Peugeot 405 Manual

Fuel pump - testing, removal and refitting
Fuel/exhaust systems - carburettor models / Fuel pump - testing, removal and refitting


Note: Refer to the warning note in Section 1 before proceeding.

Testing
1 To test the fuel pump on the engine, disconnect the outlet pipe which leads to the carburettor. Hold a wad of rag by the pump outlet while an assistant spins the engine on the starter. Keep your hands away from the electric cooling fan. Regular spurts of fuel should be ejected as the engine turns. Be careful not to spill fuel onto hot engine components.

2 The pump can also be tested by removing it. With the pump outlet pipe disconnected but the inlet pipe still connected, hold the wad of rag by the outlet. Operate the pump lever by hand, moving it in and out; if the pump is in a satisfactory condition, the lever should move and return smoothly, and a strong jet of fuel should be ejected.

Removal
3 Identify the pump inlet and outlet hoses, and slacken both retaining clips (see illustration).

4.3 Arrows on raised fuel pump unions indicate the direction of fuel flow
4.3 Arrows on raised fuel pump unions indicate the direction of fuel flow

Where the crimped-type Peugeot hose clips are fitted, cut the clips and discard them; use standard worm-drive hose clips on refitting. Place wads of rag beneath the hose unions to catch any spilled fuel, then disconnect both hoses from the pump; plug the hose ends to minimise fuel loss.

TU engine
4 Where fitted remove the insulating cover from the fuel pump, then slacken and remove the bolts securing the pump to the rear of the cylinder head. Remove the pump along with its insulating block. Check the block and renew it if necessary.

XU engine
5 Unscrew the nuts securing the pump to the distributor end of the cylinder head and lift off the pump (see illustration).

4.5 Removing the fuel pump (XU engine)
4.5 Removing the fuel pump (XU engine)

6 Remove the insulating block from the studs on the cylinder head.

Refitting
7 Ensure that the pump and cylinder head mating surfaces are clean and dry, then offer up the insulating block and refit the pump to the cylinder head. Tighten the pump retaining bolts/nuts to the specified torque, then refit the pump insulating cover where fitted 8 Reconnect the inlet and outlet hoses to the relevant pump unions, and securely tighten their retaining clips.


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