Xantia High Pressure pump

[Mark_Lancaster2026]

I have been having an issue since I acquired my car a couple of week ago. reluctant and sluggish starting. 1.9 TD 1998
I took it to Chevronics a Citroen specialist, they replaced the glow plugs and repaired the battery terminal . checked the heater circuit, found a couple of air leaks in the pipe system, finally they feel that there is an air leak associated with the High Pressure Fuel pump.
they are suggesting a rebuild which will be expensive ,
the number on my pump is Bosch 0460 494 446 , it seems that the last 3 digits are the important number , but I don’t know in what way,
Can i install a different unit if it is for a xantia such as a 406?

[mickthemaverick]

Chevronics are generally well thought of around the forum but as you are in Bedfordshire give B L Autos in Welwyn Garden City a call and ask John his opinion.

[Mark_Lancaster2026]

Ok thanks I will do
I am waiting for a quote from Chevronics and it might not be as scary as I first though,

[Stickyfinger]

Nearly always the drive shaft front seal letting air be drawn back into the pump which then needs to "re-prime/build pressure" to start.
These seals can be replaced.
The pump/engine is VERY common and most diesel specialists will have grown up with them (versions) on PSA/Ford Transits/LandRovers etc...

Finding a local diesel specialist might be a much cheaper way ahead....
Kits like this: https://www.merlindiesel.com/product/parts-sett/
NOTE: always check with the seller the kit includes the front shaft seals

(from memory some have 17/18mm seals some 20mm seals dependant on date of manufacture,,,so check this as well.

[CitroJim]

I'd be very surprised if there is an air leak on the pump itself. The pump, whilst in operation, is always under pressure and any sealing issues would be revealed by diesel leaking out - not air leaking in.

The front seal is just in front of the low pressure lift/transfer pump. Any problems with this seal will result in very obvious diesel leaks.

If the pump is generally clean and dry, chances are it's OK.

Air leaks on the 1.9TD fuel system are common and are almost always caused by leaks around the fuel filter, especially on the end of the fuel heater thermostat shaft - the white, circular bit you can see near the base of the filter body, the fuel primer bulb, perished leakoff pipes and especially the little sealing cap on the last injector. It's a shocker for perishing and being quite well hidden, not obvious.

A good way to diagnose air ingress problems is to temporarily replace the pipe between the filter outlet and the fuel pump inlet with a translucent pipe. You can then readily see any air bubbles.

Any replacement pump you may find will need a full (expensive) overhaul unless it's proved it's had a recent one. So if there is a problem on your pump it's best to have yours overhauled rather than fit another. It's likely to be both cheaper and easier in the end. One big issue may be with the immobiliser - that alone makes it a lot better to overhaul what you have rather than replace.

[Mark_Lancaster2026]

From what I was told by Chevronic's there was some fuel spraying out when starting around the input shaft , they have checked the hoses and seals. The reference on my pump is not one that I can get off the shelf I talked to Merlins and they said it would be £1200 for a rebuild although I have found a company in Lithuania who can do it for £400 . as the car has done only done 19000 miles ,I am hoping that its just the seals and the issue is because its been standing for a while.
I am now waiting for a quote from Chevroincs to see which way to go, I was trying to see if you could use a pump suitable for another Xantia but I don’t know the significance of the reference numbers. I have been told they are important but not why they are important
thanks for the input it been a big help

[CitroJim]

If the mechanics could see fuel spraying out then that's indeed the seal. If, once started, the engine runs well and there's no leaks anywhere else then just replace the seal. It's just a standard garter seal and nothing special. The pump does not need to be dismantled to replace it.

The pump has to be removed from the engine to enable this though. Due to a bit of forethought by the designers, there's no need to disturb the timing belt although if you have no record of the cambelt and waterpump being changed, I'd strongly advise you take the opportunity to do so.

An elderly camblet breaking on these engines is very disastrous and that would be a shame on such a low mileage car.

Keep us posted

[Mark_Lancaster2026]

Hi Jim
that good to know as I had expected to have to do a cam belt change. it was done 2 years ago along side water pump, but has only done 1500 mile in that time.

regards

Mark

[CitroJim]

No need to disturb the cambelt then I have a policy of replacing them every five years on lightly used cars - a little conservative maybe but rather that than having one let go due to old age.