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Injection Nozzle Traverse, Remove and Install
Important: On
removal, lay injection nozzle traverse aside in correct order to
ensure correct allocation on reinstallation
 Remove
| 1. |
Remove injection lines
| • |
For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003 
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| • |
For Y 20 DTH as of MY 2003, Y 22 DTR
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| 2. |
Remove inlet manifold upper section
| • |
For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
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| • |
For Y 20 DTH as of MY 2003, Y 22 DTR
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| 3. |
Remove cylinder head cover
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| 6. |
Detach oil leak line from injection nozzle traverse.
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| 7. |
Remove fastening bolt (1)
| • |
Raise injector nozzle traverse slightly and pull forward out of
cylinder head
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| 8. |
Place new seal ring (2) on injection nozzle
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Install
Important: The use of KM-6318 is mandatory in order to prevent damage
to the gaskets
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| 9. |
Place KM-6318-2 (2) over camshaft
bearing 2 (3)
| • |
Ensure that the sliding surfaces (4) point to the control
side
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| 10. |
Fit KM-6318-1 (1) on camshaft bearing
2
| • |
Note the displacement of the holes (7) of the camshaft bearing
and screws (5) from KM-6318-1
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| • |
Stop (6) must be located on the transmission side of KM-6318-1
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| 11. |
Slide KM-6318-2 in direction of arrow
until stop lies against KM-6318-1
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| 12. |
Shove new seal ring (1) on injector nozzle traverse
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| 13. |
Carefully insert the injector nozzle traverse of cylinder 1 and
2 until it lies flush (arrow) in the cylinder head
| • |
If necessary, assist with light taps using plastic mallet
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| • |
Ensure that no dirt enters the injector nozzle traverse as this
can cause malfunctions
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| 14. |
Slide KM-6318-2 (3) in direction of
arrow, detach KM-6318-1 (2) from camshaft
bearing 2 and remove KM-6318-2
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| 15. |
Repeat installation of injection nozzle traverse using KM-6318 for cylinders 3 and 4
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Important: The tightening
procedure described in the following is the only way to guarantee
that the injection nozzle traverse is correctly tensioned on the
injection nozzle
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| 16. |
Insert traverse injection nozzle with new fastening bolt
| • |
I: Hand-tighten fastening bolt using torx nut and extension
(without toggle or ratchet)
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| • |
II: Then turn another 360°
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| 17. |
Attach new oil leak lines to injection nozzle traverse
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| 18. |
Install valve bridges
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| 20. |
Install cylinder head cover
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| 21. |
Install inlet manifold upper section
| • |
For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
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| • |
For Y 20 DTH as of MY 2003, Y 22 DTR
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| 22. |
Install injection lines
| • |
For X 20 DTL, Y 20 DTL, Y 20 DTH up to MY 2003
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| • |
For Y 20 DTH as of MY 2003, Y 22 DTR
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