Xsara Picasso Injector

[Huskyxantia]

Marc, im going to do a leak off test soon i know the 2 ive got the chuff from may well could be clogged, do you have by any chance an exploded diagram of the injector numbered
0445110076 and if possible the tip end torque me thinks 30nms ? Cheers

[GiveMeABreak]

That's more likely a manufacturer reference or an injector calibration code.

Torque setting for nut (11) is 3 dan.m

ESSENTIAL: Do not touch the nut at "c".

The nuts (11)
The cups (10)
The clamps (9)
The diesel injectors (5)
The sealing rings (7)
The seals (6)
The shims (8)

N.B.: If it is impossible to remove the diesel injectors, remove the fixing stud of the flange (9). Move the diesel injector by lifting it at "d" Using a flat spanner or pliers.

[Huskyxantia]

Many thanks , this will give me good reference. Think i might take some pics when doing the mine and post on the forum a sort of how i did my injector remove clean amd reseal job

[Huskyxantia]

The star of my picassos black death.

So mpg dropping the smell imside the car then the chuff noise ... i will be documenting my task and first ever undertaking of taking out all my injectors reseating and all new seals myself , thanks to marc for his help with all the diagrams . Stay tuned

See the small patch below the injector ? See photo...

[GiveMeABreak]

A work of caution, PSA say it is 'essential' to replace the removed diesel injection high pressure pipe(s)!

I will put an official guide together for you and provide a link here shortly...

[GiveMeABreak]

Ok, so here's the official procedure for you as promised:

Xsara Picasso 2.0 HDi 90 Removing - Refitting Bosch Injectors

[Paul-R]

Marc put 'essential' in quote marks for a reason. Almost no-one except dealers fit new pipes. I changed an injector on our 308 last year and reused the existing pipe and there's been no problem since then that I'm aware of. I'm not the only person that doesn't fit new pipes either.

[mickthemaverick]

Likewise I've changed injectors on 5 different engines and never replaced a pipe and never had a problem.

[GiveMeABreak]

There is a reason why this is the case and I'll put this here for reference. Like anything it is up to the individual what they do or don't chose to do, but I will only provide the official take on this, as basically the guidance is there for a reason - it's not a conspiracy theory.

This is what Delphi have to say on the matter:

Importance of Renewing High Pressure Pipes

It is important to consider renewing the high pressure pipes on Common Rail systems after any intervention on the high pressure system. This is for a number of reasons:

1. To prevent leakage.

When a pipe gland is tightened on first application, the surface of the sealing dome is deformed to provide a tight seal between the pipe and injector / rail / pump components. If the pipe is subsequently re-used the pipe further deforms but is also work hardened so a tight seal is more difficult to achieve.

See the following evidence:

The pipe above shows a cross-section of a pipe after single use and the bore is unrestricted.	However, the above shows a pipe after multiple uses and clearly the pipe diameter is restricted.

2. To prevent dirt or swarf ingress.

When a screw thread is tightened, minute particles of swarf are generated and are encased within the grooves of the screw thread. When the thread is released these particles are free and subsequent re-use may dislodge these particles and contaminate the component being worked on. When you consider how small the injector nozzles are, it is not hard to see how the smallest part of debris can cause a blockage and subsequent injection issues.

3. Hydraulic performance.

When the pipe gland nut is tightened the dome of the pipe deforms. Subsequent re-use will continue to deform the sealing edge as described above. However, the other consideration is that the bore of the pipe deforms and can cause restriction of flow, which in turn affects performance of the fuel system and also the engine.

[mickthemaverick]

It's good to read the evidence for the change of pipe from the manufacturer which basically is theoretical evidence and differs from the empirical evidence gathered by myself, Paul and others. So you pays your money......... !

[GiveMeABreak]

The pictures are pretty conclusive and more than theory as they clearly show the restriction, which is going to affect flow levels - I've lost count of the number of times we've had fuel pressure issues on the Forum and injector issues - many times after injectors have been replaced. But each to make their own decision as you say Mick

[mickthemaverick]

The pictures are pretty conclusive and more than theory as they clearly show the restriction, which is going to affect flow levels -

Yes there's no doubting that, although the second picture's caption does describe it as 'multiple uses'. I might therefore be lead to thinking that you can get away with refitting the original pipe once, as borne out by our experiences, but a second and subsequent refitting is going to lead you down the path described.

[Paul-R]

Yes, I noticed the term "multiple uses" as well. I'm pretty sure that as I had to crack the seals on the leak-off pipes that I was the first one to reuse the injector pipes. I must admit that I was concerned about cleanliness but more from being in a grimy area of the engine rather than off the pipe itself.

[Huskyxantia]

I remewed mine last autumn as they were spilt , ive a spare 2 meteres stored so i should be ok, just waitimg on parts now.

[Huskyxantia]

Leak off test today all measurmemts the same 3 times tested.
Reseated 3 n 4 injector its made a difference but im not doing mega miles , new seal kit should be with me next week i hope.

Some pics below of the task.