How much we looking at if the injector needs to be replaced?

On closer inspection, the injector all the way to the right as you look into the engine is the leaking one, when i went to check the ccables feeding into it the top one is solid pipe with fabric over coating, but the bottom one you can see leading away to the right in the picture is rubber & came off the injector to reveal it was just slipped over a dead end that had been clamped closed (squashed in other words)

Diesel leaking from here for sure, not sure if its coming from anywhere else, rubber hose leads to small plastic loooking resevoir that has two side by side just in front of the battery.

What should this have been doing and does it need a new injector or can i seal the squashed end?

car is driving perfectly fine, no spluttering, stalling, jumping, problems starting at all, just a very small amount of diesel making the cabling damp with diesel.

When you pull the throttle cable with bonnet open you can see it oozing ever so slightly.

reccomendations?

1. Clean the affected area carefully.
   
2. Have a run out for a few miles.
   
3. Re-inspect the affected area and see if you can now tell whether the leak is from the supply pipe (unlikely), injector, or return pipe.
   
4. If you've identified which the leak is from, replace that one. Not only is diesel expensive, but it's also flammible.
   

Is the return pipe the one i mentioned that is now clamped closed?

Final injector, rubber pipe leads off to right in engine, top of outlet of pipe is clamped shut but leaking.

I think so, and it it's been clamped closed, that could cause a leak in itself, if you're got over-supply from the pump to the injector(s).

What I'm not sure of is what the return arrangements on that engine are, beyond that the return pipes are low enough pressure that you could use fabric armoured rubber or fuel-proof plastic. I think we have absolved the feed pipe (hard metal one entering the injector through the union) and a leaky injector.

You could be on to something there, it idles about 950rpm, just under the 1 mark, is this because it is getting to much fuel?

Also, what RPM should the engibe be at if you are travelling say 70mph, mmine is approx 2750, does this sound about right?

You could be on to something there, it idles about 950rpm, just under the 1 mark, is this because it is getting to much fuel?

Also, what RPM should the engibe be at if you are travelling say 70mph, mmine is approx 2750, does this sound about right?

That idle doesn't sound way off tbh. Maybe slightly high.

the 70mph revs sound about right. Fairly short geared due to the low powered engine.

Phil

You're just describing a standard diesel leakback setup. Every modern (i.e. post 1980) diesel I've seen has this - a small portion of the injected diesel is used to lubricate the injectors, and it then runs back at low pressure to the filter/tank to be used.

The fabric-coated pipes are just plain rubber push-on ones, but they tend to deteriorate over time. My '98 Felicia D needed new ones when I bought it in '06, and again just before I sold it this year. The same was true for my 05 diesel Focus. A kit is about £4 from a motor factor, with enough pipe to do them and a cap. It's not high pressure, so there shouldn't be any issues with leaks with them just being pushed on. Simple, easy fix.

However, looking at your picture, it doesn't look right - my Felicia diesel didn't have a pipe and then a piece of nylon tubing going off, that last injector had a plain cap (as found in the kit) to block it off - where does it go?

FTR - Diesel is not flammable at standard temperature and pressure (i.e. when it's just in the normal everyday environment). You can throw a match in it and it won't light. It only burns at the right temperature which is one of the reasons that diesels have such extreme injection pressure.

Ok, i will take a pic now & show where it leads to, if the end of the injector is supposed to be capped then i have a cable feeding onto the end of an injector that shouldnt be there, where should this cable go?

Ok people, here are some pictures,

1. In this pic you see the outlet under injector is squashed closed (unsucessfully it now appears) this should be capped, yes? I doubt it can be capped now so can i seal it somehow?

2. These are the parts in the engine the cable that was fixed to the injector outlet above feeds to, what do they do as i then have a cable that leads nowhere?

3. I have traced out the cable coming from the injector in white to the part shown above, it then feeds into another cable that runs from the back of the engine to the front. The second one beside it i have traced in red where that leads to and that has one that hangs down in the pic also not attached to anything, what are they both & where should each one lead to as the car appears to be runing perfectly?

I don't have my VAG books here, but my Citroen one quotes 800+/-50 for the XUD19 (with or without turbo).

Let's sort the leakback system, then worry about the idle speed though.

