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Pelican Technical Article:

Fuel Pump Replacement

Nick Czerula

Time:

3 hours3 hrs

Tab:

$300

Talent:

*****

Tools:

Phillips & flathead screwdriver, 10mm socket, fuel pump collar tool

Applicable Models:

BMW 525i/xi Sedan (2004-07)
BMW 528i/xi Sedan (2008-10)
BMW 530i/xi Sedan (2004-07)
BMW 530xi Wagon (2006-07)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)
BMW 545i Sedan (2004-05)
BMW 550i Sedan (2006-10)

Parts Required:

Fuel pump, fuel pump sealing O-ring

Hot Tip:

Clean top of fuel tank before removing pump

Performance Gain:

Repair faulty fuel pump

Complementary Modification:

Fuel filter is not serviceable

The fuel supply system in a BMW E60 consists of:

  • Fuel tank
  • Fuel filler with associated breathing and venting pipes
  • High pressure fuel pump assembly with fuel filter and fuel level senders

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.

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 doesn't 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 terminals under the rear seat cushion, below the access panel. See our tech article on fuel pump testing.

Replacing the fuel pump on a BMW E60 can be done without removing the fuel tank. There are access panels under the rear seat cushion that allow servicing. It is best to replace your fuel pump with the fuel tank drained. This reduces the amount of possible spilled fuel and fuel vapors. When replacing, work in a well-ventilated area. Working outdoors is a good choice. Do not use incandescent work lights or power tools. Fuel and fuel vapors are highly combustible.

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're 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.

Drain your fuel tank. Run the vehicle for about 20 seconds. This equalizes the amount of fuel in the siphon unit.

Disconnect the negative battery cable. See our tech article on battery replacing and reconnecting notes.

Remove the fuel cap, then slide an anti-static siphon hose down the fuel filler neck. Once the hose has bottomed out, pump fuel out of the fuel tank into a suitable storage container. If you are unsure of the amount of fuel in your tank, you can monitor the fuel level via the fuel level sender units. As the fuel level drops, the fuel level sender resistance drops. You can measure this across the terminals at both sender units with a digital volt / ohm meter (DVOM). You will need a wiring diagram from a repair manual.

In order to replace the fuel pump, the left side fuel unit has to be removed. This tech article will show the pump replacement beginning with removing the left side fuel unit.

Working in the rear of the vehicle interior, grab the corner of the rear seat cushion and pull it up to detach the locking tabs. Remove the seat cushion from the vehicle. See our tech article on Seats removing.

The fuel pump /sending unit is located in the right (green arrow) side of the fuel tank.
Figure 1

The fuel pump /sending unit is located in the right (green arrow) side of the fuel tank. The sending unit / fuel filter / siphon unit are located on the left (red arrow) side.

Once you have removed the rear seat, peel the insulation away from the left side rear seat cushion area of the body.
Figure 2

Once you have removed the rear seat, peel the insulation away from the left side rear seat cushion area of the body.

Hold the carpet out of the way.
Figure 3

Hold the carpet out of the way. Then remove the four 10mm nuts from the access panel (red arrows).

Remove the access panel lid from the body by lifting it up.
Figure 4

Remove the access panel lid from the body by lifting it up. Be sure to replace the panel gasket (red arrow) if it is damaged.

Next, you have to remove the lines at the fuel unit.
Figure 5

Next, you have to remove the lines at the fuel unit. Press the retaining tab (red arrows) in toward the line and hold it. Then slide the line off the fuel pump module. Be careful not to damage the hose or the fuel pump module. Cover the line with a rag when removing (inset). This prevents fuel spillage.

Next, lift the line straight up to remove it.
Figure 6

Next, lift the line straight up to remove it. Place the line out of the way next to the fuel unit collar (red arrow).

Next, you have to unscrew the fuel pump module threaded collar.
Figure 7

Next, you have to unscrew the fuel pump module threaded collar. There is a BMW special tool (number 16 1 022) made to do this. The tool has notches that match the teeth on the collar (red arrows). Loosen the collar (inset). However, if you do not have this tool you can use a brass punch and a rubber mallet. Using the brash punch and a rubber mallet, tap the threaded collar on one of the ridges counter-clockwise to loosen. Once loose, unscrew the remainder of the way by hand. If the collar is damaged during this process, you will need to replace it with a new part.

Remove the collar from the fuel tank and store it in a safe place.
Figure 8

Remove the collar from the fuel tank and store it in a safe place. Slowly lift the fuel unit up slightly out of the tank enough to access the fuel lines and electrical connector. Remove it at an angle. Be careful not to bend or damage the sending unit.

Then press the retaining tabs on the fuel line (green arrow) and slide the fuel line off the fuel unit in the direction of the red arrow.
Figure 9

Then press the retaining tabs on the fuel line (green arrow) and slide the fuel line off the fuel unit in the direction of the red arrow.

Next, the siphon jet pump has to be removed.
Figure 10

Next, the siphon jet pump has to be removed. Press the black retaining tab (red arrow) and hold it down while sliding the siphon jet pump out of the bracket in the direction of the green arrow.

