Fuel Pump Removal

By: RayMan (from BimmerForums.com)

For anyone thinking about doing this yourself its pretty straight-forward...just like UD///M says. This morning my car had a hiccup when I tried starting it and the car just wouldn't start. Checked all the fuses (hoping it was something simple) but after talking to a few mechanics I went out and picked up a new pump (about USD$ 125).

My car is a 94 325i cab but I'd guess most e36's are similar. If your radio requires an activation code - make sure that you have it. Disconnect the negative cable on the battery. Also, you might want to release some pressure in the fuel line by opening the gas cap. Then start by removing the rear seat (the part you sit on). Don't need to remove the backrest half. The sit should just pop off by giving it a firm tug upwards.

You will then see 2 round panels that are about 8 to 10" in diameter. They are held in place by 4 philips screws. The panel you want to remove is the passenger side one.

Once the panel is removed you will see the top of the pump assembly. Disconnect the 2 molex plugs. (I think one powers the pump and the other transmits the fuel level reading for the gauge). Then disconnect the 2 hoses by unscrewing the hoseclamps.

The top of the pump assembly is held down by a large black plastic ring which is screwed on fairly tight. You can remove it by using a large flathead pointed at one of the notches and tapping with a hammer.

Now the fun part. Make sure you have rags around and preferably a plastic tray or bucket to hold the old unit so you don't drip gas everywhere. You might have to do a little twisting and turning to get the unit out. At the top of the unit is a thick rubber gasket which the dealer recommended I replace. It's about $5 so probably better safe than sorry (even though mine was in pretty good shape).

Now its just a matter of putting in the new one by doing the reverse order of what you just did. Make sure that you put the new gasket onto the new fuel pump assembly before installing the unit.