Lucas EPIC Injection Pump Overhaul Guide

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Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

The Lucas EPIC Injection Pump as used on the XUD11BTE engine as fitted to 2.1TD Xantias and later 2.1TD XMs is generally reliable but can suffer leaks and problems with the ESOS valves. Both are relatively easy to resolve but need the pump to be fully disassembled. This is a guide on how to do just that and covers the complete disassembly and reassembly.

The EPIC, compared to the earlier DPC and the Bosch VP/AS series is actually quite and easy pump to work on. One job needs a press but for most jobs you will not need to disassemble this far.

(Due to how I'm covering this job over on Club-XM it is at the moment a little out of sequence as I've actually done the most difficult reassembly bit first after my initial experimental disassembly. This will be corrected in due course and so I can insert the relevant stages later I've made some place-holder threads)

Before disassembly the entire pump must be thoroughly cleaned and drained of all diesel as far as possible.

To disassemble fully a hydraulic press will be needed. Apart from that no other specialist tools are required bar for a good Torx set, a 32mm spanner and a few pin punches.

Your work area must be spotlessly clean and tidy. Dirt is the enemy of diesel pumps. Use LHM for reassembly lubrication.

(initial disassembly guide to follow)
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

(Next disassembly place-holder)
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

Right, here we go. Part 1 of how to reassemble an EPIC.

This is how to reassemble the most difficult bit - the driveshaft and lift pump in the front housing.

Start by driving out the front seal with a pin punch:

Image

Begin lift pump assembly by placing the pump bottom plate in the housing with the grooved face facing up. You can't actually get it wrong because the screw holes will only line up one way. Lubricate everything as you go. I use clean LHM.

Image

Next, place the rotor housing in place with the cutouts facing the bottom plate. Again, it will fit only one way.

Image

Insert the rotor:

Image

Followed by the four pump vanes. beware of the small springs behind each vane. Ease them in with a small jewellers screwdriver and ensue they sit correctly.

Image

Place the top plate onto the lift pump with the dished face upwards. Again it'll only go one way:

Image

And the lift pump screws:

Image

Rebuild the front roller bearing by coating the outer race and rollers in Vaseline and carefully assembling, ensuring all stay very firmly in place.

Image

It should then look like this when fully reassembled:

Image

Great care is now needed to ensure the rollers don't fall out but if enough Vaseline is used they will be OK.

Invert the body and replace the dished washer on top of the lift pump assembly making sure the tang and groove is correctly engaged:

Image

Carefully insert the driveshaft whilst turning the housing through 90 degrees. Ensure the dished washer and rollers remain in place.

Image

If all is in place correctly the big bearing will poke out of the housing about as far as shown here:

Image

Now we come to the very tricky bit and that's pressing the front bearing inner sleeve into the bearing and onto the driveshaft. This is an interference fit.

Set up the press with an MDF pad on the pressbed. Place the pump body with the drive end of the driveshaft facing up. Be careful to enause the dished washer does not fall out of place by keeping the large bearing held in the housing. Lubricate the bearing inner sleeve with LHM and slip it onto the end of the drive shaft with the grooved end facing toward the pump body. The sleeve will go down a little way and then stop just above the bearing rollers. use a 19mm deep socket as a mandrel and carefully press until the sleeve is around half way in. It wont' take too much pressure.

Image

All the time you are pressing keep the housing moving to ensure the bearing sleeve properly centres. A little more pressure will be needed to press the sleeve all the way and when the sleeve is fully home the pump will seize. Some end-float is needed here but I do not know and cannot determine from the documentation how much there should be. I'd say a tad.

To achieve this, reverse the pressing direction by inverting and supporting the pump on a suitable fixture (I used a piece of U channel) and press down on the end of the drive shaft until it gives a little.

Image

Repeat the above until the right amount of end-float is achieved. Fine adjustment can be carried out by carefully striking dead-blows on the end of the driveshaft from a heavy hammer. Screw on the driveshaft nut and strike on that, not the naked end of the shaft.

