XM 2.5 won't start

[endorfin]

There was no delay, it turned off instantly. More bizarrely, when I removed the plunger and started the car, after the usual cranking it started...then I realised I hadn't even connected the live to the solenoid. So it will start with a solenoid with no plunger and no live?

Anyway, it is definitely an air leak....I thought it may be a porous fuel filter pump so I replaced the whole thing with one of these heated fuel filtered, but without the heated element fitted and a spin on filter. I added a squeeze bulb to the fuel line going into the filter head and primed it, bleeding fuel from the bleed screw. It started after some cranking as usual, switched off and left it for 5 mins and tried again, same problem, wouldn't start, squeezed the bulb until firm and it started. Got to be an air leak either in the fuel pipe or the fuel pump seals.

Replacing the bulkhead fuel hose looks simple enough, if that isn't it then may be the metal pipes? or tank strainer...what else can it be?

[xmexclusive]

Put the clear hose on the supply side before the squeeze bulb.
Look for fuel present when you leave it.
Look for air bubbles after it has been left.
Hoses behind the engine are a pig to tighten clips on.
If you want to be sure first try with the clear hose into a can of diesel.
Pump fuel up with the squeeze bulb and try to start and run.
The fuel pump is on the engine and sucks fuel up from the tank.
Air leaks here play havoc with starting.

When you ran with no plunger in the solenoid the only reason for reconnecting the wire was to avoid a loose live wire.
No plunger present leaves the fuel feed open all the time.

John

[endorfin]

That's a good idea, will try with a clear hose in a can of diesel and see if this eliminates the problem, won't be able to do this until Monday now as I'm away til then. Also on Monday I need to take the XM to Wales to pick up a 1.9 XUD engine for the ZX, at least I can get it started with the squeeze bulb. Will try with a hose in a can of diesel 1st and if this eliminates the problem will try to fit a new supply hose on the bulkhead.

[endorfin]

Update on this, took the car to my brother's garage in North Wales...he put the supply and return pipes (fresh hoses) from fuel pump into a can of diesel got engine running, then left it for half hour to see if problem was still present. When we tried to start it in half an hour it took bit of cranking before it fired so it's looking like the problem is the fuel pump somehow.

I've a squeeze bulb on the supply pipe and a one way valve on the return pipe but problem is still present, it must be drawing air in through the pump, or injectors?

I have a spare Bosch VP37 pump, off another 2.5 (marc61's old 2.5 exclusive) but putting it on is beyond my abilities and it's a big job to get a garage to do for it to turn out not to be the pump!

[marc61]

Endorfin, this must be driving you bonkers!

Think I'd try swapping the glow plug relay for a spare one if you've got one. Failing that if you leave the ignition on for 6-8 seconds after the light goes off, does it start any better at all? If better, then I'd get a relay.

Are you certain there's no diesel leaking or dampness anywhere upstream of the pump - anywhere between the tank and the pump? Have a look where it exits the tank underneath the back seat, nothing damp or cracked?

Cheers

Marc

[endorfin]

I wish it was related to glow plugs but I don't think so as if it were it would start again easily once it was warm but even 20 mins after running all day it will fail to start again, it's definitely air leak in fuel somewhere. I think we eliminated everything else when we put supply and return pipes directly from fuel pump into a can of diesel and problem was still there. It's almost certain it's the fuel pump.

Will be taking it to a pump specialist soon for a test.

[endorfin]

I finally sent the car to CMS Citroen in Bexhill, I should have taken marc61's advice and checked the glow plug relay was working cos turns out that the live feed to the glow plugs had failed (not the relay itself, just the wire) Got an email back from the garage the same day to say it was all fixed.

Was a bit taken aback by how much CMS charged me, £93.20 of which £6.50 was parts (£5 wire and £1.50 for 2 clips) and the rest labour!

Really can't think why I didn't check the relay after being advised to here, especially when I changed all the glow plugs in case it was that. I think I was so convinced it was connected to the fuel pump I disregarded everything else, to my expense!

[marc61]

Glad it's sorted! Life's like that. I reckon the human brain prefers to convince itself that the problem is complex and that things are much worse than they are, before going back to being objective again and discovering the problem was much simpler to solve. That pretty much sums up the majority of my experience when attempting to fix Citroens at least!

Cheers

Marc