Incidentally, whilst diesel won't flash over at RTP, any hydrocarbon will keep burning in an oxygen atmosphere when given a suitable source of ignition.

Pic 1: OK, the "crushed" injector end shouldn't be, it should be an outlet just like the others (where they have the pipe put on them) - I would think you would need to get it VERY clean (using brake cleaner), get a cap from the kit mentioned above, and then fit that with some silicone, and then not use the car until the silicone has set. Or it may be possible to put some pipe on there and clamp it onto the injector with a tiny hose clamp and then block it at the other end.

However, I'm wondering where the leak off is going at the 'other end' of the chain. You have four injectors - No.1 is by the cambelt end (the other end of the engine) - where do the pipes from that one go? They should bleed back into the fuel system (can't remember exactly how, was March last time I looked at one), so if that's not the case, that would lead to a pressure build-up in the system, hence the leak. The leak-off is low pressure, but will build if it doesn't have a drain off. It may even be possible to unscrew the leak-off nipple and replace it. What's for sure is that whoever did this was a bodging **** and they've screwed things up!

Pictures 2 and 3 - I think your idle may well be related to the bodgery. These aren't cables, they are hoses and probably vacuum ones. Again, it's been a long time since I've had a diesel pump off one of these engines, but I'm pretty sure that there's some extra connections which went to the items in pic 3, which IIRC are solenoids for air? Either way, I think you need to find someone with a 1.9D Felicia who can trace them out for you and tell you where they should go; I think the two problems are interrelated, and I'm 100% that the leakoff shouldn't be going to them.

Thanks a million, think a haynes manual may have to be invested in.

Pic 1: Or it may be possible to put some pipe on there and clamp it onto the injector with a tiny hose clamp and then block it at the other end.

I was thinking along the lines of a small olive nut used in plumbing with gasket sealant filled inside it then pushed & allowed to set?

I think anything that will make a semi-positive contact if fitted correctly will work OK - the leakback connection is low volume and low pressure providing there are no blockages, so I'd think if you prepare it correctly it'll be fine. I'd go for the replacement leakback pipes kit and use part of that - it'll "look" right as well as work when you get it right.

I wouldn't bother with a Haynes manual - they are a waste of time, IMO. Better off trying to find a PDF of some factory manuals or similar, or asking someone on here to trace out where those pipes should go - I'd be amazed if such info was in a Haynes manual.

I think anything that will make a semi-positive contact if fitted correctly will work OK - the leakback connection is low volume and low pressure providing there are no blockages, so I'd think if you prepare it correctly it'll be fine. I'd go for the replacement leakback pipes kit and use part of that - it'll "look" right as well as work when you get it right.

I wouldn't bother with a Haynes manual - they are a waste of time, IMO. Better off trying to find a PDF of some factory manuals or similar, or asking someone on here to trace out where those pipes should go - I'd be amazed if such info was in a Haynes manual.

I found a factory manual alright but it was in checzh i think.

I fixed the leak, i had a very small brass key that had a square recessed head on it, just the width of the outlet, i cleaned the outlet down with a cloth & dried it with a hair dryer, filled the recess with builders silicone an pushed it onto the head of the outlet, i then took it back off & refilled it with more silicone & pushed it on again, this time it squeezed out the nd of the key arounf the outlet pipes base.

I left it for two days to dry fully without starting, tested it yesterday & i have a 100% seal with no leaks.

The location of the hoses now, one seems to be the correct length to fit onto a little device that is located at the very front of the head where the acceleatro cable is, there was an small outlet on top of this device that had nothing connected to it.

The other one has me baffled as to where it goes.

The device at the front of the head where the accelerator cable goes is the diesel pump!

I seriously think you need to post another thread asking people for the location of their pipes on 1.9 diesels. It'll sort the problem quickly, and no-one is going to be looking in this thread, they will still think it's about gears.

The device at the front of the head where the accelerator cable goes is the diesel pump!

I seriously think you need to post another thread asking people for the location of their pipes on 1.9 diesels. It'll sort the problem quickly, and no-one is going to be looking in this thread, they will still think it's about gears.

Im pretty sure its not the diesel pump, it is very small, about the size of a PC fan made of black plastic, nothing was coming out of the outlet when there was no cable on it.

I'll take a picture & start a new thread on it.