peugeot 206GTi fuel pump casingcracked
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Thread: peugeot 206GTi fuel pump casingcracked

  1. #1
    UNM
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    Default peugeot 206GTi fuel pump casingcracked

    My old 206GTi came back home yesterday for me to fix the lower engine torque mount bushing.

    For some time now, there has been a slight petrol smell from outside the cabin.

    I investigated and find there is a pinhole leak on the fuel return line fitting as it enters the fuel pump casing.

    So, anyone got a spare fuel pump? recommend a place to get one if not? Could this be repaired with fuel tank repair putty? It seems to be under some pressure as I can see a very fine spray/stream of petrol from the pinhole when the engine is running.


    Are the fuel pump connectors easy to get off?


    I feel I should fix it for the new owner, even though it is not something we agreed on as part of the sale.

    Todays main task is to get a rental car while my own car is written off and to fix the engine bushing. Anything else I can get done is a bonus.

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    Edit: Looking at Haynes manual, pump seems identical to 307 fuel pump and connectors have a push button to release connector. Much easier than some makes I have worked on.


    Imlachs will charge me about $50 to $60 for a complete fuel pump assembly and as it is a common part, should be easy to find. That is likely the best option, rather than a half-assed plastic repair.
    Last edited by UNM; 9th February 2016 at 12:02 PM.

  2. #2
    the famous 18E pug206gti's Avatar
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    G'day,
    do a bit of a search back through the threads. I had a similar problem. We tried some glue stuff, Bond - X or similar. Ended up buying a new pump. Make sure you buy a pump with the connectors facing the correct way. I seem to remember there is a right and left hand version. Best of luck.
    regards,
    Les W.


    206 GTi 180
    the stealth Pug
    Did I do anything last night that suggested I was sane?








  3. #3
    UNM
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    thanks for that. According to google searches, glueing fuel pumps works sometimes. It is the best thing ever. It is useless. etc. etc.
    Without knowing the exact plastic the pump is made of, I don't want to apply glue that is not going to chemically bond to the existing plastic - especially as it is under pressure.

    Excellent point to check direction of connectors.

  4. #4
    UNM
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    I swapped out the pump today with a used one sourced from a wreckers. While removing the old pump, the retaining ring split (see photos)
    peugeot 206GTi fuel pump casingcracked-img_20160211_132700.jpgpeugeot 206GTi fuel pump casingcracked-img_20160211_132748.jpgpeugeot 206GTi fuel pump casingcracked-img_20160211_132807.jpg


    Fortunately, when removing the replacement pump at the wreckers, I took a good condition retaining ring (phew).

    A couple of things worth noting about the pump replacement. I found a citroen C5 at the wrecker and the pump retaining ring and connectors looked like mine, but the ring had been butchered by somebody already, looking like the pump had already been replaced. When I got it out I found it was unbranded, with part number E10304M and had a date code of 2010, but I was not absolutely certain it was a match, so I took a VDO pump (part 9638038780) out of a peugeot 406, which google said was suitable for a 206. Once I compared the pumps side by side, they were same height top to bottom, same diameter top and the C5 pump fitted perfectly in the 406 tank.

    As the C5 pump was in significantly better condition visually and 10 years newer I bought it, fitted it and it is working fine, fuel gauge reads perfectly accurately.


    Google claims the E10304M is an Airtex pump assembly, suitable for Peugeot 307 1.6 2000 on. No mention it is compatible with the 206, but it certainly is.

    Incidentally, the second photo shows an alignment mark. This should be pointing directly to the front of the vehicle to start screwing it down and when completely screwed down it should face to the left of the vehicle, where there is a corresponding alignment mark on the fuel pump.
    Last edited by UNM; 11th February 2016 at 01:48 PM. Reason: add info

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    UNM
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    The new owner of my car had an issue with petrol dripping from the tank if he filled it right to the top just after getting it.

    I referred him to an independent peugeot specialist in Surrey Hills as I was too busy to help at the time and suggested that the o-ring probably needed replaced.

    He took it in there and they informed him that 'someone had worked on the fuel tank and it has a crack in it' (so he told me). He apparently confirmed with them that they had seen the crack. They quoted $700 for a new fuel tank, plus fitting. I obviously felt bad as I thought I may have botched something, even though I enlisted the help of a neighbour with over 30 years experience as a mechanic.

    So a couple days ago, having sourced a used petrol tank, he turned up for me to fit the replacement tank.

    I removed the tank very easily using the instructions at peugeot206cc.co.uk. Only took about 45 minutes to disconnect the exhaust handbrake and drop the tank. We then flipped the tank and it dripped from around the O-ring.

    Removed the fuel pump lock ring, reseated the O-ring, re-tightened the lock ring, all good and no leaks when tank is filled to the brim. Nice to know my original diagnosis was accurate.
    addo likes this.

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    1000+ Posts N5GTi6's Avatar
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    Something to be said for the 'professional' v's the home mechanic.....

    Hope you were able to return the used tank

    Cheers

    Justin
    '07 C3 Exclusive
    '10 308 Sportium Touring
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    UNM
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    Quote Originally Posted by N5GTi6 View Post
    Hope you were able to return the used tank
    Regrettably no. Shipping back to Canberra would have been way more than the value of the tank.

    As my friend lives with his aunt, he didn't want to clutter up her place with an unwanted fuel tank, so he kindly left it in my garage instead with instructions to try and sell it.
    The tank is now listed on aussiefrogs under the parts for sale section. I also still have the old fuel pump which would be useful for a working fuel sender, or pump cartridge insert if anyone wants one and is willing to swap across a good pump top plate.

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    Contented Peugeot Driver addo's Avatar
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    Now the pump is bone dry, worth giving it a two second buzz with the battery, just to stop it seizing.

    There's a lot of interchanges with pump motors, always good to have a spare 3 Bar one on the shelf.

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    Been thinking about applying the heat gun to try and get the fuel line connections off it without having to cut them. Reckon that would work? It has now been a couple months since it was disconnected, so will not have any lingering fuel vapour, but I don't know how flexible those lines get under heat. Most insert replacements seem to use regular jubilee clips and aftermarket rubber fuel line rather than the original plastic.

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