Ensure the driveshaft spins easily and smoothly.

The rest of the assembly will follow in subsequent posts but is relatively easy compared to this!
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by red_dwarfers »

Does the press need to come out to play to replace the seals?
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

red_dwarfers wrote:Does the press need to come out to play to replace the seals?
No Kev, for seals it's easy. The press is only needed for real hard-core bearing replacement or lift pump work..
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by spider »

Guide looks promising Jim. :)

I've used ATF for testing / lubrication etc when I had no LHM around previously, I'd not had any noticeable ill effects from it. Although not 100% ideal the 'carburettor' type inline element, I used one of those inline with the ATF bottle so there was some extra filtration available.

Note that I did use a vacuum bleeder to 'fill' the pump with derv prior to startup though, mainly to keep the smoke level down on initial startup so the neighbours did not lynch me from the nearest tree, figuring ATF would not combust as well if at all (probably in a fashion) but would likely smoke the street out.

If doing this change the filter afterwards otherwise it will be red stained from the ATF and the law may think you've been using agricultural fuel instead even though you've not, but initial glance would look like that. I guess the same could happen in NI if using LHM as their 'coding' is green I think.
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by shelleyamy »

Jim

Mine has developed a leak from underneath the pump(failed its MOT), looks like where the two halves of the body meet.
Is it easy enough to split and re-seal, and what parts would i need, it runs perfect, just leaks.

Any advice on removing it from the Peugeot 406 2.1.

Would you consider re-sealing it for me,(more than happy to pay).
Thanks,Mike
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

Mike, the replacement of the seal is quite easy and you don't need to go anywhere near as far as I have above. I'll try to put up some pictures of the disassembly required to do that.

As for removing the pump, you can do it without disturbing the timing belt but you do need a special puller which you can make yourself and I can supply diagrams of how to do that. You also need to remove the alternator to give access to the lower fixing nut on the triangular flange. The rest is easy enough and is just a case of disconnecting cables and pipes.

Mark the pump body in relation to the cradle before you remove it to get the static pump timing more or less right. Even so it's a god idea to check the static timing upon refitting and again I have the procedure for that.

I will check on sources of replacement gaskets and seals.
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by shelleyamy »

Jim
Managed to get it off. Did it before your reply, so struggled to do it without removing the alternator. Will be removing it for refitting.
I can't see any obvious signs of leaking, but it was from below, possibly from the little plate,(lower front side) held on my 2 security screws. Only when the engine running, a drip about every ½ second, and doesn’t increase with revs.
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by lexi »

Excellent Pump Pron Jim :shock:

A version of this pump is in Transit too I think.
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

lexi wrote:Excellent Pump Pron Jim :shock:

A version of this pump is in Transit too I think.
And in some Renaults and Fiats :shock:

I do apologise for not continuing this thread but for one reason or another I was unable to do anything forum over the weekend..

I have found a supplier of seal/repair kits for the EPIC. Good news is they're not expensive but the bad news is they're in France...

They are Autodiesel13 and have supplied to the UK before. I have not used them myself but have word from a reliable source on another forum they’re OK.

I'll try to get the photo sequence of the basic strip of as as far you need to go to replace seals up this evening.
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by red_dwarfers »

I bought my seal kit from Electro Diesel in Exeter. They got the kit in next day!
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by Rhothgar »

nice work, Jim though I have visions of you 'moonwalking' around your garage with your trademark Michael Jackson white glove!
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by CitroJim »

red_dwarfers wrote:I bought my seal kit from Electro Diesel in Exeter. They got the kit in next day!
Excellent Kev :-D Saves going to the trouble of ordering from across the channel :-D
Rhothgar wrote:nice work, Jim though I have visions of you 'moonwalking' around your garage with your trademark Michael Jackson white glove!
:lol: :lol: They're not that kind of glove Roger. Think more of a doctor rather than a dancer...
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Re: Lucas EPIC Injection Pump Overhaul Guide

Post by myglaren »

Not like this doctor I hope:

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