205 1.7 D Lucas pump leaking

[makemine205]

Well, now i have a fuel drip coming from the rear end of the fuel pump. Between the aluminium body and the big black steel ring on the end of the pump. I,m trying to find a diagram for the pump, where is there one ?.
And is it an easy job to do or a pain ?. Is there a gasket or o-ring involved , Funny how its only started leaking in very cold weather ???.
On start up it takes several seconds of cranking and some pumping on the accelerator . After the engine has warmed up the leak stops , due to metal expansion i think.
Any help appreciated .
Thanks.

[CitroJim]

The usual cause of a leak is the top cover gasket (a shaped O ring) failing by going hard... Occasionally it can be caused by wear in the bushes carrying the fast idle and governor (throttle) shafts...

It's quite a straightforward job to renew the gasket... It can be done in-situ. You need to do it under clinically clean conditions as no muck whatsoever must be allowed to enter the pump...

I'd recommend you clean the pump exterior and everything else in its vicinity to within an inch of its life before commencing...

Remove the throttle and fast-idle/emergency stop levers, noting their positions and after removing the four cover screws the top cover can be gently lifted off whilst carefully pressing down the throttle shaft as you lift..

A while back, an overhaul kit could be obtained for quite a small outlay and containing, amongst much else, the gasket you need and new O rings for the throttle and fast idle shafts... I've no idea if they are still available but I'm sure the usual auction site will provide

Be aware that some people's skin can be very sensitive to diesel... Try to avoid skin contact when doing the job. I recommend wearing nitrile gloves... Not latex as the diesel will attack them...

I have an exploded diagram of the pump somewhere. I'll try to find it for you...

[CitroJim]

This thread from long ago may help too... Freshly written after I did the job on my old (and sadly long-gone) 205D. Nearly 14 years ago now!!!

viewtopic.php?t=20656

[makemine205]

Many thanks for your reply.
All this now after i had just stripped down and cleaned and repaired the starter motor with a new brush holder kit AAArrrggghhh!.
Oh well point taken about clean conditions !. Looks like i put up a polythene tent in my workshop or just go get a recon unit .
Whats the likely cost £ of a recon pump unit from a trusty source , low to high please, never been down this road before .

[CitroJim]

Whats the likely cost £ of a recon pump unit from a trusty source , low to high please, never been down this road before .

A figure that bears more than a passing resemblance to a telephone number I'd imagine

[205alex]

My I have diesel running down from my Luacs pump when i drive my 205 na 1.7 diesel, what are the most common parts of the pump that leak, will post a photo of it after i next drive it but seems to come from underside.
Pump number is 8443B930A.
Many thanks

[CitroJim]

The top lid gasket and the O rings around the throttle and fast idle/emergency stop shafts are the usual places where these Lucas DPC pumps leak. Sometimes the shafts wear the lid badly enough it needs to be replaced...

Overhaul kits containing the necessary O rings and gaskets should be still available.

The job can be done without removing the pump from the engine but some care and clinical cleanliness is needed. It's actually easier than it might at first look.

I can offer more advice as necessary... I think the procedure will be on here and a search should find it. I know I've written extensively about it in the past...

EDIT: How to do the job is indeed in this very thread - scroll up a bit and you'll find it Written by me!

[205alex]

Hi Jim thanks for getting back so fast, I have indeed had a good read of your previous posts already, it definitely seems quite complex to me but doable and I am looking at getting this kit - https://injectionpumps.co.uk/product/co ... out-turbo/

I did the timing belt on the car this year so thought a full replacement could be an easier option for me having done the timing belt part of this job before.
If I decided to go for a replacement does it need to be exact or do most lucas pumps fit, for example I have found a remanufactured CAV DPC 8445B210A from a partner/306 for £175

Cheers!

[CitroJim]

Hi Alex, I should have said welcome to the forum yesterday! I have now

No, the Partner/306 one you see is unlikely to be useful to you as that'll be the later semi-electronic model and needs and ECU and immobiliser setup to work. Also it'll be for the 1.9D and will over-fuel a 1.7D. Best to overhaul what you have and the link to the kit is the one and a good price.

If you feel happier removing the pump then do but honestly, to do the top lid there is no need... Especially on a non-turbo 205. You have loads of room to work.

I once did one in the rain on a nephew's drive in the middle of winter!

[205alex]

Hi Jim,
I have still not actually got round to fixing the fuel leak as it hasnt really been affecting my use of the car however with the mot in a week I'm going to try to fix it this weekend:
I bought an old lucas pump for 30£ to practice on and having taken the top off I had a couple questions:

- In the original post it says to check the one way valves in the fuel line banjo unions, Im not sure what im looking for here/where the one way valves are?

- The o ring I have in my kit which seems to be for the lid is just a large circular o ring and is not shaped like the lid - I was wondering if this is normal?

- Lastly when putting the practise pump back together I the idles/stop spindle seemed to fit in any rotational oriantation - how crucial is ith this goes back in exactly as found?

Even if you can help me with one of these questions that would be a great help,
Thanks!

[CitroJim]

Hi Alex,

That was a very good plan to get hold of another pump as a practice piece

Your practice pump may not have the banjo unions on the inlet and return fuel ports as they are attached to the fuel lines... If they are, and on your working pump, you'll find they look similar but have differing bore sizes. All you need to do is check they're clear any obstruction in the direction of fuel flow. You know yours are as the pump and car is running well. You must replace the copper washers each side of the banjo bolt.

The lid gasket is usually shaped but there's no reason for it to be. As long as it fits snugly in the lid groove it'll be fine.

The throttle and stop spindle orientations critical. Take photos/take notes as you lift the lid so you know the orientation come reassembly time.

Hope that helps and all the best with the MoT

[205alex]

Thanks a lot Jim!
Got it done today and doesn't seem to be leaking anymore.
Initially was idleing very low when I first put it back together but reassebled the idlle/stop levers putting the spring clips on last and now car seems to idle as it did before.

[CitroJim]

Alex, that's awesome news Well done!