Removal procedure
1. Disconnect the negative battery cable.
2. Remove decorative cover. See «Decorative cover» in this section.
3. Remove the hoses and ducts of the charge air system. See «Air injection system» in this section.
4. Remove the crankcase breather valve (PCV) and adapter. See «Crankcase ventilation valve and adapter (PCV)» in this section.
5. Remove the fuel line to the injector located between the common rail and the injector. See Part 1F1, Engine Controls - 2.0 Diesel.
6. Remove the fuel return line assembly. See Part 1F1, Engine Controls - 2.0 Diesel.
7. Remove the decorative cover bracket together with the coolant return pipe from the expansion tank.
8. Remove the upper timing belt cover.
9. Disconnect the camshaft position sensor connector
10. Remove nozzles. See Part 1F1, Engine Controls - 2.0 Diesel.
11. Remove the cylinder head cover with gasket.
Cleaning procedure
1. Clean the sealing surface of the cylinder head cover.
2. Clean the sealing surface of the cylinder head.
3. Clean the cylinder head cover bolts.
4. Clean the cylinder head cover bolt holes.
Installation procedure
1. Apply sealant (LOCTITE 5900) on the surface of the front/rear camshaft cover.
2. Install the cylinder head cover with a new gasket to the cylinder head.
Tighten
Tighten cylinder head cover bolts to 12 Nm (8.9 lb-ft).
3. Install the upper timing belt cover.
4. Install the decorative cover bracket with the coolant return pipe on the expansion tank.
5. Install the fuel return line assembly.
6. Install the fuel line to the injector located between the common rail and the injector. See Part 1F1, Engine Controls - 2.0 Diesel.
Tighten
Tighten the timing belt upper cover bolts to 11 Nm (97.4 lb-in).
Tighten the coolant return pipe bolt to 9 Nm (79.7 lb-in).
Tighten the connecting block bolts to 11 Nm (97.4 lb-in).
Tighten the decorative cover bracket bolt to 11 Nm (97.4 lb-in).
