Fuel Pump Housing/tank Seal?

[Ronin]

My Brother in law has just bought a C5 1.8 16v 01 plate virtually identical to mine at a car auction (oh dear)!!!! Told him not to but he liked mine and got the old auction fever.

 

He has noticed a smell of petrol and came over for advice. I checked the fuel lines and removed the undertrays to get a good look and everything was fine. I also looked around the fuel tank and found nothing until I lifted up the rear seat bench and removed the black plastic seal that hides the top of the fuel tank.

 

Needless to say this was the culprit. It is sloshing out of this seal.

Now before I go and remove the housing and try to re-seat it (looks like it hasn't been screwed on properly as the white assembly can be pushed up an down) I just want to know is there a knack, a risk or anything I should know before tackling it. I dont want to cause more problems as the the car seems to be running fine otherwise.

 

I have had experience with the xantia fuel tank so i'm not afraid to give it a go... Some advice would go a long way and is much appreciated guys... Especially considering that Haynes haven't brought out a manual for the C5 yet !

 

Oh and can you buy a seperate "o" ring seal for the top of the fuel tank or does it come as part of a kit?

I seem to remember being able to get a new one for a xantia once as it was a "replace once removed" item.

 

Thanks in advance.

[Ronin]

My Brother in law has just bought a C5 1.8 16v 01 plate virtually identical to mine at a car auction (oh dear)!!!! Told him not to but he liked mine and got the old auction fever.

 

He has noticed a smell of petrol and came over for advice. I checked the fuel lines and removed the undertrays to get a good look and everything was fine. I also looked around the fuel tank and found nothing until I lifted up the rear seat bench and removed the black plastic seal that hides the top of the fuel tank.

 

Needless to say this was the culprit. It is sloshing out of this seal.

Now before I go and remove the housing and try to re-seat it (looks like it hasn't been screwed on properly as the white assembly can be pushed up an down) I just want to know is there a knack, a risk or anything I should know before tackling it. I dont want to cause more problems as the the car seems to be running fine otherwise.

 

I have had experience with the xantia fuel tank so i'm not afraid to give it a go... Some advice would go a long way and is much appreciated guys... Especially considering that Haynes haven't brought out a manual for the C5 yet !

 

Oh and can you buy a seperate "o" ring seal for the top of the fuel tank or does it come as part of a kit?

I seem to remember being able to get a new one for a xantia once as it was a "replace once removed" item.

 

Thanks in advance.

 

 

Well I managed it but it was a chew on simply because it is fairly cramped to get your hands in through the inspection hole.

here is a run down for anyone who needs to do this in the future. It's basically the same proceedure for all C5 petrol models.

 

You need two parts from the main dealer (don't worry, they aren't expensive)

1. "o" ring gasket seal for fuel tank (blue in colour)£7.36 inc vat

2. Plastic circlip for the main fuel pressure hose (you can't re-use this item as you have to physically break it up in order to remove the hose)£2.24 inc vat

 

MAKE SURE YOU HAVE LOW FUEL IN THE TANK FIRST!(it stops the housing from rising back up)

 

remove the inspection cover (underneath the rear bench seat) disconnect the main multiplug that connects to the white housing( usually yellow) then try to start the engine a couple of times. This helps to depressurise the fuel line.

disconnect the negative battery terminal.

Disconnect the two other multi plugs on either side of the housing (blue)

make sure you move the cables out of the way of the housing assembly but make sure they dont drop down the side of the fuel tank.

Cover main housing multiplug terminals with tape( you'll find out why later).

Push the fuel line onto the its connecter as far as it will go while using a thin flatblade screw driver to lift the white plastic circlip as far as it will come out from the hose end (this is where you need three hands)

Now use some snips and cut through the white circlip only!!!. Use a set of needle nose pliers to remove the remaining circlip bits.

Now get an old rag and place it over the hose end and gently tease the hose from the housing. Be prepared for some fuel under pressure to remain in the system to splash back out at you (thus the tape over the terminals!!!).

Now all that remains is to remove the large plastic black ring that secures the housing in place.

Use a large flat blade screwdriver and a hammer against the plastic raised lugs around the outside of the securing ring. Don't go crazy, just lightly tap away until it becomes easy to remove by hand.

gently lift up the housing (be mindful of which direction the red arrow in pointing) and you will see the old "o" ring that need replacing.

The reverse proceedure is pretty straight forward but some handy tips are:

Use some petroleum jelly around the top edge of the housing to help the black retaining ring move around a lot smoother than when it came off

Have a second pair of hands to push down on the pump housing and keep it down while you start to screw the black ring on. Start to tap it back into position until the arrows line up (however.... keep pushing down on the housing to make sure it is seated properly and not out of position. There should be no give at all . If there is, then the black ring can be tapped around again one full turn.

 

Make sure that the fuel line is securely fitted and a new circlip is in place. Connect it all up... don't forget about the negative terminal on the battery ...Lol I did!

Start the car a couple of times to make sure the fuel is getting through and keep the inspection cover open , get you helper to sit in the back while you reverse, brake and accelerate forward vigarously to check for leakage.

If its ok.... replace the inspection coverand have a coffee and pat yourself on the back... JOB DONE!