A Quick step by step guide to replacing the Injector fire seal (special copper washer available on eBay
) on a Citroen C3 1.4HDi 16v (2002).
Disconnect the Battery and remove the sound shield to reveal the injectors.
Remove all the injector connector and leak-off pipes
(The injector connectors need a squeeze and pull, the leak-offs are clipped on and need a pull to remove)
Use a 17mm Crows foot spanner (click here to get one)
to slacken the injector pipe nut (use it again later to tighten the nut to the correct torque).
Use a 7mm Ball End Socket
to slacken the injector clamp mounting nuts.
Remove the injector pipe clamp that clamps the injectors pipes in pairs.
A problem you may encounter is that the injector clamp nut cannot be removed because it is restricted by the plastic inlet manifold. To avoid having to remove the inlet manifold it is possible to grind away a small amount of excess plastic that makes up the inlet manifold. Take off enough plastic that is required to remove the clamp nut and clamp, but no more.
bakersvill has some extra information which can be used in place of grinding any plastic away. The post can be seen in full in his reply to this post and in part in this quote below.
bakersvill wrote:A few notes that might help, you can undo the nuts holding the air intake down and lift it back just enough
to get full access to the hidden nuts.
Try to remove the 'hidden' injector clamp nut, this will reveal how much material needs to be removed from the inlet manifold to remove the nut. (More will be required to be removed to free the clamp
.) If you are happy with the quantity to be removed, start up the Dremel tool (from Amazon - click here)
Both clamp nuts can now be removed, the injector nut freed, the injector connection capped off and the injector pipe sealed from dirt ingress with the fingers of rubber gloves
Try to remove the injector clamp, if it won't come off, Dremel a little more away - be sensible and take ONLY what you need. The clamp can be angled to allow removal with less plastic (inlet manifold) material removal.
Remove the injector clamp nut and withdraw the injector! (unless its stuck, then use penetrating fluid and wiggle the injector using a spanner and the flats on the side of the injector).
With the injector removed, now is the best time to have your injector tested - send away service (here)
. The service includes an ultrasonic clean, fuel delivery measurement, coil resistance measurement, injector response time measurement, back-leak flow (leakoff) and temperature measurement, backed up with a printout of the results. If you are removing more than one injector, carefully mark each injector so they go back in the correct cylinders when refitting them because each injector is coded by the number on the injector to injection ECU to obtain the best performance from each injector.
The picture above shows a diagnostic screen with the 4 injectors performance attribute coding matched to the ECU positions 1 to 4, get each injector back into the cylinder it came from and you won't need to even think about this.
Very delicate and very expensive - be very careful!
Look here for a Replacement C3 HDi 16v Injector (rare, click here)
and here for a for a possible C3 HDi 16v Injector (1.4 Diesel)
Pull out the injector and check for the copper - fire seal- washer. If its not there, its down the hole. Hook it out, you will need a new one, available cheaply from here (click)
The tool is a length of scrap acrylic, with a taper filed on the end. The picture shows the tool with the copper fire seal washer attached (covered with black gunk) after removal.
There is a proper tool designed for removing and installing the copper seals (click here).
to find out more.
Clean everything that is covered with the black substance.
A Socket Set extension bar is used to stop the gunk getting into the cylinder.
Refit is reverse of removal, with a new copper washer, injector clamp ring and injector clamp nuts. Check for leaks, road test, smile.
Parts cost less than £20, took me half a day. Cleaning the gunk took ages. The engine now sounds like it used to and has more power. (back to normal).
I added 1 measure of redex diesel treatment (amazon)
to a half tank of fuel considering how dirty the injector looked.
If you don't have some of the less common tools, you can get a 17mm Crows Foot 3/8" Adaptor from here (Amazon.com)
and a long 7mm Ball End Hex 3/8" Socket Adaptor from here (Amazon)
If you need a Torque Wrench (Used to tighten the Injector Clamp Nuts and Injector Pipe Nuts correctly), have a look here - on Amazon