High Pressure Pipe Removal and Installation
Precautions: Precautions for Fuel System Service · General safety (00)
NOTICE:
If the union nut of the high pressure pipe connecting to the high pressure pump / fuel injectors is loosened and tightened without holding the union nuts (1), the high pressure pump / fuel injectors may be damaged.
Hold the union nuts whenever loosening and tightening the union nut of the high pressure pipe.
Removal
1)Release fuel pressure. 
2)Disconnect negative (–) cable at battery.
3)Remove engine cover.
4)Remove air cleaner outlet pipe.
5)Remove high pressure pipes as follows.
•For high pressure pipes between fuel injector and common rail.
a.Loosen high pressure pipe union nuts (1) from fuel injectors.
b.Loosen high pressure pipe union nuts (2) from common rail (3), and remove high pressure pipes (4).
•For high pressure pipe between high pressure pump and common rail.b.Loosen high pressure pipe union nuts (2) from common rail (3), and remove high pressure pipes (4).
a.Loosen high pressure pipe union nuts (1), and remove high pressure pipe (2).
Installation
NOTICE:
Failure to take proper precautions when installing the high pressure pipe can cause damage to the high pressure pipe and may lead to fuel leakage.
Take the following precautions when removing and installing the high pressure pipe.
•Never reuse high pressure pipe.
•Before tightening the union nut to specified torque, tighten the union nuts of the both sides evenly and gradually by hand.
•When the union nut of high pressure pipe is tightened using the crowfoot flare-nut wrench (14 mm and 19 mm) until the torque wrench reads the specified torque, the pulley will actually be tightened to a torque much more than the specified torque. This could damage the related components.
Use the formula shown below to determine the correct reading of the torque wrench for its length. Then tighten the union nut of high pressure pipe until the torque wrench indicates the value thus determined.
•Before tightening the union nut to specified torque, tighten the union nuts of the both sides evenly and gradually by hand.
•When the union nut of high pressure pipe is tightened using the crowfoot flare-nut wrench (14 mm and 19 mm) until the torque wrench reads the specified torque, the pulley will actually be tightened to a torque much more than the specified torque. This could damage the related components.
Use the formula shown below to determine the correct reading of the torque wrench for its length. Then tighten the union nut of high pressure pipe until the torque wrench indicates the value thus determined.
Tightening torque formula.
M = T x L / (L + “a”)
M: Value indicated on torque wrench
T: Specified tightening torque
L: Effective length of torque wrench
“a”: Effective length of extension
| “b”: | Handle center line (power point) | “c”: | Pivot point (fulcrum) |
Reverse removal procedure noting the following points.
•Use new high pressure pipe.
•Tighten injector side union nuts and high pressure pump side union nut to specified torque using crowfoot flare-nut wrench (14 mm) with torque wrench.
•Tighten common rail side union nuts to specified torque using crowfoot flare-nut wrench (19 mm) with torque wrench.
•Check for fuel leakage.
•Tighten injector side union nuts and high pressure pump side union nut to specified torque using crowfoot flare-nut wrench (14 mm) with torque wrench.
Tightening torque
High pressure pipe union nut (fuel injector side and high pressure pump side) (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)Tightening torque
High pressure pipe union nut (common rail side) (b): 19 N·m (1.9 kgf-m, 14.0 lbf-ft)