16 14 010 Removing And Installing Or Replacing Fuel Pump (Petrol/Gasoline)

WARNING: This page is about a different car, the 2010 BMW 135i, 2009 BMW 135i, and 2008 BMW 135i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

For the following special tools, refer to FUEL SUPPLY SYSTEM .

16 1 020

Recycling

Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

IMPORTANT: Ensure adequate ventilation in the place of work!
Avoid skin contact (wear gloves)!
Before starting the engine for the first time:

Fill fuel tank with at least 5 liters of fuel.

Necessary preliminary tasks:

Draw off fuel from fuel tank . See 16 00 005 DRAINING AND FILLING FUEL TANK .
Remove rear seat bench . See SEATS - REPAIR (CONVERTIBLE) or SEATS - REPAIR (COUPE) .

Release screws (1) and remove cover (2) from right side of fuel tank.

Fig 1: Identifying Fuel Tank Cover

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USA national version:

Disconnect plug connection (1).

Unlock and detach vent lines (2).

If necessary, remove fuel line for independent heating.

Fig 2: Identifying Plug Connection And Vent Lines (USA National Version)

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ECE national version:

Disconnect plug connection (1).

Unlock and detach vent line (2).

If necessary, remove fuel line for independent heating.

Fig 3: Identifying Plug Connection And Vent Lines (ECE National Version)

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw cap with special tool 16 1 020 and remove service cap.

Installation:

Procedure for tightening screw cap, see next work step.

Fig 4: Removing Service Cap

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IMPORTANT: Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 1 020 until notch (1) points to marking (2).

NOTE: Illustration shows the tank removed.

Fig 5: Identifying Screw Cap Notch

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Carefully raise service cap (1).

Unlock and detach vent line (2).

Installation:

Clean sealing faces and install new seal (3).

Make sure that the lever sensor moves freely before fitting the service cap.

Locating rods (4) must fit correctly in the hole of the delivery unit.

Fig 6: Identifying Service Cap And Vent Line With Seal

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Installation:

Service cap can only be installed in one position.

When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.

Fig 7: Identifying Service Cap Lug

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Disconnect plug connection (1).

Installation:

Connect cable with cable tie (2).

Ensure correct routing of cables.

Fig 8: Connecting Cable With Cable Tie

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Unclip black return lines (1) from bracket.

Unlock and disconnect quick-release fastener (2) of fuel line.

IMPORTANT: Do not use any tools to release the fuel feed line.

Draw off remaining fuel from surge chamber.

Carefully lift fuel pump with fuel level sensor (3) out of fuel tank.

If necessary, turn fuel pump 90° counterclockwise and tilt towards lever sensor.

Fig 9: Identifying Fuel Level Sensor And Return Lines

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