securely tighten its retaining clip.