1.6 Hdi Intake Manifold Seals

[Rusty Sprocket]

Morning all 

 

I am trying to solve a constant oil leak from the top end of my 2009 C4 Grand Picasso 1.6 HDI.  I am planning on changing the intake manifold oil seals but am concerned about taking the injectors out to remove the manifold as I recently had the injector seals replaced and dont really want to disturb them 

 

How easy is it to remove the manifold.  can it come off without removing the injectors, and are the fuel lines a difficult job.

 

Any pointers would be appreciated 

 

many thanks 

 

[paul.h]

The injectors do not need removing, just the electrical connectors and fuel lines (as well of a lot of other things to gain access to the air intake). You can get the Citroen workshop procedures through ebay on 3 dvds as the Citroen service box but the procedure is copied below, less the pictures which do not copy from the dvds. It says to disconnect the battery but I do not know if this is necessary since many procedures say this when it is not needed.

 

2. Removing

ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel injection (HDi) engines.

CAUTION : After switching off the ignition: wait 15 minutes before disconnecting the battery, to ensure that the initialisations of the various ECUs are memorised.

Disconnect the battery.

Remove the engine style cover .

 

 

Remove and move aside the brake fluid reservoir (1).

Remove :

• The air union (2)
• The air union (3)

CAUTION : Cover the openings of the air inlet circuit .

 

 

Unclip and move aside the manual priming pump ( 4).

Move aside the manual diesel priming pump support .

2.1. Upper integrated air intake system

Disconnect the connector (at "a").

Remove :

• The 3 bolts (5)
• The cover (6) fitted with the air flow sensor

 

 

Remove :

• The air cleaner (7)
• The bracket (9)

Unclip the components (8), (10) (at "b").

Separate and remove the components (8), (10).

2.2. The lower integrated air intake system

Remove :

the windscreen wiper arms and the scuttle grille

 

 

Unclip the 9 soundproofing (12) fixing clips.

Remove :

• The engine fuse box cover (13)
• The 2 bolts (14) ( each side of the vehicle)
• The scuttle support (11)

Unclip :

• The 2 mountings (15) ( each side of the vehicle)
• The 3 mountings (16) (Under the soundproofing )

Remove the sound-deadening ( 12) (Carefully).

 

 

Remove :

• The 2 nuts (18)
• Air inlet (17)

 

 

Unclip the harness and move it aside (at "c").

Disconnect the connector of the diesel injectors (at "d").

Remove and move aside the electrical harness carrier bar (20).

Remove :

• The bolts (19)
• The turbocharger noise attenuator (21)
• The oil trap (22) : Position tool [2] in its place

N.B. : Remove the turbocharger noise attenuator pivoting it in the centreline of the turbocharger manifold.

CAUTION : Cover the openings of the air inlet circuit .

 

 

CAUTION : clean the high pressure unions before slackening.

Uncouple the fuel supply and return pipes (at "e") ; Plug by means of the tool [1].

Remove and move aside :

• the exhaust gas recycling duct (23)
• The diesel injectors fuel return pipe (24) ; Plug by means of the tool [1]

Slacken the unions (25) on the diesel injectors ; Apply a counter-torque to slacken the unions (at "f").

 

 

CAUTION : Use a mirror to carry out the operations mentioned below (if necessary).

Remove and move aside the exhaust gas recycling heat exchanger.

CAUTION : Do not disconnect the exhaust gas recycling heat exchanger coolant circuit.

Remove the support (26).

Slacken the unions (27) on the fuel high pressure common injection rail.

Remove the high pressure fuel pipes .

CAUTION : Plug the unions on the diesel injector and fuel high pressure common injection rail ; Using the tools [1].

 

 

Remove :

• The bolts (28)
• The air intake manifold (29) ; Plug using the tools [3]

3. Refitting

CAUTION : At refitting, all the removed seals must be replaced with new seals.

CAUTION : Replace the removed diesel injection high pressure pipe(s).

Remove tools [ 3], [2]and [1].

 

 

Replace the seals ( 30), lubricating them slightly (with engine oil).

Refit the air inlet manifold ( 29).

 

 

Refit the high pressure fuel pipes (new).

Position the tools [ 8] and [9].

Pre-tighten ; By means of tools [4], [5] and [6] :

• The unions (27) on the fuel high pressure common rail : 2 ± 0,5 daNm
• The unions (25) on the diesel injectors to 2 ± 0,5 m.daN ; Apply a counter-torque to pre-tighten the unions (at "f")

Tighten ; By means of tools [4], [5] and [6] :

• The unions (27) on the fuel high pressure common rail : 2,5 ± 0,3 daNm
• The unions (25) on the diesel injectors to 2,5 ± 0,3 m.daN ; Apply a counter-torque to tighten the unions (at "f")

Remove tools [ 8] and [9].

 

 

CAUTION : Follow the tightening sequence (order from 1 to 9).

Refit the oil trap (22).

Tighten the bolts to 1,3 ± 0,2 daN.m (in the order indicated).

Refit the 3 bolts (19) ; Tighten to 0,8 ± 0,1 daN.m.

Proceed in the reverse order to removal.

Reconnect the battery.

CAUTION : Perform the operations to be carried out following reconnection of the battery.

Operate the manual priming pump several times to prime the fuel circuit.

Action the starter and the manual priming pump until the engine starts.

Allow the engine to idle for 2 minutes.

4. Checking for leaks

CAUTION : Spray the product [7] onto the diesel injector unions and onto the fuel high pressure common injection rail .

Put the vehicle on a hoist.

Remove the under engine protection .

Spray the product [7].

Allow the product to dry.

Start the engine.

Check the absence of leaks.

Accelerate up to an engine speed of 4000 rpm.

Check the absence of leaks.

Carry out a road test.

Check the absence of leaks.

Replace any defective parts.

Refit :

• The protective panel under the engine
• The engine cover

[Rusty Sprocket]

Many thanks Paul