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Cost: £35.00

This video clip shows exactly how an in-tank electric fuel / diesel pump can be modified to store the present fuel gage / sender unit and remove the faulty intank pump, replacing it with an easy accessible in-line fuel pump.Many vehicles, consisting of my Citroen picasso are fitted through an in-tank fuel pump. And also inevitably room prone to failure, particularly if you room running waste vegetables oil mixes or bio fuel. These pumps often have two filters in the tank that are prone to clogging up also when run on pump diesel. Have road tested auto today it runs great, much more power than with the initial manufacturer pump. Examine out my Channel for much more interesting videos.

Hope you discover this video helpful, if you perform don"t forget to give it a thumbs up and share and who knows, I could even gain my £35 earlier off the proclaiming :P

Rant: Citroen Picasso Fuel Pump Nightmare ended. Citroen in their limitless wisdom made decision that placing a fuel pump i m sorry is vulnerable to pack up inside the fuel tank, which method you need to jack the vehicle up, put it top top stands, drainpipe the fuel, remove the exhaust heat shield, move the hand brake cables, remove the 4 bolts, remove the rubber filler pipe hose, remove the pipes and also unplug the cables. Then you need to pull the tank out sufficient to eliminate the fuel pump. Or salary a garage to do same. Reassemble having actually forked out £125 because that a new pump just to discover the new pump lasted approximately 2 years before it too gave up the ghost. The poxy tank had been eliminated no less than six times, entailing cleaning the pump filters, and hoping above all really hopes that the pump would run and it did for a couple of miles, climate braking under again and also again. Well enough was enough. I eliminated the old pump which also includes the tank fuel gage gizmo. Threw the pump away and also secured a stole rod v cable ties to hold the pipeline on the bottom that the pump. Put the pump-free sender unit. Refitted the fuel tank, reduced through the main fuel pipe and fuel pump wires and also fitted a 3 bar exterior pump that works like a dream. Never again will certainly I need to remove the fuel tank and also if this pump packs up which i doubt, it will take 10 minutes to adjust and cost a just £35.00. Up Yours. Citroen.

You are watching: Convert in tank fuel pump to inline


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1. Never ever crawl under a vehicle supported by an hydraulic jack. Always use axle was standing or ramps under wheels.

2. You will should siphon off the bulk of her fuel. If you have the brand-new external pump already, this deserve to be supplied by running 2 wires to your battery terminals, connecting confident to positive and also earth come negative. Secure size of tubing to pump and also insert right into tank. Attach wires to carry fuel to numerous 20 litre containers v screw capped covering for safe storage.

3. Cut a 20 / 25 litre plastic container open on one side as per picture. This will certainly serve to drain excess fuel

4. Slide your drainage container under tank and also unscrew filler water tap jubilee clip, easing rubber pipe turn off to afford the staying fuel to it is in drained. I recognize it should be apparent but don"t exhilaration or have any naked flames or anything that can cause a spark near the fuel gift emptied.


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The Citroen Picasso tank has 4 bolts, 2 ~ above the centre bracket that crosses the center of the tank and also one at every end. First remove the exhaust warmth shield and pull the hand brake cables out of the holders, remove wiring clips and also pipe clips and remove filler hose fully one drained. Ar drainage container ago under bottom hose coupling. Eliminate all 4 bolts and also ease towards filler end of tank by pulling and also raising far end with your foot so it have the right to be eased out and also down, taking care not to kink any type of pipes. Once lowered the wiring connector and the 2 fuel pipes deserve to be removed.

Then unscrew plastic collar the holds fuel pump in place. This unscrews anti-clock-wise. Usage a long screw driver come leaver the collar roughly if the can"t be moved by hand.


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The Citroen Picasso 2 litre HDI calls for a 3 bar pump to open the press sensor. This is necessary for the auto to run. The pump presented is wrong because that this vehicle, however can be equipment to other vehicles. This form of pump is noisy. The correct pump is displayed secured come the vehicle. This one delivers 3.5 bar and also works well v the Picasso.


