Peugeot 405 Manual

Fuel pump - removal and refitting
Fuel/exhaust systems - single-point fuel injection models / Fuel pump - removal and refitting


Note: Refer to the warning note in Section 1 before proceeding. The fuel pump is mounted either on the outside of the fuel tank (external) or on the inside of the fuel tank (internal) according to model.

Removal
External mounted
1 Depressurise the fuel system (Section 8).

2 Disconnect the battery negative lead.

3 Chock the front wheels then jack up the rear of the vehicle and support on axle stands (see УJacking and Vehicle SupportФ).

4 Disconnect the electrical connections on the pump (see illustration).

9.4 Fuel pump showing electrical connections (A) and fuel hoses (B)
9.4 Fuel pump showing electrical connections (A) and fuel hoses (B)

5 Loosen the clips and disconnect the inlet and outlet fuel hoses.

6 Cut through the plastic cable-tie and slide the pump from the rubber mounting straps.

Internal mounted
7 For access to the fuel pump, tilt or remove the rear seat as described in Chapter 11.

8 Using a screwdriver, carefully prise the plastic access cover from the floor to expose the fuel pump. The pump is located under the right-hand cover.

9 Disconnect the wiring connector from the fuel pump, and tape the connector to the vehicle body, to prevent it from disappearing behind the tank (see illustration).

9.9 Unplug the wiring connector then release the fuel feed and return hoses
9.9 Unplug the wiring connector then release the fuel feed and return hoses (arrowed) from the fuel pump

10 Mark the hoses for identification purposes, then slacken the feed and return hose retaining clips. Where the crimped-type Peugeot hose clips are fitted, cut the clips and discard them; use standard worm-drive hose clips on refitting. Disconnect both hoses from the top of the pump, and plug the hose ends.

11 Noting the alignment marks on the tank, pump cover and the locking ring, unscrew the ring and remove it from the tank (see illustration). This is best accomplished by using a screwdriver on the raised ribs of the locking ring. Carefully tap the screwdriver to turn the ring anti-clockwise until it can be unscrewed by hand.

9.11 Unscrew the locking ring . . .
9.11 Unscrew the locking ring . . .

12 Displace the pump cover, then reach into the tank and unclip the pump from the tank base. Lift the fuel pump assembly out of the fuel tank, taking great care not to damage the filter, or to spill fuel onto the interior of the vehicle. Recover the rubber sealing ring and discard it - a new one must be used on refitting (see illustrations).

9.12a . . . then lift out the fuel pump . . .
9.12a . . . then lift out the fuel pump . . .

9.12b . . . and recover the rubber sealing ring
9.12b . . . and recover the rubber sealing ring

13 Note that the fuel pump is only available as a complete assembly - no components are available separately.

Refitting
External mounted
14 Slide the pump into the rubber mounting straps and secure with a new plastic cable-tie.

15 Reconnect the fuel inlet and outlet hoses.

16 Reconnect the electrical connections.

17 Lower the vehicle to the ground and reconnect the battery negative lead.

18 Start the engine and check for leaks.

Internal mounted
19 Ensure that the fuel pump pick-up filter is clean and free of debris. Fit the new sealing ring to the top of the fuel tank.

20 Carefully manoeuvre the pump assembly into the fuel tank, and clip it into position in the base of the tank.

21 Align the mark on the fuel pump cover with the centre of the three alignment marks on the fuel tank, then refit the locking ring.

Securely tighten the locking ring, then check that the locking ring, pump cover and tank marks are all correctly aligned (see illustration).

9.21 On refitting tighten the locking ring until it is correctly aligned with
9.21 On refitting tighten the locking ring until it is correctly aligned with the fuel tank mark (arrowed)

22 Reconnect the feed and return hoses to the top of the fuel pump, using the marks made on removal to ensure that they are correctly reconnected, and securely tighten their retaining clips.

23 Reconnect the pump wiring connector.

24 Reconnect the battery negative terminal and start the engine. Check the fuel pump feed and return hoses unions for signs of leakage.

25 If all is well, refit the plastic access cover.

Tilt or refit the rear seat as described in Chapter 11 (as applicable).


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