Injector seal leaking ... again

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My Name: Ploddit

Contributor
Posts: 10
Joined: Fri Aug 15, 2014 10:42 pm
Model: C3 2002-2005, Original shape model
Year: 2004 (54)
Engine Size: 1.4 (8v)
Fuel Type: Diesel
Mileage: 80000
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No

Post

2004 1.4Hdi 8v 8HX

I replaced the four injector copper washers a while ago, maybe a year/10,000kms with OE Citroen part

Now number 2 from the flywheel is leaking quite badly when cold, the chuff chuff noise at cold, I checked by soapy water over each injector to see the bubbles with the airbox/filter at 90 degrees to its normal position. The 13mm bolt holding down the injector fork is tight.

I have a Citroen guide which only has torque for the 16v of .4 m.daN which equals 4Nm or 2.95ft/lbs followed by 65 degrees turn.

https://service.citroen.com/dtt/CDP/donn ... 1_2005.pdf

I did my best to clean out the well, particularly the area where the washer sits, I suspect I have over tightened the fixing bolts well above 4Nm +65, this torque represents a strong hand tighten or 400grams weight on a one meter bar, therefor 800g on a 50cm and most usefully for us 1.6kg on a 25cm lever.


I have read about the fact that these bolts need angular torqueing means they are stretch bolts which should be replaced each time. I have even read somewhere the forks should be renewed? Of course we all know that the hard fuel pipes should also be replaced.

Any thoughts before I have a clean and try a new washer, and I'll see if I can get a bolt.

Whilst surfing I came across the Mercedes spec, it is well known issue known as the black death, 7nM plus 90 plus 90.
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My Name: C3CAR

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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)
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Post

Hello Ploddit
Ploddit wrote:Now number 2 from the flywheel is leaking quite badly when cold, the chuff chuff noise at cold,
the chuffing of an injector in a video (here) and some instructions for the 16v may be useful for others with a similar noise.
Ploddit wrote:I have a Citroen guide which only has torque for the 16v of .4 m.daN which equals 4Nm or 2.95ft/lbs followed by 65 degrees turn.
The 8v is 15Nm then angle tighten a further 70° for the fuel injector clamp bolt.
Ploddit wrote:I did my best to clean out the well, particularly the area where the washer sits,
Obviously this needs to be perfectly clean to get the same quality of seal they achieved at the factory.

[img]
https://ws-eu.amazon-adsystem.com/widge ... troenc3-21[/img]

there are even kits of Diesel Injector Seat Cutters (on Amazon) that have been produced to help achieve this.
Ploddit wrote:I have read about the fact that these bolts need angular torqueing means they are stretch bolts which should be replaced each time. I have even read somewhere the forks should be renewed? Of course we all know that the hard fuel pipes should also be replaced.
Its worth changing all the suggested parts to save having to do the job twice. This is good practice for a garage to follow because they don't want the customer coming back. But if its a home DIY mechanic, maybe they want to save some money and only replace the bolts and parts that really did need replacing and don't mind doing the job twice?. Maybe its time for a new bolt for number 2.
Ploddit wrote:and I'll see if I can get a bolt.
Citroen are very good for parts like these obscure ones.
My Name: Ploddit

Contributor
Posts: 10
Joined: Fri Aug 15, 2014 10:42 pm
Model: C3 2002-2005, Original shape model
Year: 2004 (54)
Engine Size: 1.4 (8v)
Fuel Type: Diesel
Mileage: 80000
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No

Post

Thank you for the torque figure I couldn't find it.

I looked at a seat cutting tool or even the special brushes but there are none where I live (new Caledonia). I will try with a new washer then when I go to the capital (300km) I will see if they have a few bolts.
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