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Pelican Technical Article:

Fuel Pump Testing

Nick Czerula

Time:

3 hours3 hrs

Tab:

$300

Talent:

*****

Tools:

Phillips & flat-head screwdrivers, socket set

Applicable Models:

BMW 323Ci Coupe/Conv (1999-00)
BMW 323i Sedan/Wagon (1999-00)
BMW 325Ci Coupe/Conv (2001-06)
BMW 325i/xi Sedan/Wagon (2001-06)
BMW 328Ci Coupe (1999-00)
BMW 328i Sedan (1999-00)
BMW 330Ci Coupe/Conv (2001-06)
BMW 330i/xi Sedan (2001-06)

Parts Required:

Fuel pump, fuel pump sealing O-ring

Hot Tip:

Keep you skin safe from spilled fuel during testing

Performance Gain:

Restoring engine performance

Complementary Modification:

Replace fuel pump if faulty

The fuel supply system in a BMW E46 consists of: 

  • Fuel tank
  • Fuel filler with associated breathing and venting pipes
  • Evaporative emissions control valve and pressure pump
  • High pressure fuel pump assembly with fuel filter and fuel level senders 
  • Fuel pump relay
  • Fuel pressure regulator
  • Fuel rail and electric fuel injectors

A faulty fuel pump can cause poor engine performance and hard starting problems. When it fails completely, you may be left with an engine that does not start. If you suspect your fuel pump has failed, you can confirm the fuel pump has received the correct voltage when commanded ON by the fuel pump relay using a digital volt ohm-meter (DVOM). If the correct voltage is present, but the pump does not activate, it is likely faulty. Use the DVOM in conjunction with a wiring diagram to determine the correct terminals for testing. You can access the terminals under the rear seat cushion, below the access panel. 

The fuel tank is two-lobed. There are two fuel level senders, one in each lobe on the left and right sides underneath the rear seat cushion. The left fuel tank lobe holds the fuel level sender and fuel filter, while the right tank lobe holds the fuel pump. 

To avoid marring the trim if you need to pry anything, work with a plastic prying tool or wrap a screwdriver tip with masking tape before prying out the trim panels, switches or electrical accessories.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches. 

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you are working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability. 

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Pressure testing

Remove engine cover over fuel injectors. See our tech article on engine covers, removing.

Remove fuel test port cap (green arrow).
Figure 1

Remove fuel test port cap (green arrow).

Install fuel pressure gauge.
Figure 2

Install fuel pressure gauge. Be sure all test hoses are installed and routed properly.

Next, start or attempt to start engine.
Figure 3

Next, start or attempt to start engine. Fuel pressure should be 3.5 bar +/- 0.2 (50 psi +/- 3). Once you test pressure. Recharge fuel system by cycling key or running fuel pump, note fuel pressure. Then allow fuel system to sit under pressure for 15 minutes. Pressure should drop no more than 0.5 bar in that time period. If it drops you could have a faulty fuel pump check valve or a leak in the fuel system.

Working in rear of vehicle interior, grab corner of rear seat cushion and pull up to detach locking tabs.
Figure 4

Electrical testing Working in rear of vehicle interior, grab corner of rear seat cushion and pull up to detach locking tabs.

Then pull seat cushion up and out of vehicle.
Figure 5

Then pull seat cushion up and out of vehicle.

Next, peel carpet away from seat cushion area of body (green arrow).
Figure 6

Next, peel carpet away from seat cushion area of body (green arrow).

Peel back access cover to expose fuel pump access panel.
Figure 7

Peel back access cover to expose fuel pump access panel.

Remove four 10mm nuts from access panel (green arrows).
Figure 8

Remove four 10mm nuts from access panel (green arrows).

Remove access panel lid from body by lifting up.
Figure 9

Remove access panel lid from body by lifting up. Move away enough to access electrical connector on fuel pump module.

