Lucas Epic Injection Pump Repair Manual
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Quick update:
Decided to have the re-seal work done for me,(couldn't face refitting and still leaking). First couple of calls resulted in 'won't touch em mate'. So took it into P B Asher in Southampton, the guy there knew what it was and what leaks on em. Agreed to split and replace seals and o rings and then pressure test for £130 and I would supply the kit. And will turn around when I get the kit to them.
'I bought my seal kit from Electro Diesel in Exeter. They got the kit in next day!'
Kev, I got back to late to call Electro, how much was the kit?
MikeThe Lucas EPIC Injection Pump as used on the XUD11BTE engine as fitted to 2.1TD Xantias and later 2.1TD XMs is generally reliable but can suffer leaks and problems with the ESOS valves. Both are relatively easy to resolve but need the pump to be fully disassembled. This is a guide on how to do just that and covers the complete disassembly and reassembly.
The EPIC, compared to the earlier DPC and the Bosch VP/AS series is actually quite and easy pump to work on. One job needs a press but for most jobs you will not need to disassemble this far.
(Due to how I'm covering this job over on Club-XM it is at the moment a little out of sequence as I've actually done the most difficult reassembly bit first after my initial experimental disassembly. This will be corrected in due course and so I can insert the relevant stages later I've made some place-holder threads)Before disassembly the entire pump must be thoroughly cleaned and drained of all diesel as far as possible.
To disassemble fully a hydraulic press will be needed. Apart from that no other specialist tools are required bar for a good Torx set, a 32mm spanner and a few pin punches.