94 Xantia no electrical power to injection pump

[quintet]

Hi all, i have an ongoing issue with my xantia, it's a 1994 turbo diesel with a bosch pump, it doesn't have an immobiliser/keypad. This fault has come and gone for many years but up until today has always cured itself without any thing at all being done to the car...hence the issue has been going on for so long. There are very similar if not identical posts/thread on here but im unable to find an actual cure, so the issue is as follows -

This fault is rare & might not happen more than 3-4 times a year, the car can be left for any length of time (minutes-weeks) and it's not a problem, however on occasion i'll come to it and it will not start, there is always the battery light & parking light illuminated but no other dash lights (inc' glow plug) & i can crank it as much as i want & it turns over perfectly but will not start, now up until today the car has always sorted it's self out after a length of time, sometimes 30 seconds, sometimes half an hour but its always fixed its self so i've never been able to diagnose the issue (not broken down = no fault to be found...), however today after the car had been driven about 5 miles i parked it up, came back to it a few minutes later & the elusive fault has returned and stayed broken (1st time ever the fault has not fixed it's self). As it happens the suspension was being looked at so the car was in 'high' , upon it breaking down (long story short...) an AA patrol gave the injection pump a direct feed off the battery via the 3 pin (black) plug and still it wouldn't fire, he tried x2 power feeds (using a fused wire in case something went pop!) to this plug & it fired but it made the AA patrol jump & i let go of the ignition key & it died immediately and has refused to start since. So basically there is no power to the injection pump, nor the pre heater control unit or the post heater control relay, switching the ignition on/off and it does not click.

I have been given a contact number & a gent said he'll come and look at it tomorrow as will i but if anyone can shed some light on what might be the fault i would appreciate it. I should point out the car is a manual so has no autobox inhibitor switch, anyway knowing my luck i'll go out tomorrow & it'll have fixed it's self again!

[xantia_v6]

It could be the ignition switch, but given your description of the intermittent nature of the fault, I would suspect a corroded wire in the 10AV harness that runs under the radiator.

[quintet]

It's possible it could be a faulty ignition switch although i've changed the whole lock set in previous years (due to door lock/barrel issues) and i 'think' the fault was there before i did this, i think i've still got a spare ignition barrel so it will be getting tried if needed. On one of the threads that i recall reading (that vaguely covers this subject) i recall that someone said the wiring harness had failed at the offside corner where it goes through a tight'ish bend and through a couple of panels/brackets but this makes it difficult to get to & might necessitate a front end strip down I do have a suspicion this is going to be a wiring fault & one that will need tracing back from the 2 glow plug supplies that currently have no power.

[xantia_v6]

Here are the wiring diagrams applicable to your car 1255 is the Bosch pump:

There is also a chance that there is a faulty soldered joint in the fuseboard (BF00) under the dashboard.

[white exec]

Check out (or replace) the Bitron double (injection) relay. Usually brown, double width, and labelled Bitron 240.xxx. New replacements may be branded Omron (now own Bitron, Italy), and 240.101.

This relay needs to function properly, and in conjunction with the engine/injection ECU, for the engine to start.
Check the relay's pin connections are clean.
It contains 4 diodes as well as two separate relays, and the diodes have been known to fail.

Caution: Do NOT unplug/reconnect the main engine/injection ECU with the battery still connected, or it and the Bitron relay can be damaged. Citroen advice is to disconnect both battery connections first.

[CitroJim]

Check out (or replace) the Bitron double (injection) relay. Usually brown, double width, and labelled Bitron 240.104 or similar. New replacements may be branded Omron (now own Bitron, Italy), and 240.101.

Good call Chris I had exactly this problem on one of my Activa years ago and swapping the double injection relay cured it...

[xantia_v6]

What Bitron? See diagrams above.

[white exec]

Mike, it will be on the injection ECU diagram (and/or immobilser, if there is one).
It's job is to tell the injection ECU it's ok to start, whether there is an immobiliser (keypad) present or not.

[quintet]

Here are the wiring diagrams applicable to your car 1255 is the Bosch pump:

There is also a chance that there is a faulty soldered joint in the fuseboard (BF00) under the dashboard.

