Bosch diesel pump repairs!

[oscar]

Hi my fuel pumps got a leak from the top gasket area and as been on veggie oils etc probably could need a rebuild etc as a bit lumpy from cold till warmed up after quite a while.
So it's either find a 2nd hand one or sort this one out? but don't have a lot of time as need in few weeks time going to dorset way for me one fishing trip i seam to get a year now?
Does anyone know where can get pump sorted or could grease someones palms if they can do it? i can get gasket/seals etc
I'm a bit limited now with mechanicing etc now as spine/disc problem which gives me no feelings/ crap grip in me hand.
Found a few pumps but mines the one with the potentimeter on top of throttle part which if im right? is ASC one?
Is that one of a kind or is that part interchangeable onto another pump or is it like all newer things and it's this one like it or lump it type?
Where as older cars you could get round things and mod it.

Anyway hoping someone can be of use

[CitroJim]

Replacement seal sets can be obtained from Brickwerks at a very good price. They're for a VW but are the same.

This kit does not include the front seal which is advisable to replace at the same time. This is a normal, standard 'garter' seal and I can advise later the size and source.

As for repairs, these pages may help.

Sadly, I'm unable to take on such a job. It is not easy and best entrusted to someone who knows what they are doing. Most diesel specialists will not just re-seal. They'll want to recalibrate and basically rebuild the pump at terrific cost but it's worth sounding a few out.

Note that the pump MUST be removed from the car/engine to do the work.

Hope that helps...

[oscar]

Hi thank you for reply.
I will have a look but think probably beyond my friend and me as i think he is thinking can do on car as is? and he only has his house and i think there would be a slight atomic reaction there with the MPO(mechanical permission officer) the wife.
How do you get the immobilizer off if you can without damaging it so can replace? mind you can i guess do with out it.
But what does/would that entail if it's bypassed?.

The other thing i guess is if it's leaking from that gasket would it still be ok to use for while till can sort out.apart from a leak it's not massive well wasn't? (fingers/legs crossed)

[citronut]

a diesel component service guy told me that sometimes a diesel pump can leak because the one way valves in the supply/return banjo union/s are sticking,
this cause's pressure to build up and push fuel out were ever it can,

this was on a BX with the Lucas pump,

as your car is on veggie oil is it possible the one way valves are just clogged up with goooo


regards malcolm

[CitroJim]

as your car is on veggie oil is it possible the one way valves are just clogged up with goooo

That Malcolm, is a very good point Thanks for being on the ball this morning!

The banjo union in question is on the return fuel line and is screwed into the side of the LDA ('UFO') housing just above the armour and has a very small hole in it and a mesh filter. Both can clog up. The small hole is calibrated to regulate the internal pump transfer pressure. Have the banjo out and give it a careful clean.

Also, whilst you have the banjo out and the return fuel line disconnected ensure it is clear all the way back to the fuel tank buy blowing down it and listening for bubbles in the fuel tank. I have indeed known this line to become blocked in cars running on veg and causing the pump to leak because it was developing too much internal pressure.

[citronut]

ensure it is clear all the way back to the fuel tank buy blowing down it and listening for bubbles in the fuel tank.

that conjurers up some very interesting image's Jim

you would need a very wide head , very big ears ( dumbo comes to mind ) , or a long extension tube to reach your mouth whilst your ear is at the filler neck,

or i spoz a delectable assistant could do the blowing bit oooh la la,

regards malcolm

[CitroJim]

or i spoz a delectable assistant could do the blowing bit oooh la la,

That conjures up an image too

Actually, if you take the fuel filler cap off and it's quiet you can hear the bubbles. I normally use an airline to do the blowing...

[oscar]

Hi thanks for that i'm going to try that out.what's the best thing to clean veggie gear up with?
What i was thinking of was to get another pump then repair this one etc as spoke to spares place and going to have a poke for model number on pump and they''l see what they have and should get with code?

