Fuel Pump advice please

[I'm-no-mechanic 3 3 Cars]

I'm having trouble restarting my 205, she's been parked up since Sept 2022 and although I initially started her periodically she got neglected.

 

She is a 1998 205 Generation 1.4i.  I've replaced the battery and she also has fresh fuel, we attempted to pump out what we could of the little fuel that was still in the tank prior to popping the new fuel in.  She will momentarily kick into life with some Holts Easy Start.

 

We believe we've isolated it to the fuel pump and I'm wondering if there is anything further we can do to try to get the pump going or do I just need to replace it? 

 

We've had the fuel pipes off at the engine and fuel doesn't seem to be delivering.  There doesn't seem to be any sound coming from the pump when the ignition is turned on.   We've checked the fuse and the relay for the pump; I swapped the relay out and put it in place of the ignition relay and the ignition electrics all light up.  I'm not sure I feel confident to replace the pump myself if that's what's required, I might have to get it towed to the garage if that needs doing, how difficult a job is it?

 

Any help would be appreciated, hopefully we'll then have another 205 back on the road!

[I'm-no-mechanic 3 3 Cars]

Just to add that the fuel pump and fuel gauge sender access bays were both pretty grim and I've cleaned them up but it hasn't changed anything.  The pump contacts were / are much better than the sender contacts but the sender and gauge have been working all along.

[DamirGTI 358]

Stuck pump , very common nowadays if you leave it in old petrol for few years .

 

You "might" get it spinning again by banging on the tank from the bottom just under the pump , with rubber hammer or by hand .. but if it was left for 4 years as a non runner i doubt it'll work but try ..

Can also unstick them sometimes with cordless drill 18v lithium battery but try only with the pump out of the tank on the bench , as otherwise it can go "sparky bang" ! 

 

Pump removal is really easy , few 7mm screws , mark hoses feed/return unclip and lift it up from the tank .. and drain/syphon that old petrol out , if unsure call mobile mechanic .

 

Tricky bit will be finding good quality replacement pump , theres s**t loads of Chinese Mickey Mouse fuel pumps , buy only Bosch .

Edited March 10 by DamirGTI

[I'm-no-mechanic 3 3 Cars]

On 3/10/2026 at 8:56 PM, DamirGTI said:

Stuck pump , very common nowadays if you leave it in old petrol for few years .

 

You "might" get it spinning again by banging on the tank from the bottom just under the pump , with rubber hammer or by hand .. but if it was left for 4 years as a non runner i doubt it'll work but try ..

Can also unstick them sometimes with cordless drill 18v lithium battery but try only with the pump out of the tank on the bench , as otherwise it can go "sparky bang" ! 

 

Pump removal is really easy , few 7mm screws , mark hoses feed/return unclip and lift it up from the tank .. and drain/syphon that old petrol out , if unsure call mobile mechanic .

 

Tricky bit will be finding good quality replacement pump , theres s**t loads of Chinese Mickey Mouse fuel pumps , buy only Bosch .

Thanks DamirGTI.  I have tried a rubber mallet from underneath but no joy.  I also hoped it could be the inertia switch, but sadly not. So it looks like replacing the pump.

 

I'm hoping I've found the right one, I've found a couple of listings for a Bosch 0580314165, I don't suppose you or anyone else can confirm this is the right part?

 

Because the car was originally Dutch registered I can't search sites for parts by vehicle registration.  Just as a reminder my car is a 205 Generation 1.4i from 1998.

 

The links I've found are as follows:

 

https://www.autodoc.co.uk/bosch/1156389

 

https://www.onlinecarparts.co.uk/bosch-1156389.html

 

My Haynes manual says I should also fit new collars and new gasket, will these come with the new pump or are these parts I need to source separately?

 

Thanks again for your help.

[DamirGTI 358]

Yes that'll be the right pump for SPi TU engine .

 

Gasket which seals the pump to the tank is OE item (might be aftermarket ones im not sure) , not included with the fuel pump as a set/kit .. if it's still good reuse it , might add some petrol resistant sealer on it if you wish .

[Richie-Van-GTi 81 2 Cars]

Have you tried putting 12v direct to the pump? 

[I'm-no-mechanic 3 3 Cars]

3 hours ago, Richie-Van-GTi said:

Have you tried putting 12v direct to the pump? 

Yes, thanks Richie-Van-GTi, appreciate your comment, I did give that a go. 

 

I ordered a new pump on Friday, so hopefully that will arrive soon and solves it.

[I'm-no-mechanic 3 3 Cars]

On 3/19/2026 at 12:52 PM, DamirGTI said:

Yes that'll be the right pump for SPi TU engine .

 

Gasket which seals the pump to the tank is OE item (might be aftermarket ones im not sure) , not included with the fuel pump as a set/kit .. if it's still good reuse it , might add some petrol resistant sealer on it if you wish .

Hi DamirGTI,

 

I've now got the part, ordered through pl.autofixer.com but on their ebay site in the end: https://ebay.us/m/COjymW

 

I've now got my pump assembly out of the car but my rubber seal is badly perished and disintegrating. Does anyone know if this something I'm going to be able to easily replace? Do you have any thoughts, even a link to where I can buy one?

 

Many thanks.

Edited March 30 by I'm-no-mechanic

[I'm-no-mechanic 3 3 Cars]

[I'm-no-mechanic 3 3 Cars]

I had to cut the short length of fuel pipe in the end, it looked like I would be best replacing it anyway. I believe I need 8mm to replace it.

 

I'm not sure how these old pipe clips were supposed to be removed anyway, it doesn't look like they are designed for removing.

 

The ones in the rest of the system are awkward enough! Is there a special tool for these for putting them back in or are they best just replaced with new?

[Tom Fenton 1,632]

Google Clic Clip pliers, those clips are good and reusable.

[I'm-no-mechanic 3 3 Cars]

42 minutes ago, Tom Fenton said:

Google Clic Clip pliers, those clips are good and reusable.

Thank you, much appreciated.

[I'm-no-mechanic 3 3 Cars]

She lives!

 

Thank you DamirGTI and Tom Fenton and Richie-Van-GTi.

 

The pump replacement proved a bit awkward but got there in the end.

 

Think my other 205, a 1987 GL, is going to need the fuel pump looking at too, really glad that's not an in tank pump!