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1slick66 05-03-2011 08:13 PM

fuel pump removal
Hi: I 'm new to this site, sounds very informational, I have a 1994 525I, did some testing of relays, fuses, etc.:dunno: to fuel system, it looks like my fuel pump is bad, would like to know how to remove fuel pump from module or housing, so i can replace just the fuel pump, and not the whole module, any expert, step by step advice would be appreciated. thanks!

somerandomdude 05-08-2011 08:45 PM

Step 1. Disconnect the battery. Always do this when working on the fuel system.

Step 2. Open the trunk lid and lift up the carpet. You will see a cover with a bunch of screws holding it in place. Take the screws out and remove the plate.

Step 3. Disconnect the plug from the sending unit.

Step 4. Undo all the nuts holding the sending unit in place. Also disconnect the hoses attaching to it. Remember where they go! I don't remember what size the nuts are.

Step 5. Carefully lift the sending unit out. There are 2 wires coming out and 2 more hoses coming out that is attached to the fuel pump sitting in the bottom of the tank.

Step 6. Reach inside the fuel tank and look for 2 clips holding the pump in place. They are built into the pump. You might have to work it as the return line attached to the pump going into the bracket at the bottom of the tank.

Step 7. Undo the wires from the pump and undo the hoses from the pump. Now is the time to get new hose clamps. Remember where the wires go. It will be marked on the new pump as well as the old one. Look for - and + signs on the pump. Mark witch wire went to what.

Step 8. Install is in reversal.

Here's a little advice. Before you seal up the tank. Make sure the pump turns on by jumping terminals 87 and 30 where the relay sits. Have a friend listen for the pump. If all is good, button everything up and enjoy your new fuel pump. It's also a good idea to change the fuel filter located behind the rear passenger wheel in the wheel well area. Sorry that I don't have pictures. But, I think you'll get the idea.

1slick66 05-09-2011 01:57 PM

Hey Somerandomdude: Thank you very much for all your information, this was exactly what I needed, good advice, worked out great, did everything you mentioned, now just waiting for fuel pump to arrive, Thank You!!! I did find a site on line for super prices on fuel pumps,ordered from treperformance, what a difference in price from original BMW. saved $200.00 if it functions OK.

somerandomdude 05-09-2011 02:31 PM

Good, glad to hear it's working out for you :) Keep us updated! I picked up a new Bosch unit on Saturday from a local auto parts store. It was 347 dollars for it. Can't complain at least lol.

vetaldj 05-29-2011 05:38 PM

Do you need to pump all fuel out from the tank? I need to do this as well and dealer wants $1600 for this job...

somerandomdude 05-29-2011 06:59 PM

Just make sure it's not filled up to the top. I did mine with a little less then half of tank left. You will get your hands wet. Also, make sure to clean out any debris out of the holder for the pump and make sure nothing falls in there.

laurenarce 08-07-2012 11:43 PM

Fuel Pump Threaded Collar Ring Removal Tool
If you're having problems removing the threaded collar ring on the fuel pump or fuel level sender unit, we sell a tool to un-tighten the ring for removal and tighten it for install. See our webpage at:


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