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Old 29-09-17, 07:09 AM   #1
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Join Date: Sep 2017
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Default Boxer 1998 2.5 turbo diesel fuel pump leakage

I'm currently in France on vacation with our motor-home based on a Boxer 2.5 turbo diesel from 1998 and have problems.

We've had issues with the fuel system for some time. Normally if I start up the engine after being off overnight I would have to keep the engine on until it is warm. If I turned it off before it was warm I wouldn't be able to start it up again without having to pump the air out of the system over and over until it eventually started. Once warm I could turn on and off without issues.

Now the engine cut out when it was cold but it won't start after many attempts. The difference now is that when I try to pump the air out, I hear gurgling noises and fuel starts to leak from the fuel pump about where the throttle arm/wire goes into the pump.

The van has been towed to a garage, but the amount he has suggested to repair the van is more than what I paid for it in the beginning. And as this is France and I can't speak French I am unable to communicate well as almost everyone I have spoken to about this does not understand what I'm talking about.

I found this on a Fiat forum when searching: "I have sorted the fuel leak by taking off the actuating lever and putting a couple of o rings on the shaft,replacing the lever this pressed down the orings therefore sealing the leaking fuel." It was for a 1997 Ducato 2.5 diesel.
It sounds like something I could try, but is that something I could do myself? Can it be done with the pump in place or does it have to come out? Does the Boxer have the same fuel pump as the Ducato?

On another forum I got a tip to contact a local diesel specialist, but doing so without being able to communicate in French isn't easy (I've had a go).

Does anyone have any tips or temporary solutions I could try? We have so many hours invested in building our motor-home and over a month of vacation left so we are very reluctant to walk away, but the price the mechanic as asking for is jaw dropping.
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Old 29-09-17, 04:41 PM   #2
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Join Date: Oct 2012
Location: falkirk
Posts: 13,928

boxer and ducato are the same van but there are many engines some fiat some peugeot fuel pump will be bosch or lucas/cav not made by peugeot or fiat

Sounds like the shaft seal is leaking but to be honest the engine should still start like that you could force feed it with an electric primer pump this would probably get it going but your pump probably needs an overhaul as the cutting out is due to the pump too.
assume nothing check everything twice !!
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Old 29-09-17, 05:56 PM   #3
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Ok, thanks. We went back to the garage this afternoon and he had started pulling this apart and gave us a quote for overhauling the pump. It was extremely high but we checked towing costs to get it towed to another garage, and that was pretty high too, and no guarantees that the next garage won't give us the same price... So we said yes... Now we are committed. I hope he knows what he is doing.
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Old 30-09-17, 10:27 AM   #4
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Join Date: Apr 2014
Location: Lanark
Posts: 143

Hope he doesn't just fit a couple of o rings and charges you a fortune. I've had bad experiences with French garages in the past, They tried to charge me again for the tow to the garage which had already been agreed to be paid for by the breakdown insurance. keep and eye on them and check the invoice and make sure nothing has been added on that wasn't agreed. Don't sign for the repair until you're 100% happy. Good luck.
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