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Injectors, Remove and Install
 Remove
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Disconnect ground cable from battery.
For X 20 XEV: Disconnect wiring harness plug (1) from intake air
temperature sensor and throttle valve potentiometer.
For Y 22 XE and Z 22 XE: Detach wiring harness plug from
throttle body.
Remove or detach wiring harness plug (2) from hot film mass air
flowmeter, crankcase ventilation hose (3) from cylinder head cover
and air intake hose from throttle body and air cleaner housing. Lay
air intake hose to the side.
Caution
Fuel escapes, observe safety regulations and national
legislation. Depressurise fuel using Fuel Pressure Gauge
KM-J-34730-91 via test connection (4) – collect escaping fuel
in suitable container.
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Remove
Remove crankcase ventilation hose (1) from cylinder head cover
and vacuum hose (3) from fuel pressure regulator.
For X 20 XEV: Detach ground cable from fuel distributor
pipe.
Detach fuel return line (4) and fuel feed line (5) from fuel
distributor pipe – counterhold on fuel distributor pipe.
For X 20 XEV: Detach Bowden cable (6) from throttle body and
wiring harness plug (7) from idle speed stepper motor.
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Note: There are a
total of 6 plug connections on the underside of the plug strip.
Illus. E 5392 shows the injector plug connections (positions 1 to
4).
Remove
Press retaining clip for injectors for 1st cylinder and 4th
cylinder in plug strip towards engine side (with screwdriver)
– collect retaining clips with bar magnet.
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Lift plug strip (1).
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Unscrew fastening pins (arrow) for fuel distributor pipe.
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For X 20 XEV: Remove fastening clamp (1) for fuel distributor
pipe adapter from Bowden cable bracket.
Unscrew fastening bolt (2) for fuel distributor pipe.
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Remove fuel distributor pipe with injectors from intake
manifold.
Remove spring clip for injector and remove relevant injector
from fuel distributor pipe.
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Install
Insert injector with new seal rings in fuel distributor pipe and
fasten with spring clip (1) – ensure correct seating.
Caution
The positions of the spring clips for the injectors only allow
the plug strip to engage in a certain position. Align all spring
clips so that correct contact of the plug strip to the injectors is
ensured.
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Install
Insert fuel distributor pipe with injectors carefully in intake
manifold.
Install fastening bolt and fastening pin for fuel distributor
pipe – tightening torque 8 Nm / 6 lbf. ft.
For X 20 XEV: Attach fastening clamp for fuel distributor pipe
adapter to Bowden cable bracket.
Connect plug strip to injectors. Ensure correct seating, plug
strip must engage audibly.
Attach fuel supply line and fuel return lines to fuel
distributor pipe – tightening torque 15 Nm / 11 lbf. ft.
For X 20 XEV: Attach Bowden cable to throttle body and connect
wiring harness plug to idle speed stepper motor.
Attach vacuum hose to fuel pressure regulator, crankcase
ventilation hose to cylinder head cover, air intake hose to
throttle body and to air cleaner housing.
For Y 22 XE and Z 22 XE: Attach wiring harness plug to throttle
body.
For X 20 XEV: Attach ground cable to fuel distributor pipe.
Connect wiring harness plug to intake air temperature sensor and
throttle valve potentiometer.
Connect wiring harness plug to hot film mass air flowmeter.
Attach crankcase ventilation hose to cylinder head cover.
Connect ground cable to battery.
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