Peugeot 206 Fuel Pump Relay Location: A Comprehensive Guide

The fuel pump relay on a Peugeot 206 is typically located in the engine bay fuse box. For most model years (1998-2009), you’ll find it labeled as "Relay R4" or "R5" (depending on production date) within a black plastic fuse box near the battery. This relay controls power to the fuel pump, and accessing it requires removing the fuse box cover. Always disconnect the negative battery terminal before inspection or replacement to prevent electrical shorts.

Understanding the Fuel Pump Relay’s Role

The relay acts as a switch for the fuel pump’s electrical circuit. When you turn the ignition key, the engine control unit (ECU) signals the relay to close, sending 12V power to the pump. A failed relay will prevent fuel delivery, causing non-start issues. Symptoms include a silent fuel pump (no humming sound when ignition is on), engine cranking but not firing, or intermittent stalling. Unlike fuel pump failure, relay problems often lack warning signs like performance loss or noise.

Step-by-Step Location Identification

  1. Locate the Engine Bay Fuse Box:
    Open the hood and identify the rectangular black plastic box (approx. 20cm x 15cm) positioned next to the battery. Earlier models place it directly atop the battery; post-2002 versions may shift it leftward toward the windshield.
  2. Access the Fuse Box:
    Release two plastic clips on the box’s sides and lift the cover. A diagram is printed on the cover’s underside or inside the lid, listing relay positions.
  3. Identify Relay R4/R5:
    Peugeot 206s use standardized labeling:
    • Pre-2001 models: Relay R5 (third relay from the left, top row).
    • 2001-2009 models: Relay R4 (second relay from the right, top row).
      The relay is a small (3cm x 2cm), cube-shaped, gray or black component with four metal pins. It’s often grouped with identical-looking relays, so match its slot to the diagram.

Year-Specific Variations

Production changes affect exact placement:

  • 1998-2000: Relay R5 (right side of fuse box, below fuse F2).
  • 2001-2005: Relay R4 (center position, adjacent to fuse F7).
  • 2006-2009: Relay R4 remains standard, but some diesels (e.g., HDi) use relay "805" in the same slot.
    If the diagram is missing, consult your owner’s manual or search "Peugeot 206 fuse box layout" for your model year. Never guess—misidentifying relays can damage ECU circuits.

Testing for Relay Failure

  1. Swap Test: Replace the fuel pump relay with an identical one (e.g., horn relay R2) and listen for the fuel pump’s 2-second hum at ignition. If the pump activates, the original relay is faulty.
  2. Multimeter Check: Set to continuity mode. With the relay removed, probe pins 30 (power input) and 87 (output to pump). No beep indicates internal failure. If pins 85/86 (ECU control pins) show open circuit, the coil is damaged.

Replacement Procedure

  1. Safety first: Disconnect the battery’s negative terminal using a 10mm wrench.
  2. Pinch the relay’s sides and pull it straight out. Avoid twisting—pins bend easily.
  3. Insert a matching replacement: Peugeot part numbers 0001469798 (Bosch 0332014150) or 9641790480. Generic 30-amp mini ISO relays work if pin configurations match.
  4. Reconnect the battery and test ignition.

Why DIY Fixes Succeed (and When to Seek Help)

Replacement takes 15 minutes with basic tools. Most failures stem from corroded pins or worn internal contacts—simple fixes requiring no mechanical expertise. However, if relocating the relay fails to resolve starting issues, suspect wiring damage near the fuse box or a faulty fuel pump. Professional diagnosis is advised for complex electrical faults.

Long-Term Maintenance

Prevent future failures:

  • Apply dielectric grease to relay pins during installation to inhibit corrosion.
  • Ensure the fuse box cover seals tightly—water ingress causes 70% of relay corrosion cases.
  • Inspect the relay every 60,000 miles or during routine battery service.

Accurate relay identification eliminates unnecessary fuel pump replacements. By locating Relay R4/R5 promptly, you avoid costly towing and shop fees for a component costing under $25. Always verify placement using your VIN or model year before starting repairs.

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