Introduction
Vehicle engine 1.6 HDi FAP 16V 110 hp
Leaking injector seals are a common problem on PSA's 1.6 HDI engine.
The symptoms are:
- a smell of exhaust gas in the passenger compartment.
- a characteristic sound of compressed air escaping from the combustion chamber.
- exhaust fumes in the engine compartment.
Parts
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Open the hood and remove the engine cover
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The 4 injectors are located in the center
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Inspect the injectors with a lamp to find the leak at the engine block. Even if the leak is on only one injector, it is necessary to replace the 4 seals.
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The leak is coming from the seal of this injector. There are traces of oil and carbon.
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Disconnect the vehicle battery
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Disconnect the electrical harness from the 4 injectors
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Disconnect the air mass meter connector
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Disconnect the last connector from the harness
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Use an 8mm hex key to remove the 3 fixing points of the electrical harness support
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Remove the electrical harness
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Using needle-nose pliers, carefully remove the 4 injector clips without deforming them
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Move the diesel hose harness aside without disconnecting it from the rest of the fuel supply circuit.
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Start by removing the nuts from the high pressure lines, injector side
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Use a 14 key
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Push the nuts back up along the pipe. Do not twist the pipe which is still attached on the other side to the common injection rail.
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The injector is held by a flange fixed at 2 points on the cylinder head
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Use a size 8 hex key on the nuts of the column screws
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The injector can now freely exit its injection well
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But the seal leak can create a residue of burnt gas. Using a pair of pliers, carefully remove the injector by making small rotating movements.
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The faulty copper seal is located at the bottom of the injector well
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Use a swab to remove the seal
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Compare copper gaskets. The dimensions of the new gasket have been modified by Peugeot to ensure better sealing.
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Remove the gasket placed on the engine block at the inlet of the injector well
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Clean the seal area and surroundings
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Vacuum and clean the inside of the well
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Place the injector on a clean work surface. Do not touch the tip when cleaning. Identify the injector according to its cylinder so as not to mix them up when reassembling.
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Remove the engine injector protector
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Clean the injector body with a degreaser and a clean cloth
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Compare injector seals and protector
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Position the new elements on the cleaned injector
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Place the engine block gasket in the groove
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Check that the lip of the seal is correctly inserted into the groove and push lightly with a flat screwdriver
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Replace the injector
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Tighten the clamp
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Tighten the high pressure line nut
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Reassemble the injectors
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Reassemble the diesel harness and the injector wiring harness
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Reconnect the battery
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Start the engine and check the injectors for leaks.
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