Fuel Injector Top Pipe... just broke it!

[OOG]

Hello.... i've been lurking on here for a few months, and have found this forum to be a godsend! But i've got a pressing issue that i can't find anyhting on via the 'Search' function...

I'm part way through changing the head on a 2.4, waiting for a Stevo one which should finally be here today...

Just taking the injectors off the old head and noticed that the pipe that runs across the top of the injectors (leakage pipe i think? 23760 on this diagram: http://www.toyodiy.com/parts/p_J_199...KPGT_2201.html ) is broken. Break looks new so i'm guessing that i've done it whilst trying to undo something else nearby...

Is this pipe crucial? It's broken between the first and second injector rings. Sounds stupid, but will a bit of silicon tubing do as a short-term replacement?

[NiftyNev]

It's the fuel injector nozzle leakage pipe which returns unused fuel to the pump. You will have to replace it unless you are very good at silver brazing and can do a suitable repair and not block up the pipe in the process. They are easy to break if you allow them to twist as you remove the nuts from the injectors.

Nev

[OOG]

I've made up a slight (well, maybe not so slight!) modification!

File broken stub end down on ring, fit pressure nipple (from local model shop!) and Tygon Silicone tubing (diesel proof) ove gap. Fuel-tight seal, should fit over injectors, justs looks a bit odd...


Now my big worry is that i've noticed that the woodruff key for the camshaft isn't on the old head... now where the hell has that gone?!

[NiftyNev]

Have you got a pic of this repair? I'm just wondering if the return is under any significant pressure.

Nev

[OOG]

Sorry for the delay in replying, i've spent most of the time in between swearing at a Toyota...

Not much point in showing a photo of the mod as i've decided to bin it and just buy a replacement set from RoughTrax. When i got the engine running again i had the (seemingly common if this forum is anything to go by!) rough-idle/white smoke problem, couple with diesel p*ssing down the side of the block form the first two injectors. There were also large air bubbles visible running down through the silicon tubing i had used...

So i'm hoping the rough idle is due to air running back through the injectors from my 'bodge' on the leakage pipe. I'll also change the glow plugs as they were looking a bit sh*gged.

And just a general thanks to everybody who posts useful stuff on this forum, you wonder how people getting on with running a Surf without using it!

[Albannach]

So i'm hoping the rough idle is due to air running back through the injectors from my 'bodge' on the leakage pipe.

Air can't get from the Leak-Off pipe to the injectors.

[NiftyNev]

Air can't get from the Leak-Off pipe to the injectors.

Maybe it could. This connects back to the pump.

Nev

[OOG]

Air can't get from the Leak-Off pipe to the injectors.

The Tygon silicone tubing i was using is clear. Large air bubbles moving from injector two ring to injector one ring, and then from there down directly to the pump. If it's a closed system then surely there must be a possibility of that air finding it's wa back through to the injectors?

[NiftyNev]

The Tygon silicone tubing i was using is clear. Large air bubbles moving from injector two ring to injector one ring, and then from there down directly to the pump. If it's a closed system then surely there must be a possibility of that air finding it's wa back through to the injectors?

I agree. It is a closed system as far as I can see.

Nev

[lord lucan]

if one of the leak off pipes had a split it would draw air in overnight and a bugger to start in the morning, i had this only last week on a transit that had come in. on another note have a good used one £20 posted

[OOG]

Lord Lucan; i'm off to Cornwall for the next week and a half but i'll get in contact with you when i get back if that's cool?

I'm having trouble with other people's opinions... some say the leakage pipe feeds directly to the pump, a couple of others say it goes back to the tank via the pump. I'll replace it anyway to rule it out. Also new glowplugs, new washers for the bottom of the injectors etc etc... and possibly a big bottle of Redex!

The washers that sit under the pipe (with the two wee holes in them) do they HAVE to line up with the two holes in the ring on the pipe? Or will the fuel run with them in any orientation?

[lord lucan]

Lord Lucan; i'm off to Cornwall for the next week and a half but i'll get in contact with you when i get back if that's cool?

I'm having trouble with other people's opinions... some say the leakage pipe feeds directly to the pump, a couple of others say it goes back to the tank via the pump. I'll replace it anyway to rule it out. Also new glowplugs, new washers for the bottom of the injectors etc etc... and possibly a big bottle of Redex!

The washers that sit under the pipe (with the two wee holes in them) do they HAVE to line up with the two holes in the ring on the pipe? Or will the fuel run with them in any orientation?

hi the fuel will run which ever way you put them on

[Albannach]

Apologies, I assumed the leak off would run back to the tank, didn't realise it was a closed loop.

[OOG]

Just to close the thread off, i've replaced the pipe (found a neighbour with a breaker), put the injectors in WITH THE CRUSH WASHERS THIS TIME!!! and now it runs like a fine Swiss watch.

Well, like a Surf, but you get the idea!

[Albannach]

Just to close the thread off, i've replaced the pipe (found a neighbour with a breaker), put the injectors in WITH THE CRUSH WASHERS THIS TIME!!! and now it runs like a fine Swiss watch.

You fitted the injectors without the crush washers? No womnder it didn't run right!

Good spot of luck having a neighbour who was breaking a Surf.