If you do de armour pump how do you go about then bits like stop solenoid etc

Many thanks for quick help

[CitroJim]

Veg is notoriously difficult to clean up once it's hardened and polymerised. Not much attacks it but often a good solvent will soften it and it can then be removed by gentle mechanical means.

If you de-armour the pump it is essential you have a set of non-armour type distributor head bolts to replace those you'll mangle and always be very careful to leave at least two bolts in the distributor head at all times or you risk breaking the HP pumping element.

Even with the armour fully removed you can retain the immobiliser module or you can do away with it and run an ignition-switched 12v feed via a fuse direct to the stop solenoid.

There are two pumps fitted to the 1.9TD Xantia. Up until about 1996 the Bosch VP20 mechanical was fitted. This pump is often not armoured and can be identified as having a micro-switch on top of it and no black circular load pot on top of the throttle shaft. Later 1.9TDs has the Bosch AS3 semi-electronic pump with an ECU to control timing. An easy way to spot this is the presence of an ECU box in the engine bay, an engine management light and a thin black wire running from No.3 Injector. The two pumps are not directly interchangeable. Part numbers don't matter as long as you use the identifying features above.

Good idea to have a spare pump to rebuild

[Xaccers]

The immobiliser is a block that sits on top of the stop solenoid, and it just allows 12v (or not) to the solenoid.
If you fit a vp20 you can fit the immobiliser to it, but you will have a constant ecu light on as the edu will be trying to adjust the pump timing.
You can just remove the bulb from the console.
Best bet is get a new as3, de-amour it and replace the seals, swap it over and do the same with your leaking pump then sell it as being already refurbed.
The immobiliser code is stored in the actual immobiliser block.
Running with a leaking pump will rust proof your engine

[oscar]

Hi yes mines the AS3 one.
Had a look for number in larger digits got 602-1 couldn't quite see smaller ones in that line black like digits on side/front of pump.

One thing i do need is what is the size/inner diameter of the primer bulb pipe work as need to replace that.and found a load on flea bay but some of the listing help charts don't work correctly( don't fit zanty 1.9td) but fit pug/xsara and others.
so looked for others and gave me loads of sizes. 8mm/9mm/10mm/12mm

did find one in louth selling loads of citroen parts new one was lucas pump for xm if i remember right £125. plus spheres and D shafts ive book marked it if anyone needs

[citronut]

the OE part No. is 157973 and the piping up to and from is 8mm internal X 10mm external
on running the part No. by all family's on service citroen the same primmer bulb fits all of the list below

2 document(s) found for SYNERGIE
2 document(s) found for XANTIA II
1 document(s) found for AX
2 document(s) found for BX
1 document(s) found for C15
1 document(s) found for BERLINGO
6 document(s) found for ZX
4 document(s) found for XANTIA
1 document(s) found for DISPATCH I & II

regards malcolm

[oscar]

Hi thank you Citronut.
I didn't think there would be that many different sizes being used by citroen or prob pug? And i'm sure my first ob's was correct in that there chart/widget was tit's up as tried a few models in it and not one worked.
Had same with a filter yet on item page on listing say's fit's 1.9td.
I thought i found one of them in silicone a while back but only found rubber types now.
Mind you i do have a seller saved that did many bit's for bio/veggie oil runners so will have a look to see what they have.

[oscar]

Been having a look at leak today as been out in it the leak is coming from round top gasket.
If it's dribbling down front of engine will it get onto timing belt? which is my main concern.
But if im right? would it be less if say on the motorway so using fuel as opposed to light throttle? going to try to get to return pipes etc once this monsoons gone?.

I guess it's all the bit's off that end of engine to do?
Where do you recommend to change pumps over once ive got another one ready? as the one i knew has retired now

[oscar]

Found a pump today for it but wanted to know what the difference is with them and what to look out for? i'e the large digits on mine are 601-2 and found a 601-5 mines an AS£ one with ecu and potentiometer on top of throttle shaft type with key code on center consul.
Guy at spares place think it's from a 97 odd car so probably one with chip in key?
Where would be the best place to find out about the versions and what fits etc.