Disconnect fuel pump electrical connector by sliding locking tab using a flat-head screwdriver, then pulling connector off fuel pump module.
Figure 10

Disconnect fuel pump electrical connector by sliding locking tab using a flat-head screwdriver, then pulling connector off fuel pump module.

Connect DVOM across fuel pump terminals (green arrows).
Figure 11

Connect DVOM across fuel pump terminals (green arrows). Turn key ON, DVOM should read battery volts (around 12 volts). If not voltage is found, check relay and fuel pump fuse. With key ON, fuel pump will receive voltage for 3-5 seconds, if engine doesn't start.

I suggest load testing using a test light and a DVOM.
Figure 12

I suggest load testing using a test light and a DVOM. Connect DVOM across fuel pump electrical connector terminals and take a reading, it should read battery volts when key is turned ON. Then connect an incandescent bulb style test light to battery ground and touch the test light probe tip the positive wire you are backprobing with DVOM. Your reading should hold steady, a maximum drop in voltage of 0.5 volts is OK. Anything more is a problem. In this photo, voltage head steady at the initial reading. You can also jump out your fuel pump relay (to bypass it) for testing. Open glove compartment and remove all items from within.

Remove suspension strut rivet then detach strut from glove compartment (yellow arrow).
Figure 13

Remove suspension strut rivet then detach strut from glove compartment (yellow arrow).

Remove suspension strap rivet then detach strap from glove compartment (yellow arrows).
Figure 14

Remove suspension strap rivet then detach strap from glove compartment (yellow arrows).

Next, remove five Phillips-head screws from glove compartment (green arrows).
Figure 15

Next, remove five Phillips-head screws from glove compartment (green arrows). Lower glove compartment, disconnect flash light electrical connector and detach wiring harness from back side, then remove glove compartment from dashboard.

Lower plastic trim panel and disconnect footwell light electrical connector (green arrow), then remove trim panel from vehicle.
Figure 16

Lower plastic trim panel and disconnect footwell light electrical connector (green arrow), then remove trim panel from vehicle.

Working under passenger side of dashboard, remove relay 10mm panel support fastener (green arrow).
Figure 17

Working under passenger side of dashboard, remove relay 10mm panel support fastener (green arrow). Then pull relay panel out of top clips and pull down.

Remove fuel pump replay (green arrow).
Figure 18

Remove fuel pump replay (green arrow).

Connect a fused jumper wire between terminals indicated by arrows.
Figure 19

Connect a fused jumper wire between terminals indicated by arrows. Green arrows point to terminal 30 (battery positive). Yellow arrows point to terminal 87 (fuel pump feed). This will activate your fuel pump. Check for voltage at fuel pump as you did earlier. Battery volts should be present. Terminals may vary, double check your model against a wiring diagram.

