hdi 8 valve injector seal replacement help

I have an 04 plate C3 HDI 8 Valve I need to replace one injector seal,it seems different to the 16 valve engine I am trying to remove the inlet manifold and engine cover but so far no luck,all the questions on the forum are about the 16 valve saying you can grind a bit off the engine cover and manifold but I don't know if it's the same on mine can someone tell me how to get them off I think I have all the bolts out,need help please
allan

allanmc wrote:I have an 04 plate C3 HDI 8 Valve I need to replace one injector seal,it seems different to the 16 valve engine I am trying to remove the inlet manifold and engine cover but so far no luck,all the questions on the forum are about the 16 valve saying you can grind a bit off the engine cover and manifold but I don't know if it's the same on mine can someone tell me how to get them off I think I have all the bolts out,need help please
allan

Hi allan,

The 16v bit about grinding a bit of plastic off saves having to remove the whole inlet manifold. As you have found the 8v diesel engine is different. You need to remove the cylinder head cover and oil separator to get the injectors out (unless someone finds a short cut?).

To remove the cylinder head cover on the 8v, you need to:
Remove the air filter box, fuel filter and the bracket for it, turbo charger outlet pipe, air resonator unit, and then the inlet manifold/cylinder head cover unit.

Hi,Thanks for your reply if I can just explain where I am with getting the inlet manifold/cylinder head cover unit off,can you tell me how to get the metal pipe which goes into the EGR valve? out I have the 2 bolts and the one behind the engine out but I cant get the pipe out the cover seems to be held at the timing belt end could you perhaps explain exactly which bolts to remove,I hope you don't mind all the questions
allan

The EGR pipe is held at the cam belt end by a torx head type bolt
No 73 in the picture above.

The EGR pipe is push fitted and sealed by an o ring.

Thanks once again for your help my son and I managed to get the inlet manifold/cylinder head cover unit off there was a wee bit more to take off before we got them off the EGR pipe on my car was a solid steel pipe so had to take it off from both ends anyway got to the injectors and it must have been leaking for months there was a lot of carbon around the 2 injectors at the timing belt end so removed both to be sure turned out it was the 2nd one the plastic seal was broken so we replaced both copper washers and anti vibration seals we will get it back together tomorrow.I now understand why a garage wanted £500 to do what we have just done
cheers
allan

allanmc wrote:Thanks once again for your help my son and I managed to get the inlet manifold/cylinder head cover unit off there was a wee bit more to take off before we got them off the EGR pipe on my car was a solid steel pipe so had to take it off from both ends anyway got to the injectors and it must have been leaking for months there was a lot of carbon around the 2 injectors at the timing belt end so removed both to be sure turned out it was the 2nd one the plastic seal was broken so we replaced both copper washers and anti vibration seals we will get it back together tomorrow.I now understand why a garage wanted £500 to do what we have just done
cheers
allan

Thanks for letting us know how you got on.

The EGR pipe is a fill metal pipe on the diesels, there are some pictures in the removing the EGR valve topic. If you have the factory clip in the EGR, you will need a new clip. The diesel system may need a bit of a prime using the hand primer to get it started.

That's the job done car running again as I said it was a bigger job than we thought,we learned a lot so if anyone want's any information about it let me know
allan

allanmc wrote:That's the job done car running again as I said it was a bigger job than we thought,we learned a lot so if anyone want's any information about it let me know
allan

That is great news! Thanks for the offer!

Sorry to say I am back with a chuffing noise from the engine,so I will have to get back into the garage tomorrow and get it stripped down it should be a bit quicker this time having done it in July,I bought 4 Injector seals from Citroen £13.97 what a rip off for 4 copper washers,do you have any idea why this would have happened.
I will let you know how I get on.
Allan

allanmc wrote:Sorry to say I am back with a chuffing noise from the engine,so I will have to get back into the garage tomorrow and get it stripped down it should be a bit quicker this time having done it in July,I bought 4 Injector seals from Citroen £13.97 what a rip off for 4 copper washers,do you have any idea why this would have happened.
I will let you know how I get on.
Allan

Hi Allan, if you only did two of the copper washers, maybe the other 2 need doing too?

If the same fault has appeared with the ones you have already changed, it could be due to a lack of cleaning of the injector seat and the cylinder head seat that the copper washer helps to seal, or incorrectly torqued down injector clamps. If the nuts are of the 'stiff' variety, they should be renewed each time they are removed. I don't recall if the 8v has bolts or nuts and a stud?