HDI INJECTOR REMOVAL

acrowot · Post by **acrowot** » 03 Jan 2010, 19:58

Decided to have another go with a Xantia, the HDI 2.0 90BHP, it was quite cheap but does have a problem or two, spheres need replacing but that is quite easy and cheap, but it has a slight diesel leak that appears to be coming from the base of the injector second in from the flywheel, I have not worked with this type of injector before, how difficult are they to remove, in fact how is it done, it appears to be held in by a clamp secured by a 13mm nut, not screwed in as on the the previous engines. Are there any pitfalls I should be aware of on removing it, is it likely to be stuck in the engine, has 128000 miles on it, what is likely to need replacing to cure the leak and are they Main Agent parts only, will be going to GSF tomorrow for the spheres, it would be nice if I could get the injector bits from there as well. Thanks in advance for any help with this.

Post by **Peter.N.** » 03 Jan 2010, 20:37

I have had no experience of HDi's but I do know that the injection pressure they use can be lethal. Keep you hands and face well way when testing. Don't even think about slackening a pipe off to see which is the faulty injector!

Peter

acrowot · Post by **acrowot** » 03 Jan 2010, 20:56

Hi Peter, Thanks for your reply, I know which injector is weeping, I would just like some info on how to remove it, I am aware of the pressures involved, I am led to believe that after switch off if you listen carefully after 30 secs you hear a relay release which alledgedly removes the pressure from the common line but I have no confirmation of this.
John

I don't think the injector is faulty just not seating correctly.

Post by **myglaren** » 03 Jan 2010, 21:11

If it is the same as my 2.0HDi, and presumably it will be, they have a propensity to burn away the copper washer at the seat. I have had mine replaced twice.

The 2.2s seem to weld the injectors fast but the 2.0 doesn´t seem to suffer from that problem.

lexi · Post by **lexi** » 03 Jan 2010, 21:17

There is a black seal and a copper washer that will need renewed. You will see them when the assembly comes off. The injector is held by the offset clamp with the stud and nut and not screwed in like a conventional injector.

As long as everyhing has been allowed to settle the pressure SHOULD be off.

You could disconnect battery. Clean off everything around the area with brake cleaner. As it`s a Bosch part GSF may have it or certainly a diesel injection specialists will stock it. Price it at Stealers too as sometimes it`s easier to get for not much more money.

citroenxm · Post by **citroenxm** » 03 Jan 2010, 21:28

Release the Fuel Seel pipe from the injector and rail..

(OH, Warm the engine up first, it will soften the unburnt diesel up the side the the injector and help removal..)

Unscrew the injectors electrtical plugs - all 4, and undo the 2 ten mm nuts holding it in place and move it to one side.

Pull off the leak off return pipes, then undo the ONE 13mm nut holding the clamp onto the base of the injector..

Now therotically, the injector is suppose to SIMPLY PULL out.. however, if its leaking badly Diesel soot may well be holding it in place, engineer a way of levering the injector upwards, as said it is NOT screwed in.

You will need a set of copper fire proof seals and PLASTIC sleeves.. ALL cheap enough from the dealer.. DONT do just one, if one is away the others wont be far behind and its worth dooing all 4..

Do get the engine warm, it will help you a lot.. Keep injectors in their own places.

Regards
Paul

lexi · Post by **lexi** » 03 Jan 2010, 21:30

eem to weld the injectors fast but the 2.0 doesn´t seem to suffer from Th2.2s sthat problem.

e
Wonder how some of them chipped engines get on then?

I like your new Avatar.....she is a Darling

I first saw all those fab videos of hers when I was on a 6 week stay in France.

acrowot · Post by **acrowot** » 03 Jan 2010, 21:36

Thanks to you all for your excellent advise.

Post by **myglaren** » 03 Jan 2010, 22:00

lexi wrote:
¨myglaren¨ wrote:seem to weld the injectors fast but the 2.0 doesn´t seem to suffer from that problem.
Wonder how some of them chipped engines get on then?

I imagine they could cause a few headaches. There are quite a few stories of 2.2HDiś scrapped due to welded in injectors, Hotter running wouldn´t help much. I hadn´t realised that the injectors were not screwed in though.

I like your new Avatar.....she is a Darling

I first saw all those fab videos of hers when I was on a 6 week stay in France.

She is a bit special. That is a still from California.
The quoting thing appears to have gone to hell in a handbasket all of a sudden

acrowot · Post by **acrowot** » 03 Jan 2010, 22:34

Just a thought but it seems that a spanner would fit on the injector where the clamp was, would it be ok to try and turn the injector with a view to looseing it should it be stuck.

citroenxm · Post by **citroenxm** » 04 Jan 2010, 10:10

Yes you can.. as the injector is only a push in fit there should be no harm but make sure it doesn't actually UNDO the injector halfs..

Paul

HDI · Post by **HDI** » 04 Jan 2010, 11:00

Sounds like a job for a slide hammer then !

citroenxm · Post by **citroenxm** » 04 Jan 2010, 12:48

HDI wrote:Sounds like a job for a slide hammer then !

Not sure you'd get one in the area really,

Paul

acrowot · Post by **acrowot** » 04 Jan 2010, 14:41

Ordered these today, the copper washer comes in two sizes 1.5mm normal and 1.9mm for difficult to seal injectors.