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Comments and Suggestions:
Ben-man Comments: Hi Nick, I have a 2004 330xi E46 with M54 engine. I had some rough idling that I suspected was due to a fuel supply issue. I pulled the plug off the fuel pump and found that i was only getting a consistent 4.9 V at the pump. I checked the voltage at pin 30 of the relay socket and it's a perfect 12.1 volts. When I pull the relay and use a jumper from pin/socket 30 to 87 the voltage at the pump is still 4.9V. I then ran a continuity test between pin/socket 87 and the pump and I have good continuity. Any thoughts on why the low voltage?
November 7, 2016
  Followup from the Pelican Staff: The wiring is likely faulty. Run a temporary wire, does the vehicle run? - Nick at Pelican Parts  
Ck Comments: I have a 03 e46 with codes lean bank1&2. Car run fine but at a half tank of fuel the ses light comes on. I changed the maf & hoses it ran for a week without the light coming on. I can reset it and drive it a 130 no hesitation.
November 7, 2016
  Followup from the Pelican Staff: Could be an issue with the crankcase breather. I would test crankcase pressure. - Nick at Pelican Parts  
Aaron Comments: Nick, my issue in this realm is quite peculiar. In March and April of this year, my E46 2005 325i would not start at all. Not even with a jump. It recently started working just fine in the summer months. Now it won't start at all. When the key is turn ON, I can't hear the fuel pump. When I turn the ignition ON, it tries to turn over but never does. What do you think is the issue now? Thank you.
October 17, 2016
  Followup from the Pelican Staff: Depends on what is missing from the engine when trying to start it. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose. - Nick at Pelican Parts  
Hotrod Comments: I have a 01 530I, the flexable Fuel line in the tank from pump to sending units keeps rupturing. Fuel pressure is at 50 psi, when driving it drops to 20 and the car runs bad. Please help
October 10, 2016
  Followup from the Pelican Staff: if rupturing, see if the line is not secured properly. If it is moving, the plastic line may break. - Nick at Pelican Parts  
joe Comments: i have a bmw 320i 2003 sedan e46. fuel gauge is stuck on empty. cluster test seems ok fuel gauge moves. both sensors not receiving any reading with cluster test 6.0 6.1 .already replaced fuel pump and fuel level sender still no fix. can it be the ECM since the fuel pump fuse blown when i shorted the wiring when testing. help pls
October 3, 2016
  Followup from the Pelican Staff: The signal is read by the cluster. Best bet is to grab a wiring diagram and confirm the signal is at the cluster, is it is, the cluster may be faulty. - Nick at Pelican Parts  
jojo Comments: I have a BMW 325ix year 2006. that is hard starting after sitting for a little, I checked the fuel pressure at the rail and is fine, soon as I shut it off the pressure drops to 0. Do you think its the check valve and is is located in the fuel pump in the tank on the passenger side? or dose it have something to do with the what i think is IN-TANK Regulator on the drivers side.
September 28, 2016
  Followup from the Pelican Staff: Most likely the check valve in the fuel pump. Give The Pelican Parts parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
patrick Comments: i have a 2005 E46 318i that could not start, i suspected the fuel pump but when i bridged the fuel pump relay the fuel pump worked, the problem is with the fuel pump relay on terminal 85 and 86 there is only 8.3 v dc this voltage is not enough to activate the relay what could be the course
August 14, 2016
  Followup from the Pelican Staff: Unplug the relay, what is the voltage on 85 and 86? - Nick at Pelican Parts  
Raf Comments: Why am I getting only 5V to fuel pump? 2004 BMM 330Ci
June 12, 2016
  Followup from the Pelican Staff: You have a voltage drop somewhere. - Nick at Pelican Parts  
bill Comments: bill when checking voltage i get 10.3 volt on the brown wire with zero on the white/blue wire.the fuel pump any help. bmw 325 ci converable 2005 .
May 14, 2016
  Followup from the Pelican Staff: Do you have wiring diagram to confirm what where those wires go? You may be testing incorrectly, or have a short. Brown should be ground. - Nick at Pelican Parts  
King2 Comments: I have a 1999 Bmw 328i.this car is really smooth fast every time it's on from half tank of gas to low,when I filed it up wit full tank that's a problem to get the real speed u want and I feel like the car is overloaded
April 1, 2016
  Followup from the Pelican Staff: Could be an issue with the fuel pump. I would perform a fuel delivery system test. Check fuel pressure, volume and quality.
- Nick at Pelican Parts
 
