Depending on the engine type and fuel injection device, different types of injectors are installed. Bosch fuel injection system injectors are not the same for all engine types. The nozzles are color-coded on the holders. Injectors operating in the Lucas system are marked green. If the engine has an exhaust gas recirculation system, then the injectors have a green plastic ring on the top side (which cannot be removed). Bosch fuel injection device injectors are also not the same on all engine types and may have silver, purple or blue markings on the injector holder. The marking is visible even without removing the injector. Figure 419 shows the Lucas injector markings. The Bosch injector is color-coded only at location (1).
Figure 419. Lucas injector markings (Rato-Diesel or Con-Diesel) in place (1). The plastic ring is installed only on vehicles with an exhaust gas recirculation system. On the Bosch injector, the color marking is applied only in place (1).
To identify a faulty injector, you should disconnect the injection tubes one by one and start the engine. If removing a specific injection pipe does not change the engine operation, the corresponding injector is not working.
The injector is removed as follows:
- Unscrew the injection pipe. The most convenient way to loosen the union nut is with a slotted open-end wrench. Disconnect the fuel return hose from the injector.
- Screw in the nozzle rod. This can be done with either a 27mm socket or a special tool used at Peugeot service stations. A special Citroen 7007-T tool is also suitable. Remove the spark arrestor washer and copper washer (see Figure 420). During installation, both washers must be replaced.
Figure 420. Installed injector. 1. Copper washer; 2. Spark arrester washer; 3. Union nut; 4. Nozzle rod; 5. Hexagon 27 mm, 90 nm; 6. Glow plug, 22 nm; 7. Glow plug hexagon
Installation is carried out in reverse order. The spark arrester washer (2) in Figure 420 is installed with the rounded side facing up. Install the copper washer (1). Tighten the injector stem to a torque of 90 Nm; the union nut of the injection tube with a tightening torque of 20 Nm.