Thank you for the wiring diagrams, these will come in most useful. If anyone happens to have a spare fusebox that is suitable for my car i'd be happy to buy if off you.

Check out (or replace) the Bitron double (injection) relay. Usually brown, double width, and labelled Bitron 240.xxx. New replacements may be branded Omron (now own Bitron, Italy), and 240.101.

This relay needs to function properly, and in conjunction with the engine/injection ECU, for the engine to start.
Check the relay's pin connections are clean.
It contains 4 diodes as well as two separate relays, and the diodes have been known to fail.

Caution: Do NOT unplug/reconnect the main engine/injection ECU with the battery still connected, or it and the Bitron relay can be damaged. Citroen advice is to disconnect both battery connections first.

I'm not sure how i can go about actually testing this bitron box but being a relay & if i can get to it switching the ignition on/off i hopefully will be able to feel or hear it clicking although it is somewhat buried. As for the engine ECU i'm hoping i won't have to touch that as i'm not even sure where it is most PSA cars have them mounted on the offside inner wing but i suspect mine is mounted behind the dash board (diag socket pre-dates obd 2).

[Hell Razor5543]

Give citroenxm (Paul) a shout, as he may well have the parts you are after.

[white exec]

The Bitron double injection relay is part no. 1920 3X, and still available from Citroen.
It is fitted to dozens of petrol and diesel models.
I had to get a new one recently, and it carried the type number 240.101, brand Omron.

Unless you are adept with electronic repair, they are best simply replaced. I think they're around £30.

This is what the item looks like (#4 in the photo)...

Type number might vary a little. This is an old one...

[quintet]

The Bitron double injection relay is part no. 1920 3X, and still available from Citroen.
It is fitted to dozens of petrol and diesel models.
I had to get a new one recently, and it carried the type number 240.101, brand Omron.

Are these injection relay's all the same? i would have thought they'd be different particularly between petrol & diesel engines, the reason i ask is i spoke to my local parts dept this morning, he gave me the same part number (19203x) and told me it was no longer available. Now i can sort of understand that if it were specific for my car (with it being old/rare now etc) but if it's the same relay used on many PSA vehicles then something is a bit suss regarding why i was told it's not available Anyway... todays proceedings has included a good prod around the pre & post heat relays mounted besides the underbonnet fuse box = no power to them, we replaced the ignition switch and the car came back to life, the fella working on my car (a very knowledgeable man ) then started putting the car back together but it spat it's dummy out again & packed up! but on generally moving the fuse box, 1, he came across some scotch block connectors & 2, disturbing the fuse box brought the ignition lights back to life, tomorrow all being well it'll be getting a replacement (under dashboard) fuse box & a general wiring check in that area.

[white exec]

There seem to have been a good few variants on the Bitron 240.1xx injection relay, with Parts listing different types for different vehicles. Essentially, they all appear to contain the same two internal relays, but the fitting of two of the diodes, and some other inter-connection of the pins, does vary, depending on whether the car has an immobiliser system or not.

The part number 1920 3X I quoted above is the one currently listed for a Xantia 1.9TD, and is shown as available. It is unlikely to have been superseded, so just insist that they order it, if you still need one.

The only reason I mentioned the 240.101 is that, in the case of the XM2.5TD here, when my dealer accidentally destroyed my relay, a listed 1920 3X was ordered up, and the Omron-branded 240.101 was supplied, fitted, and immediately worked.

The part is listed, so ask them to go with it, or provide its possible replacement/equivalent. It's annoying when dealers parts departments respond like this. Some are just lazy, it seems.

Sounds as if you have a few other potential intermittent supply issues, which hopefully your able guy can get sorted.

I don't have your VIN handy, so if you can post it, I'll double-check the relay part number.

[xantia_v6]

Chris, This car has a mechanical pump with no electronics and no injection relay, just a wire from the ignition switch to the pump. Take a look at the diagrams that I posted viewtopic.php?p=667533#p667533

[white exec]

Ok, my error. Forget all reference to the injection relay.