Jen Comments: Hi there. I have a 2001 Bmw 330i E46. I'm having a problem with the fuel gauge showing a quarter of petrol in the tank, but then being empty. So I replaced things like the fuel filter as well as the fuel pump with no change. Took the car in to garage, guy told me that the fuel level sensor on drivers side is dead and the other side can be fixed. Which I don't understand.. Isn't the fuel level sensor on the fuel pump?? Because if it is, how can it be if I just replaced the fuel pump.. Is it the one on the fuel pump or the other side that shows the fuel volume at the gauge? Thanks a lot.
March 7, 2016
  Followup from the Pelican Staff: There are two fuel level senders, one in each lobe on the left and right sides underneath the rear seat cushion. You may have one or both faulty. - Nick at Pelican Parts  
marlo Comments: hello, on my 325ci 2001 bmw ..about 3 weeks ago after 3 days on heavy rain ... i noticed my car on cold start would crank for 5 seconds then start..then after couple days i would do a cold start and it wwouldnt crank at all...but after the 2nd try would alwayse start up . then after 2 more days when i would shift in reverse ,i would die at a instant...that happened for about a week ...now recently i had started the car ignition on position 2 try to start but no crank!! now it wont start at all , fuel pump is good ..i can still hear it turn on each time when key is in position .i changed it out prior to the problems..battery is good all the power still works and connection are good ..fuses and relays are good as well..my guess is the fuel filter ,starter or spark plugs plugs...but any help would be nice ..thanx
February 4, 2016
  Followup from the Pelican Staff: I can't help without knowing what is missing from the system when you are trying to start it. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose.
- Nick at Pelican Parts
 
Shane Comments: Hi I have 5 volts st my fuel pump car doesn't start engine just cranks fuel pump doesn't start or prime iv changed the pump checked the fuses engine bay and glovebox both are good swapped relay with horn relay still nothing so just swapped those back what's next please should I just jump and bypass relay as in your post
January 12, 2016
  Followup from the Pelican Staff: 5 volts indicates a voltage drop. This could be due to a bad relay, fuse panel, or wiring. You will have to locate the source of the drop. - Nick at Pelican Parts  
HJ Comments: Thanks for the reply Nick. My car is a '03 330XI. What would be the best way to find out why the sending unit is not getting voltage?
January 5, 2016
  Followup from the Pelican Staff: Best bet is to get a wiring diagram, then trace the wiring for the level sender back to the source, for example to the DME. It could be a broken wire between the sender and the module.
I would grab a repair manual. It will have the wiring.
Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
HJ Comments: Hello-

I am having problems with the fuel gage. I have replaced the passenger side sending unit and have tried 2 different ones for the driver side. Could you tell me if both sending units should have 5V supplied to the connectors when the ignitions is turned on? Currently, the passenger side does have, but the driver side does not. The pump seems to works fine.
December 19, 2015
  Followup from the Pelican Staff: You didn't mention what vehicle you have. However, if talking about level senders, they should have the similar signals at each lobe of the tank. - Nick at Pelican Parts  
Cicura Comments: I have a 2004 325ci SMG. 172k mi. A couple of days ago while pulling up my driveway the engine cut off, I could restart but there was no power to continue driving, I parked the car along the street and the following day the engine would crank but not start.
I have replaced the fuel filter and pump, checked the fuel pump relay and all seems to be in order. If I use starting fluid the engine fires up. My concern now is, I have no pressure in the fuel rail. Is there another inline fuel filter? Or is the pressure regulator in the new filter defective?
Any ideas?
December 7, 2015
  Followup from the Pelican Staff: Check if the filter is installed backward. If not, Could be an issue with the fuel pump. I would perform a fuel delivery system test. Check fuel pressure, volume and quality. - Nick at Pelican Parts  
Given Comments: Its a BMW 320i 2002 Model, with regards to my previous question, I am sure that is a fuel pump because when you set the egnition on the pump must make a sound to show that is pumping but now is no long making any sound and it was taking time before it could start, so it is possible to fix a fuel pump? Or it must be replaced only.
October 30, 2015
  Followup from the Pelican Staff: Could be an issue with the fuel pump. I would perform a fuel delivery system test. Check fuel pressure, volume and quality.
- Nick at Pelican Parts
 
Given Comments: Hi is it possible to fix a fuel pump if it is please let me know thanks
October 30, 2015
  Followup from the Pelican Staff: By replacing it. Give our parts specialists a call at 1-888-280-7799. They can figure out what part or repair kit you need.
- Nick at Pelican Parts
 
