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#1 2020-07-15 10:57:49

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

replacing injectors on a citroen dispatch 1.6hdi

Hi everyone i thought i’d make a thread to help anyone who wishes to replace there injectors and seals for a 1.6hdi
I have recently replaced mine and thought i’d try to help others by taking pictures along the way
my vehicle is a 2008 9hu 1.6hdi

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#2 2020-07-15 11:09:00

Dispatcher
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Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

start by removing turbo/air/pcv valve pipe


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Last edited by Dispatcher (2020-07-15 13:11:12)

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#3 2020-07-15 11:16:59

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

Then remove turbo to intercooler pipe and covering the turbo

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Last edited by Dispatcher (2020-07-15 13:13:09)

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#4 2020-07-15 12:22:42

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

Remove the rocker cover by undoing the bolts 

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Last edited by Dispatcher (2020-07-15 13:14:24)

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#5 2020-07-15 12:31:48

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

disconnect wiring plugs from injectors,unbolt wiring harness and disconnect maf sensor, remove airbox

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Last edited by Dispatcher (2020-07-15 13:16:55)

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#6 2020-07-15 12:35:42

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

undo fuel line nuts (14mm spanner) and remove fuel injector lines (removing clips and pulling upwards to release


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Last edited by Dispatcher (2020-07-15 13:18:12)

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#7 2020-07-15 12:45:08

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

Modify a hoover (trusty henry for me) and use a screwdriver or similar and clean the area as well as possible to avoid debris later falling down the hole too smile remove the nuts from injectors, there are 2 ( 1 at front 1 at back of injector) i used a socket piece and bar to rock the injector left and right (some people may choose to do this another way but worked for me)using left and right motion and a upwards pull the injector should come out (sometimes a bit more leverage may be needed but only for stubborn ones.  Then using a screwdriver remove the old seal


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Last edited by Dispatcher (2020-07-15 13:26:09)

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#8 2020-07-15 12:54:00

Dispatcher
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Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

i ordered new seals £10 and a injector washer puller (good buy at less than £20)
I removed any copper washers that did not come out with the injector with the tool which can be inserted down the hole and through the washer and once twisted on top it expands and allows you to extract it. i used a peice of rubber fuel line hose and a sock with carb cleaner sprayed onto it and pushed it down the injector hole and twisted clockwise and repeated this motion to clean the injector meeting face and sleeve as much as possible alternating with my hoover attachement for max results


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Last edited by Dispatcher (2020-07-15 13:32:27)

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#9 2020-07-15 12:57:08

Dispatcher
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Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

To replace the rubber seals i used a 16mm socket piece, sliding the seal onto it, lowering it over the sleeve and pushing downwards with a blunt screwdriver to fit the seal between the case and sleeve (makes this very easy!)


Once you have done this you can either drop your copper washer into the hole and check it’s flat on the inner face or some washer will just slide onto the bottom of injector and you can place it in with it held on (depends on washers)

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Last edited by Dispatcher (2020-07-15 13:36:45)

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#10 2020-07-15 13:04:47

Dispatcher
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Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

Remove the small green fuel line seal and replace

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Last edited by Dispatcher (2020-07-15 13:35:01)

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#11 2020-07-15 13:09:26

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

Once injectors are replaced in location check that the fuel lines are located where the injector will be tightened up as once you tighten injector you would not want to find that you can’t get the fuel line to attach because the injector isn’t twisted to the right location
i do this by hand tightening the fuel line and then tightening up a tad so can’t go wrong then remove again before torque



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Last edited by Dispatcher (2020-07-15 13:39:47)

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#12 2020-07-15 13:45:25

Dispatcher
Member
Registered: 2019-08-20
Posts: 45

Re: replacing injectors on a citroen dispatch 1.6hdi

My haynes manual gave me the following details and this information can be specific to a vary of engines so best to check as torque settings can vary on vehicles but i’ve attached there information


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I then done everything in reverse

I personally torqued my injector nuts to 9nm
I also did the same on my rocker cover doing 9nm too and everything is working as it should with no leeks

I hope this may help someone else in the future wishing to do the same or similar smile

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