1G
High Pressure Pipes Removal and Installation
Reference: Fuel Delivery System Components:K9K
Removal
1) Check that engine is cold and fuel pressure is not under pressure referring to Fuel Pressure Relief Confirmation Procedure:K9K .
2) Disconnect negative (–) cable at battery.
3) Remove injector cover.
4) Remove oil level gauge guide (1) and injector cover bracket (2).
5) Loosen common rail nuts (1) a few turns.
6) Remove clip (1) connecting high pressure pipes.
7) Remove high pressure pipes as follows.
a) For fuel injector – common rail pipe
i) Loosen union nut of fuel injector side (1).
ii) Loosen union nut of common rail side (2).
CAUTION:
When loosing union nut of fuel injector side, hold fuel injector with wrench (3) as shown.
Do not damage fuel return pipe (4) of fuel injector.
Special Tool
(A) : 09911–78110
iii) Move union nut (1) along pipe keeping flange part (2) in contact with taper (3).
b) For injection pump – common rail pipe
i) Loosen union nut of injection pump side (1).
ii) Loosen union nut of common rail side (2).
Special Tool
(A) : 09911–78110
iii) Move union nut (1) along pipe keeping flange part (2) in contact with taper (3).
8) Plug all joint part of disconnected fuel injection circuit with cap available as a spare part to prevent them from entering dust. (Refer to “Precaution” under Fuel Delivery System Description:K9K for parts number and handling).
Installation
CAUTION:
Do not reuse high pressure pipe because it has the possibility that fuel leaks out.
CAUTION:
In case of using extension special tool combined with torque wrench (1), reading value of torque wrench is smaller than specified tightening torque. When using extension special tool, reading value should be calculated according to below formula.
Special Tool
(A) : 09911–78110
Tightening torque formula
M = T x L/(L + L1)
M: Reading value using extension special tool
T: Specified tightening torque
L: Length of torque wrench
L1: Length of special tool
NOTE:
Fit injection pump – common rail pipe before common rail – fuel injector pipes.
1) Remove high pressure pipes as follows.
a) For fuel injector – common rail pipe
i) Remove plugs (dust preventing cap) from common rail outlet and fuel injector inlet.
ii) Insert high pressure pipe flange part (1) into taper (2) of fuel injector inlet.
iii) Insert high pressure pipe flange part (1) into taper (2) of common rail outlet.
iv) Tighten fuel injector union nut (1) then common rail union nut (2) by hand.
v) Install new clip (3) to high pressure pipes.
vi) Tighten fuel injector union nut then common rail union nut to specified torque using special tool.
CAUTION:
• Do not touch pipes with wrench when tightening union nuts.
• When tightening union nut of fuel injector side, hold fuel injector with wrench (4) as shown.
• Do not damage fuel return pipe (5) of fuel injector.
Special Tool
(A) : 09911–78110
Tightening torque
High pressure pipe union nut ( a ): 38 N·m ( 3.8 kg-m, 27.5 lb-ft) ( (See NOTE below.) )
NOTE:
In case of using extension special tool combined with torque wrench, reading torque depends on the length of the torque wrench.
Therefore, calculate reading torque by using “Tightening Torque Formula” described earlier in this installation procedure.
b) For injection pump – common rail pipe
i) Remove plugs (dust prevent cap) from common rail outlet and fuel injector inlet.
ii) Insert high pressure pipe flange part (1) into taper (2) of fuel injector inlet.
iii) Insert high pressure pipe flange part (1) into taper (2) of common rail outlet.
iv) Tighten common rail union nut (1) then injection pump union nut (2) by hand.
v) Tighten common rail union nut then injection pump union nut to specified torque using special tool.
CAUTION:
Do not touch pipes with wrench when tightening union nuts.
Special Tool
(A) : 09911–78110
Tightening torque
High pressure pipe union nut ( a ): 38 N·m ( 3.8 kg-m, 27.5 lb-ft) ( (See NOTE below.) )
NOTE:
In case of using extension special tool combined with torque wrench, reading torque depends on the length of the torque wrench.
Therefore, calculate reading torque by using “Tightening Torque Formula” described earlier in this installation procedure.
2) Tighten common rail nuts to specified torque.
Tightening torque
Common rail nut ( a ): 28 N·m ( 2.8 kg-m, 20.5 lb-ft)
3) Install injector cover bracket (1) and oil level gauge guide (2).
Tighten oil level gauge guide nuts to specified torque.
Tightening torque
Injector cover bracket nut ( a ): 12 N·m ( 1.2 kg-m, 9.0 lb-ft)
Oil level gauge guide nut ( b ): 21 N·m ( 2.1 kg-m, 15.5 lb-ft)
4) Install injector cover.
5) Connect negative (–) cable to battery.
6) Check fuel leakage referring to Fuel Leakage Check:K9K .