Xsara - Key symbol and not starting - engine swap

[xsaras4ever]

Hello again to the forum from France.

Our son's xsara DW8 1.9D estate decided to join our group of ill-functioning Xsaras by breaking its cambelt.

We popped the engine and box out, and the camshaft was broken in 2 places and one of the valves was stuck.

Rather than do the head with valves and a cam and then a new timing belt and head-gasket, we decided to buy a donor.

He bought a Xsara Commercial with a DW8 in perfect running order for 430euros.

He took out the engine and box and transferred his original wiring loom to it and has fitted it to his Xsara estate.

He made a mistake - he mixed up the earth wire to the engine with the positive wire to the altenator (because they were both covered in oily muck) - connected the negative lead to the battery, touched the positive lead to the battery for about 10 seconds - it sparked and he removed it instantly.

Discovered the error, changed the wires to their correct positions, reconnected the battery.

Car turns over, does not start - key symbol is illuminated on dashboard.

We have disconnected the battery for 5 minutes , reconnected it , tried the door locks. they work with the key.

When trying the start again , key symbol stays on , car turns over but does not start.

Is it a visit to the Citroen dealership, or is there some fantastic convoluted procedure we can follow ?

Thanks again to all.

[xantia_v6]

Have you checked the fuses, including the big maxi-fuses?

[furriegurrie]

if you have a lexia and the code required you can try to registered the keys again to the car.
We had only 1 key for our Xsara 1.9TD. I ordered a spare key on VIN number with the dealer. He was kind enough to provide the 4 character code (car specific) so I could register the new key to the car.
If you do this make sure you do all the keys as it removes previously stored keys (and rf modules).

[xsaras4ever]

Hello .

yes, have checked all fuses and no, unfortunately don't have a lexia.

Its about time we bought one - anyone recommend a good supplier and price ?

Thanks.

PS: Any other suggestions ?

[furriegurrie]

I got mine through some Chinese company, it's been a while a I don't have the details anymore (and I'm not sure if the seller would still be present on Ebay.
I do not have that much experience with the Xsara, but as far as I know you'll need to have the keys re-registered with the car if that key symbol is lit.
That'll have to be done through the computer, I'm unaware of any other option...

[xsaras4ever]

Thanks again.

Before we go down the route of getting the keys re-coded, we have some questions.

1.) As the indicators and all other electrics work, it it possible for us to hotwire the stop solenoid on the diesel pump to allow us to drive the car to the dealership ?

2.) Would he have damaged the ECU ?

3.) Is the problem caused by the error in wiring or by the engine swap (ie: is there some electronics in the diesel pump which are fighting with everything else ? )

Thanks

[xsaras4ever]

Is this a good Lexia for us to buy and has anyone used this seller ?

http://www.ebay.co.uk/itm/Lexia-3-Diagn ... 0#shpCntId

Also ,

Can someone educate us on this matter

We understand that the ECU has a code and the key and ignition has a code. The key is inserted and turned, the ring around the ignition reads the code, it is passed to the ECU and compared to the code there and if it is good, off it goes to the injection pump.

Our question is ---

Is the gubbins in the injection pump intelligent or dumb : ie : does it just receive a signal to start working or does it also have a piece of electronics which contain a code and this code has to be compatible also ?

The reason we ask is because we used the replacement enine complete - with its injection pump.

Thanks

[addo]

Does the engine have its own ECU in a separate box?

[astramanmazdaman]

The pump solenoid may well be coded, does it have 3 or more black wires going into it from a multi plug ? the solenoid can be changed to an old fashioned one after the security casing has been removed enough for the solenoid to be changed then hot wired to the reverse light switch +ve on the gear box ,my old zx has been like that for 12 years and its still going strong with its new owner,
removing the pump casing is a real pain much better to remove the pump and do it off the car,and change the cambelt etc.

[spider]

99% of UK spec DW8's have the module around the pump, usual affair.

[xsaras4ever]

Its fixed at last.

Our son started cutting the module off the back of the BOSCH pump - a much larger lump of metal than is on the LUCAS pump.

On the last bolt he damaged the casing on the top of the pump.

So we unbolted the whole top and found a top off a much older BOSCH in our garage.

We fitted that, plus an old simple solenoid from the same older Bosch.

We heated the diesel pipes to fit in with the new shape and pretended the EGR did not exist.

Car fired up first turn and after adjusting the throttle-lever so a better set of splines on the shaft, it runs great.

In fact, a hell of a lot faster than it used to be and no difference on fuel consumption.

The accelerator pedal returns to idle a bit faster because there in only the spring on the pump now and no cushioning effects, but its not an inconvenience.

And the top of the pump does not leak even though we didn't change the seals - a minor miracle.

Once again, thanks to everyone on the forum for their kind help.

One car back on the road - plenty more to go !!!!!