C5 Fuel Pump Relay testing

This is the Forum for all your Citroen Technical Questions, Problems or Advice.

Moderator: RichardW

Cfiver
Posts: 38
Joined: 22 Aug 2016, 16:51
x 1

C5 Fuel Pump Relay testing

Post by Cfiver »

Can anyone tell me how to bench test a fuel pump relay?

Car is 2004 C5 Exclusive 2.2hdi auto - Won't start.

Relay is:
G Cartier
8 191 002
96 527 112 80

6 inline pins.
IMG_0772.JPG
IMG_0771.JPG
User avatar
GiveMeABreak
Forum Admin Team
Posts: 25415
Joined: 15 Sep 2015, 19:38
x 2831

Re: C5 Fuel Pump Relay testing

Post by GiveMeABreak »

Are you sure it's that and not that your key transponders have become unsynchronised with the immobiliser?

Leave car for 5 minutes, insert key, turn on ignition only, press lock button for 5 seconds, switch off ignition and remove key - try and operate central locking a couple of times. then try and start. Just a thought that it may be as simple as this.
Cfiver
Posts: 38
Joined: 22 Aug 2016, 16:51
x 1

Re: C5 Fuel Pump Relay testing

Post by Cfiver »

Thanks Mark Have gone through the BSI reset several times without success.
User avatar
GiveMeABreak
Forum Admin Team
Posts: 25415
Joined: 15 Sep 2015, 19:38
x 2831

Re: C5 Fuel Pump Relay testing

Post by GiveMeABreak »

I've tried to find this everywhere and cannot find any reference to it on the wiring diagrams unfortunately and it certainly isn't referred to as a fuel pump relay on any of these. What did you remove it from and a VIN would help too to make sure I'm looking at the right diagrams.
Cfiver
Posts: 38
Joined: 22 Aug 2016, 16:51
x 1

Re: C5 Fuel Pump Relay testing

Post by Cfiver »

Vin number is VF7**************[VIN obfuscated, can be read by forum staff]

RPO 10158
User avatar
GiveMeABreak
Forum Admin Team
Posts: 25415
Joined: 15 Sep 2015, 19:38
x 2831

Re: C5 Fuel Pump Relay testing

Post by GiveMeABreak »

I'll have a look for you later as I have to go out and see if I can fix my friends Ground Heat Pump! Better get the Lexia fired up for that one!
wheeler
Posts: 5167
Joined: 21 Sep 2002, 19:07
x 303

Re: C5 Fuel Pump Relay testing

Post by wheeler »

That's not the fuel pump relay, the fuel pump relay is an integral part of the under bonnet fusebox.
If you cant hear the fuel pump running Unplug the 16 pin grey connector on the under bonnet fusebox & check pin 11 in the plug closely, you may find it has overheated & now making a poor connection. This is the output to the in tank fuel pump.
wheeler
Posts: 5167
Joined: 21 Sep 2002, 19:07
x 303

Re: C5 Fuel Pump Relay testing

Post by wheeler »

Where was the black Cartier unit located ? I don't recognise what it is.
Cfiver
Posts: 38
Joined: 22 Aug 2016, 16:51
x 1

Re: C5 Fuel Pump Relay testing

Post by Cfiver »

Many thanks for the advice. The 'relay'? is underneath the under bonnet fuse box and Main ECU. It is adjacent to what I think is the Glow plug relay. Looking on Ebay and entering the part number there were a couple of Fuel pump relays previously advertised so very confusing. They were both sold and it looks like I will struggle to get one if needed. I will certainly investigate the grey connector pins again as you suggest. I did look at them and all the other plugs today but didn't spot any signs of corrosion or burning.
User avatar
GiveMeABreak
Forum Admin Team
Posts: 25415
Joined: 15 Sep 2015, 19:38
x 2831

Re: C5 Fuel Pump Relay testing

Post by GiveMeABreak »

He has the C5 II 5 Door Saloon 2.2 HDi Auto gearbox 4 DW12TED4 Turbo Diesel, but still no clearer on the 'box'
wheeler
Posts: 5167
Joined: 21 Sep 2002, 19:07
x 303

Re: C5 Fuel Pump Relay testing

Post by wheeler »

Scrap what I said above, I thought an 04 would have been a mk 1. The mk 2 has a different under bonnet fusebox layout (although it will still house the fuel pump relay) & i dont believe the mk2 suffers from this problem.
Are we sure this model definitely has an in tank pump? Is there a fuel hand primer fitted
wheeler
Posts: 5167
Joined: 21 Sep 2002, 19:07
x 303

Re: C5 Fuel Pump Relay testing

Post by wheeler »

GiveMeABreak wrote:
07 Dec 2018, 01:18
He has the C5 II 5 Door Saloon 2.2 HDi Auto gearbox 4 DW12TED4 Turbo Diesel, but still no clearer on the 'box'

Is it 4HX, 4HT, 4HR etc?
User avatar
GiveMeABreak
Forum Admin Team
Posts: 25415
Joined: 15 Sep 2015, 19:38
x 2831

Re: C5 Fuel Pump Relay testing

Post by GiveMeABreak »

4HX, in tank pump, but can't see any mention of a manual primer.
Cfiver
Posts: 38
Joined: 22 Aug 2016, 16:51
x 1

Re: C5 Fuel Pump Relay testing

Post by Cfiver »

IMG_0777.JPG
IMG_0776.JPG

Removed the fuse box today and scrutinised all the plugs and pins but no burning or corrosion anywhere. Car has in tank pump which I have removed and tested and it is working. Which of the onboard relays is for the fuel pump. The one second from left on the board seems looser the others and shows sign of slight separation from the silicone layer at the bottom.
User avatar
GiveMeABreak
Forum Admin Team
Posts: 25415
Joined: 15 Sep 2015, 19:38
x 2831

Re: C5 Fuel Pump Relay testing

Post by GiveMeABreak »

The wiring diagrams don't show the relays I'm afraid only the fuses and the maxi fuses.