Bosch stop solenoid xantia 1.9 td

[fridgedoc]

Hi peeps
I suspect the solenoid is not working, did stick open a couple of times in the past, due to ill health I haven't used the car for a month or so, I have fuel up to the pump but not at the injectors.
Unfortunately the haynes book is as helpful as a chocolate teapot, it looks like the solenoid is under a plastic housing, I have removed the cover over the wiring and I can see 2 holes full of mastic, I have removed a fair bit of the mastic but cannot see what type of screws/bolts are fitted ie allen key, tork ?? please does anyone know what type/size these fittings are?
Many thanks

[Jaf]

The solenoid is under the “armour”. Hateful stuff. I’ve taken it off 3 pumps now. There’s a brilliant guide on here somewhere. Need to take the pump off the car.

Pic of my pumps you can see the solenoid on the pump with the armour removed.

[fridgedoc]

Thanks Jaf, my cover is plastic not metal and has 4 or 5 wires going to it, I have removed the cover over the wiring and I can see 2 holes full of mastic, I have removed a fair bit of the mastic but cannot see what type of screws/bolts are fitted, these are the only way the plastic cover is held in place

[sparksie]

I don't think you'll get any answers to that, pretty much anywhere.
If you're right about the plastic cover, then it's non standard and nobody will know anything about it, unless you're fortunate enough to catch the attention of whoever made the modification.
In any event, having recently taken the metal armor off my own, with the pump still on the car, I can confirm it's a job best done with the pump OFF!
Once you get it off, whether metal or plastic, the solenoid is a single wire mushroom shaped device, screwed into the top cover of the pump housing . You can just bypass the immobiliser, using the wire that goes positive, from the harness, to power the solenoid directly.
If you're lucky, someone's been in there before you and has already "destructed" the armour and put some sort of plastic camouflage in, perhaps using the original screws. On mine those were small allen headed bolts and I needed two different sizes. I think they were 5mm and 6mm, but it was a few months back, so I'm open to correction

[fridgedoc]

Many thanks for your input sparksie.
This is a standard fitting for cars fitted with an immobiliser keypad (French vehicle)

[Jaf]

Can you put a photo up? Someone might recognise it.

[sparksie]

Yes, a photo is definitely a good idea.
Seriously doubt the plastic can be the only thing covering the stop solenoid. To comply with anti-theft regs, the armour has to be hard enough to deter would be thieves, who may well be equipped with portable soldering irons and could slice away plastic quickly and quietly, leaving the solenoid just as vulnerable as ever.
As an added benefit, the metal armour, to which the standard immobiliser is attached, works well as a heat sink, cooling the immobiliser. The plastic you seem to have, will not do this.

[fridgedoc]

Photos as requested .......
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I am sorry for delay in posting my health is not great at the moment, I hope that these photos are ok,
on one of them you can see the Bosch part number, it might be handy

[sparksie]

Wow!
Never seen that and I've seen plenty of XUD engines with Bosch injector pumps over the years, including some with keypad immobilisers.
I don't think that's a cover. That looks like an integrated circuit .
I think we may need Marc to get us a diagram of this, before we can advise on removal techniques.
I'll just pre-empt him and tell you he won't be able to look up your car without the VIN.
Don't worry about confidentiality, posting that. Only admin can see VIN numbers. The clever software recognises them and hides them from the rest of us.

[MikeT]

That simply looks like a de-armoured pump to me.

AFAIR, the bolts are torx though I've not seen them protected with potting compound before.

[sparksie]

Well, it certainly doesn't look like MY dearmoured pump!
Mine looks like the one posted by Jaf, a few posts back.
I stand by what I said about it not being a cover. That's an electronic component and not dismantleable.
When the screws are identified and removed, I'd be interested in a further pic, showing the electrical connection behind it.

[MikeT]

As luck would have it I've just unearthed a box of dismantled pump bits and the component in question is among them. The bolts are hex (allen key) - will get an accurate size if still needed, but they look no larger than 5mm to my ailing eye.

The part looks similar to this one

[fridgedoc]

MikeT, you may well have cracked it, I will know this morning, he says hopefully

[fridgedoc]

Nice try MikeT ....... "The bolts are hex (allen key)" ...... not on this one, after an hour or so trying my best to get the mastic out (blindly) and trying Allen keys and Torx, I played around with a hardened nail, could not feel the center of the bolt, then the penny dropped ..... phooking shear bolts.
I have spent the last hour with a drill, hammer and chisel, it's a pretty tough plastic and partly reinforced with s/steel, I am totally knackered now will try again tomorrow, if it's not raining

[white exec]

IIRC, Bosch have a website/publication with full details of their diesel pumps, including drawings of all their parts, and full description.