Turbodave Comments: Hi I have a 2001 e46 330ci it's been stood for 12 months it starts no problem but dies instantly if you take revs off starts again and does the same can drive it if I keep the revs up but that's no good I checked and replaced intake boot due to cracks but in thinking fuel pump on its way out because I hear it running not very loud I thought it use to be louder ! but would the car still run and rev up fine I was just going to replace fuel pump instead of paying to not get answers I would try a pressure test but don't own the tool thanks hope you can help
October 25, 2015
  Followup from the Pelican Staff: Could be many things. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose. - Nick at Pelican Parts  
maestro Comments: after turn ignition off press drops constant all the way to 10 psi in about 25 min is check valve in fuel pump? any ideas?
September 11, 2015
  Followup from the Pelican Staff: Sounds like either a bad fuel pump check valve or fuel injector. - Nick at Pelican Parts  
JAH Comments: I recently replaced the dead original fuel pump on my E46 325i with a Bosch pump. No probs replacing it and it fired right up and was smooth as butter... Until a few days later when I had to REALLY get on it in some traffic and the car died instantly. I quickly slammed in the clutch pedal and cranked it back up and barely got out of the jam unscathed!!! As long as I don't romp on it, it drives perfect but if I drive 9/10 or more it dies! Any thoughts?
July 27, 2015
  Followup from the Pelican Staff: Does sound like you have fuel delivery issue. I would perform a fuel delivery system test. Check fuel pressure, volume and quality.
- Nick at Pelican Parts
 
Val Comments: I have long cranks sometimes . But once the car starts it runs perfectly. I noticed that my fuel pump does not prime every time key is turned to position 2. Car starts every time though . Can u plz explain what might cause the fuel pump not to prime before starting ?
July 15, 2015
  Followup from the Pelican Staff: A faulty fuel pump check valve. - Nick at Pelican Parts  
Hank Comments: I've been having a hot start issue with my 2001 BMW 325i. It cranks 4-5 times the usual amount of time to start when hot. The fuel pressure is good after turning the key to position 1, but quickly declines after turning the key off. My mechanic says I would see a cloud of smoke coming out the exhaust if the fuel injectors were leaking and that does not occur after a hard start. Would this mean my fuel pump check valve is the issue? No SES light. My mechanic thinks it's a sensor issue, but can't pinpoint which one.
July 9, 2015
  Followup from the Pelican Staff: Could be a fuel delivery issue.

I can't help without knowing what is missing from the system when you are trying to start it. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose.
- Nick at Pelican Parts
 
Ceci Comments: Hi, I own a 2002 BMW 325i sedan E46, is having some problems when trying to start. Sometimes usually when cold but not always starts right away, when hot sometimes I crank it 5 times then starts with no problems. I can tell is running a bit rough til warms up. Took it to the mechanic, changed the fuel filter. He does not know if it is the fuel pump or fuel module. I also noticed a loud bee noise coming from where it seems to be the rear seat or exhaust. Can't hear it from inside the car but loud from outside. Can someone help me decipher what it could be. Mechanics change an arm and a leg only to diagnose. Thanks you!
June 26, 2015
  Followup from the Pelican Staff: When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume, quality and engine compression. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose. - Nick at Pelican Parts  
355pilot Comments: Had lean and misfire codes on banks 1&2. replaced, all vacuum hoses,ccv, throttle body seal, plugs, and dipstick o-ring. Car is cranking 6 to 7 seconds before starting. Replaced fuel filter. still have check eng light after several weeks of driving. Tested fuel pressure 3.4 bar running. 3.3 bar prime and 2.3 after 15 min. Car no longer misfires, runs great, just long crank to start and still have eng light. Any ideas of what to look at next.
June 19, 2015
  Followup from the Pelican Staff: What kind of vehicle are you working on? What fault codes are stored? - Nick at Pelican Parts  
ray Comments: So I have 2003 330xi that will not start. The engine cranks and turn but it will start. I have had some hard starts in the last couple weeks didn't think much of it. So one thing I noticed is that when I turn the key into the second position I don't hear the pump prime so I changed the pump. Check the fuses in glove box and under the hood.fine I thanks the relay is fine also because when I turn the key in multimeter from the pump connector reads 11.36 is that OK? I still can't figure what the problem is.
January 3, 2015
  Followup from the Pelican Staff: Battery voltage is low, should be 12.6 when fully charged.

