Fuel pump cover removal

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BigAl
Newbie
Posts: 1
Joined: Wed Jan 01, 2020 12:58 pm

Fuel pump cover removal

Post by BigAl » Wed Jan 01, 2020 1:18 pm

Hello Everyone.
Is anyone able to help with what should be a simple job? I need to get to the fuel pump under the rear seat on my recently acquired 2004 406 2.0HDI Estate (110bhp). Lifting the rear seat and insulation reveals a black plastic round access cover about 8-9 inch diameter with indentations, which is reluctant to shift. It rotates by about 20 degrees, but won’t lift out. I’m hesitant to get a screwdriver under it to lever it in case of damaging it. I’ve done my own car maintenance for 40 years so am not a novice, but this has stumped me so far. Any help would be much appreciated.

PeterN
3.0 24v
Posts: 1527
Joined: Sun Mar 04, 2012 7:04 pm
Location: Charmouth, Dorset

Re: Fuel pump cover removal

Post by PeterN » Thu Jan 02, 2020 10:42 am

Yes it is tight, it possibly hasn't rotated far enough but its difficult to put enough force on it without chewing up the plastic. Ideally you need to make up a tool that will fit several of the notches unless you can find something that will fit.

Peter

GingerMagic
3.0 24v
Posts: 3229
Joined: Fri Apr 06, 2012 9:02 pm
Location: Bournemouth

Re: Fuel pump cover removal

Post by GingerMagic » Thu Jan 02, 2020 1:21 pm

Hammer and a piece of wood - gently tap it either way to align the slots to lift it out....
It's like a massive fuel filler cap - be careful though as the edges are sharp.
1999 T4 family wagon
2005 Vauxhall Meriva
1998 406 V6 Coupe - Midlife crisis..!
PP2000 user, can help with faults / diagnostics in the Bournemouth area.

frog
2.0 Turbo
Posts: 260
Joined: Sun Aug 24, 2014 12:18 pm
Location: Netherlands

Re: Fuel pump cover removal

Post by frog » Thu Jan 02, 2020 10:53 pm

I fabricated a special tool for it. Making the tool took two hours of work, then the removal of the lid was done in about 30 seconds.

Here are a few photo's of the tool. It is really simple yet very firm. The bar is about 1 meter, good for giving enough torque. The slots in the metal hooks are cut in such a way that they fit exactly over the plastic bumps in the tank lid cover.

The metal hooks are 5mm thick. Don't use the 2 mm thin ones; they will wobble and are not able to transfer the force.

There is no special reason that the bar is not straight with the metal hooks; I just drilled the holes wrong so I drilled a couple of new holes next to the old ones...
Attachments
IMG_20200102_224339.jpg
(215.05 KiB) Not downloaded yet
Last edited by frog on Thu Jan 02, 2020 11:02 pm, edited 2 times in total.
Current "fleet":
2003 406 Estate 2.0HDi 110 - 7 seater
2001 Citroen Saxo 1.6i 8v 100

Previously owned:
2000 406 Sedan 2.0 HDi 90
2000 406 Coupé 2.0i 16v 138 - Riviera Blue

PP2000 user, can help with faults / diagnostics in the Netherlands.

frog
2.0 Turbo
Posts: 260
Joined: Sun Aug 24, 2014 12:18 pm
Location: Netherlands

Re: Fuel pump cover removal

Post by frog » Thu Jan 02, 2020 10:54 pm

More pics:
Attachments
IMG_20200102_224434_1.jpg
(193.82 KiB) Not downloaded yet
Current "fleet":
2003 406 Estate 2.0HDi 110 - 7 seater
2001 Citroen Saxo 1.6i 8v 100

Previously owned:
2000 406 Sedan 2.0 HDi 90
2000 406 Coupé 2.0i 16v 138 - Riviera Blue

PP2000 user, can help with faults / diagnostics in the Netherlands.

frog
2.0 Turbo
Posts: 260
Joined: Sun Aug 24, 2014 12:18 pm
Location: Netherlands

Re: Fuel pump cover removal

Post by frog » Thu Jan 02, 2020 10:54 pm

And the last pic (this forum seems to accept only one attachment at a time...):
Attachments
IMG_20200102_224507_1.jpg
(193.09 KiB) Not downloaded yet
Current "fleet":
2003 406 Estate 2.0HDi 110 - 7 seater
2001 Citroen Saxo 1.6i 8v 100

Previously owned:
2000 406 Sedan 2.0 HDi 90
2000 406 Coupé 2.0i 16v 138 - Riviera Blue

PP2000 user, can help with faults / diagnostics in the Netherlands.

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