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Removing and installing injection lines (X 20 DTL,
Y 20 DTL, Y 20 DTH up to MY 2003)
 Remove
Remove engine cover.
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For X 20 DTL, Y 20 DTL engines: Remove charge air pipe (1) with
charge air hose.
For Y 20 DTH engine: Remove charge air hose (3).
Disconnect vacuum hose (2) from exhaust gas recirculation valve
and unclip from front wiring trough.
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Detach compensation tank coolant hose (5) from thermostat
housing support.
Unclip compensation tank coolant hose from brackets (3) and
(4).
Remove wiring trough fastening bolts (1) and (2).
Unclip coolant hose from wiring trough and lay aside.
Detach wiring harness plug for coolant temperature sensor (6)
from coolant temperature sensor.
Lay wiring trough aside.
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Remove fastening clips (2) from fuel injection lines –
note installation position.
Detach oil leak line from injection nozzle traverse.
Disconnect fuel injection lines (1) from injection nozzle
traverse and fuel injection pump.
Inspect
Check injection line cones and replace injection lines if
necessary.
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Install
Attach injection lines to fuel injection pump and injection
nozzle traverse without tension – tightening torque 30 Nm /
22 lbf. ft.
Attach fastening clips to injection lines – note
installation position.
Connect new oil leak lines to traverse fuel injection
nozzles.
Attach compensation tank coolant hose to thermostat housing
support. Clip compensation tank coolant hose in wiring trough and
attach wiring trough to cylinder head cover or upper part of intake
manifold.
Connect wiring harness plug to coolant temperature sensor.
Connect vacuum hose to exhaust gas recirculation valve and clip
into wiring trough.
For X 20 DTH engine: Install charge air hose – tightening
torque 3.5 Nm / 2.6 lbf. ft.
For X 20 DTL, Y 20 DTL engines: Install charge air hose –
tightening torque 3.5 Nm / 2.6 lbf. ft.
Install engine cover on cylinder head cover.
Bleed fuel system - see operation "Bleed fuel system (X 20 DTL,
Y 20 DTL, Y 20 DTH, Y 22 DTR)" in group "L".
Inspect
Charge and bleed cooling system – see operation "Cooling
System, Charge and Bleed" and "Cooling System, Check for
Leaks".
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