fuel rail removal and fuel pressure valve location

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My Name: GINGERT

Contributor
Posts: 8
Joined: Thu Jan 02, 2014 5:15 pm
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 150
Trim Level: Desire
Gearbox: Manual 5 speed
DPF: No

Post

Hi guys I hope you can help before i pull whats left of my hair out.

I have a 2002 Citroen C3 1.4HDI 16V and the fuel rail needs replacing, but what started out as a relatively straight forward job has turned out to be a nightmare.

Firstly can anyone please tell me where the fuel pressure valve is.

Secondly can anyone tell me how i can best remove the fuel rail when I cant even see it.

I have removed all the ducting from the air intake as well as the air box but I still cant see the fuel rail. I know its under the EGR valve which I can just about see... do I need to remove this as well

Please please can some one offer me some good sound advice on how to get this done.

Thanks Guys

Tony :twisted:
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My Name: C3CAR

Guru
Posts: 2658
Joined: Wed May 04, 2011 10:01 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
Has thanked: 175 times
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Hi GINGERT
Firstly can anyone please tell me where the fuel pressure valve is.
Its on the end of the common rail.
fuel pressure sensor on the common rail of a citroen C3 16v HDi
fuel pressure sensor on the common rail of a citroen C3 16v HDi
Common rail fuel pressure sensor is arrowed.

Secondly can anyone tell me how i can best remove the fuel rail when I cant even see it.
The Haynes Manual (click here) has a nice section on how to do this for both the 8v and the 16v engines.

I have removed all the ducting from the air intake as well as the air box but I still cant see the fuel rail. I know its under the EGR valve which I can just about see... do I need to remove this as well
Yes, remove the EGR pipe, there are some pictures Here. You may need a new clip if yours is the original factory one. If you have the EGR out, it would be worth cleaning that too.

Remove the injector pipes from the injectors and from the rail to give better access.

This picture should help you to locate the common rail or 'accumulator rail' (arrows)
citroen c3 common rail removal
citroen c3 common rail removal

and this one,
Citroen C3 common rail
Citroen C3 common rail
where I have arrowed the common rail pressure sensor and marked the location of the common rail which is mostly obscured by the flexible plastic cooling pipe.

These pictures were taken when the engine was removed from the car thanks go to RC3D for taking them.

Apparently you can get the rail off without removing the flexible pipes because they are flexible enough to be pushed out of the way.

Please please can some one offer me some good sound advice on how to get this done.
Hopefully this can give you an idea.
My Name: GINGERT

Contributor
Posts: 8
Joined: Thu Jan 02, 2014 5:15 pm
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 150
Trim Level: Desire
Gearbox: Manual 5 speed
DPF: No

Post

Hi C3 Guru

Thanks for all your help here. I managed to do the fuel rail with a lot of bad language and bruised buckles. Once I had done this I could start the car but it was running so bad that I had to switch it off. I then decided to bite the bullet and take it to the Citroen garage for them to put it onto a diagnostic machine. It now appears that the fuel injectors are running a fault. They have told me that 2 out of the four injectors need replacing but its advisable to replace all four at the same time. The cost of this is £1300.00. Does this sound rite. Is it worth trying to get 2 injectors from the breakers or ebay. Are these easy to remove and if so can you give me any ideas on how to remove them. Are there any pit falls I need to be aware of? And also are these plug-n-play. I just can't afford the £1300 and am considering taking the car to the scrap yard.

Thanks C3 Guru for your continuous help on this.

GingerT
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My Name: C3CAR

Guru
Posts: 2658
Joined: Wed May 04, 2011 10:01 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
Has thanked: 175 times
Been thanked: 93 times

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This post will help you in removing the injectors tips-for-a-diesel-powered-citroen-c3-f6 ... l-t12.html.

You can have all 4 injectors tested and reconditioned if possible, here on ebay which may be considerably cheaper than 4 new injectors.

Trouble with ones from a scrapper, you just don't know what state they are in.

You can plug and play them, they will still function without the fine tuning from programming.


Faulty injectors will show abnormal reading in the common rail fuel pressure, often leading to non starting due to the reduced pressure in the rail.
My Name: GINGERT

Contributor
Posts: 8
Joined: Thu Jan 02, 2014 5:15 pm
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 150
Trim Level: Desire
Gearbox: Manual 5 speed
DPF: No

Post

Thanks C3 Guru

Im very hesitant at doing this as I have very limited tools and not the CROWS FOOT spanner you need, but I guess i have nothing to loose and everything to gain.

