Changing injector seals - Citroen C2

Open the hood and remove the engine cover

The injectors are located under the air filter housing

Start by removing the air filter housing cover.

Unscrew the 3 screws on the cover with a T20 torx key

Remove the cover

Unscrew the 2 T20 screws from the air box

On the box is the air mass flow meter

Use a T20 torx key to remove the 2 retaining screws

Disconnect the electrical connector from the air mass meter

Unscrew the air line fastener

Remove the air line

Disconnect the battery before working on the electrical system, for safety and to avoid an error message when restarting the vehicle.

Disconnect the intake air pressure sensor located under the windshield bay

Use a 10 key

Temporarily remove the oil filler cap to facilitate removal of the air box.

The second half of the air line is connected to the back of the air box. Reach behind it to unplug it

Carefully remove the air box from its location.

Then you have to remove the various air intake elements

Remove the clamp holding the pipe to the turbocharger using a flat screwdriver.

Unhook the line and pull slightly to remove the second small air line

Remove the 8mm screw between the turbocharger and the air resonator

Unscrew the resonator attachment on the rocker cover using a T30 torx key.

Remove the collar between the resonator and the rocker cover.

Disconnect the intake air temperature sensor

Remove the pipe first

Then rotate the assembly to place it

Continue by removing the fuel system

Start with the fuel filter

Unscrew the vacuum air line clamp attached to the top of the filter

Disconnect the first hose from the filter

Then disconnect the second hose from the diesel filter

Unscrew the screw holding the filter on its support with a T20 torx key

Gently remove the filter from its support and disconnect the electrical connector located underneath

The fuel filter bracket is fixed at 3 points. Use an 8 mm socket with an extension and a T30 torx key

Disconnect the 4 electrical plugs from the injectors

The injector wiring harness passes through the bracket

Lift the gray ring to disconnect the harness

Separate the bracket and electrical wiring from the injectors

Remove the diesel filter support

To the left of the engine is the upper timing belt cover attached to the rocker cover.

Remove the 5 fixing screws with a 7 mm socket

Several elements are positioned on the casing. An electrical cable sheath is held in place by a plastic clip

The diesel feed pipes are also fixed to the crankcase

Disconnect the diesel hoses

Remove the upper timing belt cover

Unscrew the hose clamp on the rocker cover with a T30 torx key

The hose bundle is attached to the air manifold. Use a flat screwdriver to unclip it

Disconnect the electrical plug

Disconnect the diesel supply pipes

Check that nothing is connected and remove the complete harness.

The exhaust gas recirculation system is attached to the intake air manifold

Use a T30 torx key on the two fixing screws

Separate the EGR valve line

Disconnect the last two sensors

Remove the 8 screws on the top of the rocker cover with an 8mm socket

And the 2 10 mm screws below the air manifold. Directly above the air box supports

Check that nothing is still attached to the rocker cover.

Pull up to drop it

Remove the 4 O-rings from the intake air manifold

The leak is coming from the seal of this injector

Carefully protect the cylinder head cover and plug the air intake manifold holes.

Clean as much as possible with a degreaser before removing the injectors

Even if the leak comes from only one injector, it is essential to remove all 4 injectors in order to replace the 4 seals

Use a 14 injector wrench to loosen the high pressure line nut.

Remove the flange screw holding the injector with a 13mm socket.

Remove the screw and the flange

Disconnect the diesel line harness from the 4 injectors

Carefully remove the injector from its well

Plug the injector wells and continue cleaning the top of the engine cylinder head

Arrange the injectors in the exact order of removal. It is essential not to mix up the injector/cylinder combination.

The defective seal

Clean the injectors without touching the tip at the risk of blocking it

Install the CITROEN PEUGEOT 1.4 HDI INJECTOR SEAL ASSEMBLY KIT

The kit includes the centering ring + copper gasket. The plastic centering ring is usually destroyed due to the leak that goes up the length of the injector.

Carefully clean the injector wells

Place the injector in its initial position

Place the flange and screw ensuring that the alignment with the high pressure line is correct

Tighten the screw with a torque wrench The tightening torque of the injector flange is 2.5 daN.m

Tighten the high pressure line nut with a torque wrench. The tightening torque for the high pressure nuts is 2.5 daN.m

Reconnect the diesel line harness

Remove the old gasket placed in the rocker cover part then clean the groove and place the new gasket

Lightly lubricate the new O-rings and place them on the rocker cover to make reinstallation easier.

Clean the gasket surfaces without contaminating the inside of the cylinder head and air inlets

Reinstall the rocker cover / air manifold. Tighten the 8 + 2 screws

Reinstall the diesel pipes

Replace the upper timing belt cover. Secure the various components to it.

Reinstall the fuel filter support

Then the diesel filter

Re-prime the diesel circuit with the pump

Connect the injectors

Reinstall the intake air resonator

And the air mass flow meter

Reconnect the battery. Wait 5 minutes for the computer to initialize before turning on the ignition.

Check that everything is correctly reassembled, screwed, wired...

Replace the air box

Check for proper operation