Injector headache

[Sherbingo]

Hi all. I'm new here so hopefully I'm in the right area..

I've just finished changing the copper and rubber injector seals in my 1.6 hdi. It's leaked all around every injectors since I've had it. After I finished the 4th injector I turn the engine on and it's ticking like crazy and increases when you drive in higher revs. This must be the injector knocking right? Any suggestions as I have no idea what to do about it. 

And as if that's not bad enough i still have the leak and its now worse that ever. After much inspection the leak doesn't seem to be coming from the injectors but instead from the back of the engine where the air box sits. I noticed a spray of carbon build up on the back of the air filter housing when I removed it that seems consistent to the problem area but I don't really have any idea what it is. 

Does anyone know what's back there? I'm not a mechanic I'm just poor and God loves a trier right?  

Thanks people.

[rapidyellow]

If you didnt recut the mating face of the injector/seal then having another leak is highly likely.

I now have a fiat 1.3 multijet, and recently had to replace the injector seals, first time around I didnt use a seat cutter and they leaked on new seals

so, a set of thicker seals later, an injector seat cutter tool, and taking more care of cleanliness has seen the job done

one tip to give, is when the injector is back in its fitted position and the clamp has been tightened [a bit], find a solid part of the injector and give it a clout with a hammer and cold chisel, this will punch the injector against the copper seal and then after final tightening, should be all ok.

the seat cutter tool is really cheap, be careful only to lightly work it, just to give a clean face. Go to the next thickness of seal.

[Sherbingo]

If you didnt recut the mating face of the injector/seal then having another leak is highly likely.

I now have a fiat 1.3 multijet, and recently had to replace the injector seals, first time around I didnt use a seat cutter and they leaked on new seals

so, a set of thicker seals later, an injector seat cutter tool, and taking more care of cleanliness has seen the job done

one tip to give, is when the injector is back in its fitted position and the clamp has been tightened [a bit], find a solid part of the injector and give it a clout with a hammer and cold chisel, this will punch the injector against the copper seal and then after final tightening, should be all ok.

the seat cutter tool is really cheap, be careful only to lightly work it, just to give a clean face. Go to the next thickness of seal.

Thanks for your advice, I've never heard of such a device but I will probably go find one tomorrow as it sounds helpful. The old rubber was well and truly stuck in the seating bit so maybe I haven't cleaned it up as good as I thought.

I will also loosen the 4th injector back off tomorrow and give it a tap to see if that helps seal it against the copper and stop the knocking. One problem at a time hey : ) 

[rapidyellow]

I know its for a fiat diesel, but diesels and the injectors and seals are all pretty similar, have a look at the guide I wrote for the fiat forum here

https://www.fiatforum.com/grande-punto-g...refit.html

striking the injector body to seat the injector isnt mentioned, that is something I have found out since I wrote the guide and it worked for me as I had another injector to do.

[Sherbingo]

Hey, nice one... Theres a bundle of info there that will save me scouring the web and wasting time. Could pouring water around the injectors do any damage? It crossed my mind but I thought that was probably a stupid idea at the time It looking more affective than spraying stuff to look for the leak.

[Sherbingo]

Oh good lord. Ive just read all your handy info and I had no idea the washers had a rounded bit on 1 side. I mean this vital information seems to be missing from the 20 YouTube videos I watched haha.

With a bit of luck it just needs a spin and I haven't broke anything.

[GraemeT]

Hi - black crap on the back of the engine is likely a leak around one of the seals on the DPF heater - silver cylinder lying horizontally below the airbox with concertina pipe each end.
https://www.autopartsireland.com/ekmps/s...9937-p.jpg
it's clamped/sealed at either end with a metal screw fit clamp part 16283J or else a crimped type which you may be able to tighten if you possess a miracle tool and patience - I usually just peel those off and get a screw fit - £5 on eBay
https://www.ebay.co.uk/itm/PEUGEOT-CITRO...2281423055
Getting onto the hex head on the clamp can be a contortion - I cheat and use extension socket set with a suitable torx head on it - much easier on my ancient spine.

On the injectors - worth having a good look down there when you pull them again - I've had the situation where the old injector comes out with a copper washer (yaaay!) but then refitting fails to go gas tight as there was a second washer stuck in the injector 'hole' which I'd missed. Pulling those was troublesome until smacking a flat bladed screwdriver with the correct width tip into the hole in the washer gives enough purchase to rotate the washer free and pull it out.

[Sherbingo]

Hey thanks for all the info, it's all a bit over my head at the moment but I shall certainly look into it!
Update on the injectors.... 
Number 4 had come loose and that's what was causing the tapping. Doh! Must buy a tourqe wrench.
1 and 2 looking to still be leaking so I have just removing and cleaned everything again. 
2 now looks fine but 1 is pudding fast. 
When I changed 1 for the 1st time here was NO Copper washer! Crazy but it was certainly missing... Do you think the seat needs a red cut? Would a bad seat cause a leak from around the top of the injector?
So many questions. So little time. : (

[V6BOY]

It's paramount that you cut the injector seats on a diesel specially if they are leaking in the first place.

[Sherbingo]

Right next update..

Everything was working great. Car stopped stuttering and loosing power and things were great. Until I got home and see number 4 leaking pretty bad. I kinda wanted to leave it by I've come this far... 

I just popped it back off and the plastic seal and also the rubber had been destroyed! I only did it yesterday, the plastic looked good and the rubber was new... I think I may have fcuked it when it was tapping yesterday before I realised it was becoming loose. Would that do that? 

Not a problem as I'll go get a new seal tomorrow... What I'm really confused about now tho is what these washers are? I cleaned up all the other seats and nothing ever budged. However when I pulled the destroyed rubber out of 4 it came with these 2 o rings??? 1 looks like it should be there but I can't work out why there is 2 of them and why I didn't experience this on the others!? 

Do both of these belong? Is there a o ring inside the rubber or something? I swear they where all flexible but I never checked. I mean why would I?