Xsara 2.0 HDI high pressure fuel pump removal

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willy
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Xsara 2.0 HDI high pressure fuel pump removal

Post by willy »

Other than getting off aux and timing belts anyone have any general tips on removing the high pressure fuel pump please. Are there any obscure tools or any parts I need to replace?

I'm taking it off to have a go at trying to seal one of the cylinder housings.
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by Peter.N. »

I am about to do one myself so can't speak from experience. You will need an 8mm square drive to retract the timing belt tensioner, I got an 8mm 3/8 drive sump plug socket from ebay for very little money. Otherwise I think its fairly straightforward, the pump doesn't have to be timed of course, replace the timing belt and water pump while you have it apart.

Peter
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by spider »

And new high pressure pipes if you disturb any.
Andy.

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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by citroenxm »

I DID this on a Xantia last night in an HOUR and TEN mins!!

Swapped pumps without removing the timing belt too and it all went back together perfectly. Didnt replace any pipeing either ALTHOUGH this IS highly recomended..

Remove the harness, remove the two low supply and return pipes from the top, remove the third piston plug, and the pressure regulator / stop plug on the end.. If you need to remove the fuel filter and its bracket from the block.

The pump is secured on by three 13mm nuts.. Two are up against the oppisite side to the pully, pump side against the pump brakcet, one hidden round the back, one at the front, the other one is on a bracket that is hidden just behind the pressure stop solinoid. The solinoid is the thing that points downwards on the end of the pump..

The pump nut for the pully is 21mm.. Now, what I did was leave the belt cover in place but took the 10mm nuts out and just eased the cover away enough to get a 21mm ratchet spanner on the nut.. remove the nut, then between the pump body and pump bracket force with a light hammer a large screw driver... the pump then popped off the pully.

If you can under stand any of that, even I cant... 8-[ 8-[ :| :?

These pump are NOT TIMED so theres no problem putting them back on after...

Really should of done a pictorial, but I was against the light and it was just turning dark when I finished...

My high pressure feed pipe just happened to work, but its common for them to not re seal after being done up again.
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by spider »

I think the thing that put me off reusing the HP pipes were the tails of a nice long jet of fuel at that kind of pressure, a bit different to the pulses output of an IDI unit. I think the 'jet' would only occur if anyone was silly enough to leave one disconnected or even worse attempt to open it while running *shudder*, I recall someone said seven metres but I cannot see it having much pressure left at that kind of distance.

It is annoying that the pipes are only meant to be used once though given their fittings, price to pay for a common rail unit I guess as it appears all marques insist on pipe replacement if disturbed. I know they can be reused with some care but um it is shame that the design indicates they cannot.
Andy.

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02 106D, TUD5B, gone but not really missed apart from the MPG
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by Peter.N. »

I think the reason they give for not reusing them is because of the possible presence of swarf from moving them getting into the fuel system - I think I will probably take a chance though.

Paul.

Is the pully on a seperate bearing?

Peter
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by citroenxm »

No Peter, its a tapered shaft on the pump, and the pully just pulls up onto it and tightens up..

Theres NO keyway..
Sharing a pug 207 1.6 hdi Sw 16v.
M reg Xm 2.1 td auto exclusive S2 269k and rising
L reg XM V6 12v SEi auto .. Light project

A very sad...
1994 XM 2.1 d auto
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by willy »

I wasn't going to replace the pipe now I'm worried. Where is the best place to get one from?
citroenxm
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2008 Peugeot 207 Sw 1.6 16v hdi. 217k and rising
2010 Peugeot 207 SW 1.6 8v HDi 161k and rising
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by citroenxm »

Dealer only i think.. i don't think they are silly expensive either...
Sharing a pug 207 1.6 hdi Sw 16v.
M reg Xm 2.1 td auto exclusive S2 269k and rising
L reg XM V6 12v SEi auto .. Light project

A very sad...
1994 XM 2.1 d auto
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by RichardW »

3 different ones, depending on the age:

Part Number Description Quantity Price excl. VAT Price incl. VAT Total incl. VAT Selection
0000157082 INJECTION PUMP OUTLET PIPE 25.26 GBP 30.31 GBP 30.31 GBP

00001570F2 INJECTION PUMP OUTLET PIPE 17.87 GBP 21.44 GBP 21.44 GBP

00001570J9 INJECTION PUMP OUTLET PIPE 17.79 GBP 21.35 GBP 21.35 GBP

I'd just clean it and put it back together, then check for leaks - but NOT with a bare finger!!
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by wheeler »

I thought I would add to this & say I have re used more HDi hp fuel pipes than I can even remember (easily well over 100) and I've never had one come back leaking yet.
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by Peter.N. »

Thanks for that assurance, I would certainly have tried anyway.

Peter
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by willy »

Yes thanks for that experience I will try to re-use but with care to keep clean and monitor with caution.
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by willy »

Right
I've sealed the fuel pump, it was a very small o-ring which had perished and now the car doesn't leak.I started the car after doing the belts and it ran it to warm up the coolant (did the water pump at the same time) the car ran perfectly. Took it for a test run and every so often there was a rough tappety sound which sounded like something was iminently going to fail so I slowed down at went back to check if i'd left something loose. Nope nothing loose.
Went back out on test run, no noise. Had another look in the engine and still no problem, fuel pump dry. Went out on a final test run and after a few minutes a tappety sound, almost like a misfire. Is it possible I could have got some dirt into the pump whilst i was cleaning it? If so what have I risked doing to the injectors?
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Re: Xsara 2.0 HDI high pressure fuel pump removal

Post by jgra1 »

Paul..

I have a spare pump for car,. I may change it tonight.. can you confirm that you didn't un-tension the cambelt for pump changeover?

John
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