ENGINE 77 Fig. 5 Fig. 4 Fig. 6 Fig. 7 2. Remove the EGR valve by unscrewing the screws connecting to air intake elbow and EGR tube (fig. 4). 3. Remove the air intake elbow and the gasket by unscrewing the bolts (2 Nos. M10) used for mounting on cylinder head cover (fig. 5). 4. Loosen and remove the dome nuts on the cylinder head cover (10 Nos.) remove the rubber isolators along with it (fig. 6). 5. Unscrew and remove the studs inside the cylinder head cover by accessing through the holes on cylinder head cover with a tube and ratchet spanner. 6. Tilt the cylinder head cover by approximately 30 deg towards HP pump side with one bottom edge resting on cylinder head. This avoids fouling with the valve train. 7. Lift the cylinder head cover in the tilted direction and remove the gasket aong with it (fig. 7). Note: Do not remove any FIE components like Injectors, HP pipes etc. while removing cylinder head cover. Before fitment of Cylinder head cover, check the following: - ● Clean the cylinder head cover and check for distortion of sealing sur face with a feeler gauge.( Refer figure ) ● Should the distortion be beyond limit, re-machine the sealing surface just to clear the unevenness. ● Check the condition of the cylinder head cover gasket. Replace if there is a slightest doubt about its sealing.
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