Lucas injection pump leak, a new fuel cap (bung) needed

[johnny625]

My XUD engined Xsara has developed a diesel leak on the injection pump. It leaks from the plastic cap on the front on the pump (the one that is used to access the max fuel screw).

Now when the car had some serious injection pump issues I took it to a diesel specialist who took a rather brute force approach towards unscrewing the cap using a chisel and a hammer. He fixed the pump but now about a month later it stated to leak from the visibly gouged plastic plug. I took it back to him and his answer is that he doesn't have a spare replacement cap yet he will gladly sell me a whole Lucas injection pump, lol.

Searching the local french car scrapies I got the same answer, no one sells the cap separately, yet they can offer me a whole pump for about 100 euros which is way too much for a 20 year old pump scrap bought pump.

I am kind afraid of touching the cap on the pump without having another one as a spare. I really need the car and touching the cap for example to tighten it some more might cause it to break or leak even more, basically making the car not driveable.

Has anyone got a spare Lucas pump plastic or preferably a metal cap? I will gladly pay it plus any shipping cost to my country (Macedonia). To my knowledge the caps are the same on all Lucas pumps that were put in Cits and Pugs since the 1980's.

So bummed down today.

[CitroJim]

Do you have a picture of the cap Johnny? I can't visualise it and I know my Lucas pumps well...

If I see it in a good picture I may be able to suggest a solution...

[johnny625]

This how the plastic plug looks like. This is the one that the pump on my Xsara has.




This is how a metal plug looks like.



Exactly the same thread and dimensions and fitted to early Pugs 306, possibly Citroen ZX's and BX's. Also apparently fitted to Lucas pumps in Ford Escorts and Ford Mondeos 1.8 TD's. I actually prefer a metal plug as if any work needs to be done on the pump in the future the plug can simply be unscrewed with a hex wrench instead of smacking it with a hammer and chisel as in the plastic plug case.


I would be so thankful.

[CitroJim]

Ahh yes, I now know the one... Sadly I don't have one now but one option would be to get one made by a machine shop out of aluminium..

For a half-decent shop it would be an easy job...

[johnny625]

That's exactly what I did. I visited a machining shop and in a few hours I got the best looking metal cap I have ever seen. They were even kind enough to machine a bolt head on it only an ordinary spanner is needed for unscrewing.


Fitted it on the car, no leaks what so ever.

[CitroJim]

That's an excellent result Johnny

[Amac]

That's exactly what I did. I visited a machining shop and in a few hours I got the best looking metal cap I have ever seen. They were even kind enough to machine a bolt head on it only an ordinary spanner is needed for unscrewing.


Fitted it on the car, no leaks what so ever.

What was the thread dimensions for that? I have the same issue didn’t realise the plastic was as brittle..

[ekjdm14]

Sure they sell these on evilbay now, I seem to remember getting one a few years back last time I "screwed" with a lucas pump. (at least, they have the plastic ones. metal would be better but not sure what thread it is sorry)