16v HDi inlet manifold removal

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My Name: Citroen-Driver

C3 Master
Posts: 253
Joined: Mon Dec 18, 2017 12:10 am
Model: C3 Pluriel - with or without roof
Year: 2003 (53)
Engine Size: 1.6 (16v)
Fuel Type: Petrol
Mileage: 90000
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: ET3 16-valve (90 PS)
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Citroen C3 2002-2009 16v HDi engine has a plastic inlet manifold the links into the EGR system.

The Citroen C3 HDi inlet manifold (here) may require cleaning, or more easily, a replacement if the EGR system has failed, coked-up and restricted the inlet.

You also get access to the inlet valves for inspection and possible cleaning with the inlet manifold removed.

The job also requires removal of the C3 HDi Crankcase Ventilation system (PCV) which is included here[/urll]


Disconnect MAF electrical connection and remove the air-filter box and MAF


Disconnect the MAF on a Citroen C3
Disconnect the MAF on a Citroen C3
Citroen C3 1.4 16v HDi Air filter box removed
Citroen C3 1.4 16v HDi Air filter box removed


Remove the EGR pipe from each end and the middle fixing, you may already have this removed and noticed it is restricted that lead you to removing the inlet manifold.

Citroen C3 EGR pipe disconnected from inlet manifold for inspection
Citroen C3 EGR pipe disconnected from inlet manifold for inspection
EGR pipe disconnected from inlet manifold after disconnecting from EGR valve and centre fixing point.


Citroen C3 EGR pipe restricted with gunk
Citroen C3 EGR pipe restricted with gunk
EGR pipe removed and shows a contamination build-up of oily carbon deposits restricting EGR flow.



Remove the large electrical connector mounting on the left of the engine and the MAP sensor connector.

Remove the PCV in this topic



Remove the intercooler pipe, it may be stuck and some penetrating fluid works well for this.

Disconnect the injector leak-offs and injector electrical connectors.

Disconnect the injector pipes from the top clamps, the rear common rail (just the injector pipes) and with the PCV removed, disconnect the injectors from their pipes.

Disconnect Citroen C3 HDi 16v injector pipe
Disconnect Citroen C3 HDi 16v injector pipe

Cap off all 8 connections and keep the pipe ends clean if they are to be re-used. You don't want any dirt entering the injection system at this point after the filter.

Cap off injectors and common rail when pipes are removed to prevent dirt ingress
Cap off injectors and common rail when pipes are removed to prevent dirt ingress

With the injection pipes removed there are some bolts to remove all except one is accessed from above, one is on the timing belt side and some are already removed because they also fix the PCV system that as already been removed from the engine. The hidden bolt is under the electrical connection mounting.

Remove inlet manifold bolts on a Citroen C3 HDi 16v
Remove inlet manifold bolts on a Citroen C3 HDi 16v

The manifold is sealed with o-rings so with all the mounting bolts removed the inlet manifold will lift up with a slight lever to break the o-ring seal. Lift the inlet manifold away to reveal the inlet ports.

Citroen C3 Diesel inlet manifold removed
Citroen C3 Diesel inlet manifold removed
Replace the o-rings (here) before refitting the inlet manifold and PCV. The 8 (4 large and 4 smaller) or-rings will fit many of the HDi engines, the square o-ring is used on the 1.6 16v HDi but is not needed on the 1.4 16v HDi.

Part numbers for the inlet manifold o-rings are 0263.7H 0348.R5 and 0348.R4


Citroen C3 o-rings and inlet manifold 1.4 16v and 1.6 16v Diesel HDi engines
Citroen C3 o-rings and inlet manifold 1.4 16v and 1.6 16v Diesel HDi engines
User avatar
My Name: Citroen-Driver

C3 Master
Posts: 253
Joined: Mon Dec 18, 2017 12:10 am
Model: C3 Pluriel - with or without roof
Year: 2003 (53)
Engine Size: 1.6 (16v)
Fuel Type: Petrol
Mileage: 90000
Trim Level: VTR+
Gearbox: Manual 5 speed
DPF: No
LHD or RHD: RHD (UK)
Engine name: ET3 16-valve (90 PS)
Has thanked: 48 times
Been thanked: 38 times

Post

Refitting the inlet manifold.

Obviously now is the time to clean the cam over o-ring seating points to ensure a good seal if you haven't been cleaning the inlet valves 8-)

The inlet manifold refitting is aided by lightly greasing the orings with some silicone grease (eBay - here) this ensures the parts slide together and don't get snagged or twisted to make sore the orings can proved a long-lasting seal.

There are two bolts that are slightly shorter than the others, use these in conjunction of the longer ones to tighten down, gradually the inlet manifold. The shorter bolts are ideal for the front fixings that usually have the PCV on. The short bolt will allow full tightening of the front as you evenly tighten the manifold down. Reuse the short bolt in each of the front positions than need it, leave the long bolts in place.

Fit the short bolt on the timing belt side.

Refit the injection pipes and pipe clamps

Then refit the leakoff pipes and injector electrical connectors

Next refit the PCV crankcase ventilation and oil filler cap unit with the other longer bolts,

Then attach the electrical connection mount, EGR pipe, MAF, air-filter box and its associated pipes

The diesel system will need priming using the hand priming pump, but even after that, the engine may take a lot of turning over to start.
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