I can't help without knowing what is missing from the system when you are trying to start it. When your engine doesn’t start you’ll want to check the basics. Check spark, fuel injector pulse and fuel pressure, volume and quality. Are there any fault codes? Once you figure out what is missing, it will be easier to diagnose.
- Nick at Pelican Parts
 
Chris Comments: Is there any other way to test a relay besides the manual bypass method described or replacing it? Can you use a meter at all, like maybe checking resistance or something? Thanks. By the way I have an 05 bmw 330i.
December 1, 2014
  Followup from the Pelican Staff: A resistance test is not good for a relay.

You can manually activate the relay and see if the switch sends power without dropping voltage. - Nick at Pelican Parts
 
pez320icanada Comments: Darn it. The problem code reappeared yesterday. I've done what I can do without tens of thousands of dollars of diagnostic equipment. Replaced fuel cap, changed fuel filter, and spark plugs, cleaned MAFS, and DISA, and installed the fuel line pressure check valve. I booked the car in today at the dealership. The key scan indicated a recent recall on the passenger airbag so it will all be done and hopefully corrected next week. Thanks for the follow up. I'll let you know what they find.
November 5, 2014
  Followup from the Pelican Staff: Thanks, keep me posted. - Nick at Pelican Parts  
pez320icanada Comments: There was only a cold start misfire. Codes were "misfire on start cyl 1, and lean bank 1 & 2." Otherwise the engine runs beautifully. Reasonable acceleration, given the small motor, and will cruise all day long at 140 kmh. I added an inline check valve at the pump outlet. I'll check the flow volume at the pump if the problem doesn't disappear. So far,so good though... Thanks for your help.
November 2, 2014
  Followup from the Pelican Staff: No problem, let me know what you find. - Nick at Pelican Parts  
pez320icanada Comments: 2003 320i has strong fuel pressure when running but drops to 10 pound instantly when engine is switched off. Is the check valve replaceable or should I just add a external one?
October 30, 2014
  Followup from the Pelican Staff: Is there a starting problem with the vehicle? It should hold pressure when the engine is off. If it doesn't the check valve in the fuel pump is faulty or the fuel injectors are leaking. - Nick at Pelican Parts  
dox Comments: This only tests the pump. Remove the gauge from the hose connected to the Schrader valve and run it open. This tests the filter, pipes, rail, etc. for available flow to the injectors. The flow will be less, due to back pressure through the system, but that's the idea. I obtained 1 liter per minute on a 2002 330i with 140k miles and original parts. I'd guess that's OK!
October 28, 2014
  Followup from the Pelican Staff: Be careful when pulling volume samples through any restriction, such as a rail or regulator. You can get a false failure, resulting in possible replacement of a good part. - Nick at Pelican Parts  
dox Comments: Fuel pressure is not the only concern. One must also be sure to test the fuel flow rate. What is the minimum acceptable fuel flow rate from an open test port?
October 28, 2014
  Followup from the Pelican Staff: To test fuel volume, you have to pull from the pump itself, not through the regulator or rail. BMW does not supply a spec, I have a rule of thumb I developed over the years, a pint in thirty seconds. - Nick at Pelican Parts  

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Page last updated: Fri 12/9/2016 02:19:27 AM