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Remove wiring native the defective in-tank pump, taking note of live and also earth / an unfavorable colours.

Remove the defective pump native the plastic real estate cage that it sit in and cut off or pull off the plastic water tap from the bottom the the old pump together shown.


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Cut a length of stiff steel wire so the it is slightly much shorter than whereby the old pump to be sited at the bottom of the sender unit / pump housing. Secure v cable ties together shown, come the plastic housing.

Allow adequate hose to bending at the bottom the the pump reservoir / housing. This will enable fuel to go into freely together we don"t want the end of the pipe coming to be blocked by being flat against the bottom of the housing.

Once secured the metal rod will must be bent so that it slides into the pump real estate with ease.


Check the the end of your fuel pipeline is secured with cable ties nice and also tight and also protruding listed below the level of whereby the old pump provided to rest as shown.Push pump housing earlier inside sender unit / fuel gauge housing until it clicks right into place and also fit the unit earlier inside the tank taking care to keep rubber gasket in position. Tighten firmly by hand and reconnect pipes and cable connector. Re-fit tank back to can in reverse order that it"s removal.


Step 7: disclose the Wires by Peeling ago Outer protective Cover. Cut the 2 Pump Wires that We figured out When We removed the Pump.


In the Picasso this are apparent due to being thicker 보다 the fuel gauge wires. Grey to be live and also green and also yellow to be the earth in this case. Cut the wires far sufficient down the impend to leave plenty that wiring to connect to the pump.

Crimp on two spade finish connectors to the end of the cut wires.


In the picasso, the first pump was fitted as shown by bending the brackets so the it might be bolted top top an existing 10mm stud and also a convenient hole to take a me tapping bolt. The bigger of the two fuel pipes to be cut and the ends fitted to the brand-new pump secured with cable ties. Loosened pipe was additionally tied up making use of cable ties. The pump was located in a practically recess in prior of the tank. The existing stud and hole imply an exterior pump must have actually been fitted originally and also the in-tank fuel filter and also sender unit fitted together an after believed by the manufacturer.

As it happens, this very first pump worked perfectly yet the vehicle would no start because of the pump not placing out sufficient pressure to open a sensor that compelled 3 bar pressure.


Using a brief length of 22 mm copper tubing, which to be hammered flat and formed approximately a branch in the vice together shown. The angry was supplied to close the parentheses tightly roughly the branch i m sorry was around the very same size as the pump.

Do not usage the pump because that this function as you will inevitably damage it.

Once formed, the bracket was cut with a hacksaw as shown and also a feet drilled to take the 10 mm stud located next come the tank.


Insulation tape was wrapped approximately the pump to protect against vibration and noise and also the fabricated copper bracket to be fitted under the vehicle as shown, fuel pipes to be connected. The outlet pipeline on the pump "Not the next shown" had actually to it is in warmed with a hair dryer and gently persuaded to bend to to the right the new pump.

It is worth noting the positive and negative terminals on the new pump due to the fact that you can"t view the symbols once installed.

See more: " What Did I Do To Be So Black And Blue (Fats Waller Song), (What Did I Do To Be So) Black And Blue

Silicone was supplied to alleviate vibration by easing the pump and bracket forward and also using a caulking gun to squeeze plenty between the pump and the human body on both sides. This will also aid to cut down noise and provide bonding of the pump come the automobile underside, "not that it requirements it".

Refill tank with 10 litres of fuel and also carefully check for leaks.

If every goes well, your tank fuel gauge currently works properly and also your new pump will certainly work very well. It will certainly make slightly much more noise being exterior of the tank but if it ever fails, it will certainly cost approximately £35 to replace as opposed to £133.00 native Citroen, it will certainly take around 30 minutes to readjust instead of half a day or longer when you have to remove an int-tank pump together you now recognize :) expect this video helps who to avoid having actually to adjust in-tank pumps which room prone to early on failure together I uncovered out.