Thanks


GingerT
User avatar
My Name: C3CAR

Guru
Posts: 2658
Joined: Wed May 04, 2011 10:01 am
Model: C3 2002-2005, Original shape model
Year: 2002 (02)
Engine Size: 1.4 (16v)
Fuel Type: Diesel
Mileage: 140000
Trim Level: Exclusive
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: DV4 16-valve diesel (90 PS)
Has thanked: 175 times
Been thanked: 93 times

Post

GINGERT wrote:Thanks C3 Guru

Im very hesitant at doing this as I have very limited tools and not the CROWS FOOT spanner you need, but I guess i have nothing to loose and everything to gain.
The crows foot is one of those tools you will never use again. Have a look on ebay on ebay (here), you may be able to pick one up a bit cheaper. It doesn't need to last a lifetime. If you managed the fuel rail, the injectors will be a walk in the park.
My Name: vidarm

Contributor
Posts: 19
Joined: Mon Oct 01, 2018 6:39 am
Model: C3 Picasso
Year: 2013 (13)
Engine Size: 1.6
Fuel Type: Diesel
Mileage: 40000
Trim Level: NA
Gearbox: EGS - electronic 6 speed
DPF: Yes
LHD or RHD: LHD (Europe)
Engine name: DV6 16-valve diesel (92 PS)
Has thanked: 5 times

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Hi!

Great advice - do you know if it is in the same place on a 2010 1.6 diesel common rail?

Thanks!

br,
Vidar

C3CAR wrote: Fri Jan 24, 2014 2:12 pm Hi GINGERT
Firstly can anyone please tell me where the fuel pressure valve is.
Its on the end of the common rail.

fuel-pressure-sensor-on-common-rail-citroen-C3-16v_HDi.jpg

Common rail fuel pressure sensor is arrowed.

Secondly can anyone tell me how i can best remove the fuel rail when I cant even see it.
Haynes has a nice section on how to do this for both the 8v and the 16v engines.

I have removed all the ducting from the air intake as well as the air box but I still cant see the fuel rail. I know its under the EGR valve which I can just about see... do I need to remove this as well
Yes, remove the EGR pipe, there are some pictures Here. You may need a new clip if yours is the original factory one. If you have the EGR out, it would be worth cleaning that too.

Remove the injector pipes from the injectors and from the rail to give better access.

This picture should help you to locate the common rail or 'accumulator rail' (arrows)

Citroen_C3_Commin_Rail_removal.JPG


and this one,

CitroenC3-Common_Rail.JPG

where I have arrowed the common rail pressure sensor and marked the location of the common rail which is mostly obscured by the flexible plastic cooling pipe.

These pictures were taken when the engine was removed from the car thanks go to RC3D for taking them.

Apparently you can get the rail off without removing the flexible pipes because they are flexible enough to be pushed out of the way.

Please please can some one offer me some good sound advice on how to get this done.
Hopefully this can give you an idea.
User avatar
My Name: C3driver52

Guru
Posts: 1937
Joined: Sat Apr 30, 2011 7:40 pm
Model: C3 2002-2005, Original shape model
Year: 2003 (03)
Engine Size: 1.4 i
Fuel Type: Petrol
Mileage: 79984
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: TU3 (75 PS)
Has thanked: 110 times
Been thanked: 67 times

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vidarm wrote: Tue Oct 09, 2018 6:42 am Hi!

Great advice - do you know if it is in the same place on a 2010 1.6 diesel common rail?

Thanks!
Yes. the 2010 1.6 is very similar to the 1.4.
My Name: vidarm

Contributor
Posts: 19
Joined: Mon Oct 01, 2018 6:39 am
Model: C3 Picasso
Year: 2013 (13)
Engine Size: 1.6
Fuel Type: Diesel
Mileage: 40000
Trim Level: NA
Gearbox: EGS - electronic 6 speed
DPF: Yes
LHD or RHD: LHD (Europe)
Engine name: DV6 16-valve diesel (92 PS)
Has thanked: 5 times

Post

Thanks!
I see some sources, including the official Citroen repair manual, state that it is actually at the back of the engine, facing the torpedo wall and quite difficult to get to. But this is not the case in your experience?

br,
Vidar
My Name: vidarm

Contributor
Posts: 19
Joined: Mon Oct 01, 2018 6:39 am
Model: C3 Picasso
Year: 2013 (13)
Engine Size: 1.6
Fuel Type: Diesel
Mileage: 40000
Trim Level: NA
Gearbox: EGS - electronic 6 speed
DPF: Yes
LHD or RHD: LHD (Europe)
Engine name: DV6 16-valve diesel (92 PS)
Has thanked: 5 times

Post

Thanks!
I see some sources, including the official Citroen repair manual, state that it is actually at the back of the engine, facing the torpedo wall and quite difficult to get to. But this is not the case in your experience?

br,
Vidar
C3driver52 wrote: Tue Oct 09, 2018 9:06 am
vidarm wrote: Tue Oct 09, 2018 6:42 am Hi!

Great advice - do you know if it is in the same place on a 2010 1.6 diesel common rail?

Thanks!
Yes. the 2010 1.6 is very similar to the 1.4.
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