Skip to main content

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.

  1. 
Open the hood and remove the engine cover

The 4 injectors are located in the center

The 4 injectors are located in the center
    • Open the hood and remove the engine cover

    • The 4 injectors are located in the center

  2. 
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.

The leak is coming from the seal of this injector. There are traces of oil and carbon.
    • 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.

    • The leak is coming from the seal of this injector. There are traces of oil and carbon.

  3. 
Disconnect the vehicle battery

Disconnect the electrical harness from the 4 injectors

Disconnect the air mass meter connector
    • Disconnect the vehicle battery

    • Disconnect the electrical harness from the 4 injectors

    • Disconnect the air mass meter connector

    • Disconnect the last connector from the harness

  4. 
Use an 8mm hex key to remove the 3 fixing points of the electrical harness support

Use an 8mm hex key to remove the 3 fixing points of the electrical harness support

Use an 8mm hex key to remove the 3 fixing points of the electrical harness support
    • Use an 8mm hex key to remove the 3 fixing points of the electrical harness support

  5. 
Remove the electrical harness

Using needle-nose pliers, carefully remove the 4 injector clips without deforming them

Move the diesel hose harness aside without disconnecting it from the rest of the fuel supply circuit.
    • Remove the electrical harness

    • Using needle-nose pliers, carefully remove the 4 injector clips without deforming them

    • Move the diesel hose harness aside without disconnecting it from the rest of the fuel supply circuit.

  6. 
Start by removing the nuts from the high pressure lines, injector side

Use a 14 key

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.
    • Start by removing the nuts from the high pressure lines, injector side

    • Use a 14 key

    • 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.

  7. 
The injector is held by a flange fixed at 2 points on the cylinder head

Use a size 8 hex key on the nuts of the column screws

The injector can now freely exit its injection well
    • The injector is held by a flange fixed at 2 points on the cylinder head

    • Use a size 8 hex key on the nuts of the column screws

    • The injector can now freely exit its injection well

    • 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.

  8. 
The faulty copper seal is located at the bottom of the injector well

Use a swab to remove the seal

Compare copper gaskets. The dimensions of the new gasket have been modified by Peugeot to ensure better sealing.
    • The faulty copper seal is located at the bottom of the injector well

    • Use a swab to remove the seal

    • Compare copper gaskets. The dimensions of the new gasket have been modified by Peugeot to ensure better sealing.

  9. 
Remove the gasket placed on the engine block at the inlet of the injector well

Clean the seal area and surroundings

Vacuum and clean the inside of the well
    • Remove the gasket placed on the engine block at the inlet of the injector well

    • Clean the seal area and surroundings

    • Vacuum and clean the inside of the well

  10. 
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.

Remove the engine injector protector

Clean the injector body with a degreaser and a clean cloth
    • 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.

    • Remove the engine injector protector

    • Clean the injector body with a degreaser and a clean cloth

  11. 
Compare injector seals and protector

Position the new elements on the cleaned injector
    • Compare injector seals and protector

    • Position the new elements on the cleaned injector

  12. 
Place the engine block gasket in the groove

Check that the lip of the seal is correctly inserted into the groove and push lightly with a flat screwdriver
    • Place the engine block gasket in the groove

    • Check that the lip of the seal is correctly inserted into the groove and push lightly with a flat screwdriver

  13. 
Replace the injector

Tighten the clamp
    • Replace the injector

    • Tighten the clamp

    • Tighten the high pressure line nut

  14. 
Reassemble the injectors

Reassemble the diesel harness and the injector wiring harness

Reconnect the battery
    • Reassemble the injectors

    • Reassemble the diesel harness and the injector wiring harness

    • Reconnect the battery

    • Start the engine and check the injectors for leaks.

Finish Line

12 other people completed this guide.

hemissi-nizar

Member since: 01/16/2017

21,057 Reputation

88 Guides authored

13 Comments

For my part I have a 307 1.6 l HDi 16v 90ch restyled from April 2006, great car the only problem is the copper seals on the injectors

chrimisal - Reply

And I forgot thank you to PSA for pulling the cam and making poor quality copper joints that's where the problem comes from

Kisses to all

chrimisal - Reply

And also a little tip for cleaning an oven decape injector and a nickel toothbrush

chrimisal - Reply

So to use a 8mm hex key on the nuts of the column screws it is a 7 and to remove the copper seal impossible with a brush because of the scale I have a tip advice to the good mechanic

chrimisal - Reply

Hello

Thank you for your tutorial which will help me to get started on this adventure....

Kind regards, Nicolas

nico.r91 - Reply

Add Comment

View Statistics:

Past 24 Hours: 15

Past 7 Days: 77

Past 30 Days: 356

All Time: 49,130