Disconnect the sending unit electrical connector by pressing the release tab (green arrow) and pulling it off.
Figure 11

Disconnect the sending unit electrical connector by pressing the release tab (green arrow) and pulling it off.

Once the lines and electrical connectors are removed, remove the left side fuel unit from the vehicle.
Figure 12

Once the lines and electrical connectors are removed, remove the left side fuel unit from the vehicle. Have a drain pan nearby. It will be full of fuel and some will leak. Cut a piece of mechanic's wire to about eight feet. Wrap one end of the wire around the siphon, electrical connecter and fuel line you previously disconnected from the left side fuel unit. This will help when routing the new fuel pump.

This photo shows the left side fuel unit with the level sender and integrated fuel filter.
Figure 13

This photo shows the left side fuel unit with the level sender and integrated fuel filter. To replace the fuel filter, you have to replace the entire unit.

Now it is time to remove the fuel pump.
Figure 14

Now it is time to remove the fuel pump. Move to the right side of the vehicle. Hold the carpet out of the way, and then remove the four 10mm nuts from the access panel. Remove the access panel lid (green arrow) from the body by lifting it up. Be sure to replace the panel gasket if it is damaged. Disconnect the fuel pump electrical connectors by sliding the locking tab (red arrow) away from the connector while lifting up.

Next you have to unscrew the fuel pump module threaded collar (red arrow).
Figure 15

Next you have to unscrew the fuel pump module threaded collar (red arrow).

Remove the collar from the fuel tank and store it in a safe place.
Figure 16

Remove the collar from the fuel tank and store it in a safe place. Slowly lift the fuel pump up slightly out of the tank. Then remove it at an angle. Be careful not to bend or damage the sending unit. Once the sending unit float clears the tank opening, feed the fuel lines out of the tank (red arrow). Have a bucket or plastic bin inside the vehicle with you. Catch any dripping fuel with a cloth as you remove it. Then immediately place the fuel pump module in the bucket to minimize spilled fuel. Remove the mechanic's wire from the old fuel pump. Attach it to the new one. Then feed the fuel lines into the tank. Use the mechanic's wire to pull it to the right side.

When installing, replace the fuel pump assembly sealing O-ring.
Figure 17

When installing, replace the fuel pump assembly sealing O-ring. Be sure that the O-ring is properly installed in the fuel tank before installing the fuel pump. Align the tab with the fuel tank (red arrow) and press the fuel pump module into the tank. Be sure that the plastic collar is also aligned with the fuel tank (green arrow).

Move to the left side of the fuel tank.
Figure 18

Move to the left side of the fuel tank. Pull the mechanic's wire until the fuel lines (green arrow) are in view. Reattach the fuel lines and electrical connector to the left side fuel unit. Slide the fuel unit into the fuel tank. Hand tighten the threaded collar. Then use the BMW special tool #16 1 022 to tighten the threaded collar. Or tap the threaded collar tight (clockwise) with a brass punch and a rubber mallet. Connect the fuel line. Fill the fuel tank with about two gallons of fuel before attempting to start the vehicle. Once you are sure that the fuel pump is operating normally, fill the remainder of the fuel tank and check for leaks. Once done, reassemble the interior.


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Comments and Suggestions:
1Cyclist Comments: I am considering replacing my Fuel Pump on 2007 530xi even though engine starts and runs fine. The car drips gas onto the ground sometimes when parked in front of the drivers side rear tire. Doesn't always drip. Since this is the location of the fuel pump I thought it could be the cause. Ideas?
December 7, 2016
sippi Comments: where is the fuel pump control module on the 2005 545i v8..I'm getting now communication car run for about 5mins then stalls or is a fuse..fuel pump and relay already be changed.
November 22, 2016
  Followup from the Pelican Staff: N62 engines did not use a fuel pump module. I would grab a repair manual. It will have the wiring, fuse and relay locations.


Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 
Eddie Comments: My 2004 E60 is throwing OBDII Codes p0461 fuel level sensor circuit range/performance, and p0462 fuel level sensor circuit low input. I tested the fuel pump side sending unit and it ohmed to 200 ohms. Is it necessary to test the filter side? The fuel gauge is reading empty and gas light on.
Thanks in advance
March 26, 2016
  Followup from the Pelican Staff: I would test both sides. Remove the sender and move them through the range while monitoring the resistance change. - Nick at Pelican Parts  
David Comments: I have to replace Fuel Line - In-Tank Fuel Filter Assembly to Fuel Feed Line that I ordered with the filter assembly form you and I can find a write up anywhere online. Anyway Pelican can email me or post a DiY on replacing this fuel line. It would really help.
January 5, 2016
  Followup from the Pelican Staff: You commented on our E60 fuel pump article:

http://www.pelicanparts.com/techarticles/BMW-E60/137-FUEL-Fuel_Pump_Replacement/137-FUEL-Fuel_Pump_Replacement.htm

The filter is part of the fuel assembly, see removal procedure in the article. Anything not covered, I would get a repair manual. It will have the procedure, special tools and torque specs.

Give our parts specialists a call at 1-888-280-7799. - Nick at Pelican Parts
 

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Page last updated: Fri 12/9/2016 02:47:09 AM