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    1997 BMW 328I 2.8L EFI DOHC 6cyl

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    Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

    Fuel Pump

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    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  

    Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only hoses and clamps specifically designed for fuel injection.

    1. Relieve the fuel system pressure.
    2.  
    3. Remove or disconnect the following:
      NOTE
      Remove the seat cushion by pulling the stopper outward and lifting the lower cushion upward. There are 2 access covers underneath the seat. The panel on the far right side is for the fuel pump.



      Negative battery cable and properly isolate to prevent accidental reconnection.
       
      Rear seat cushion
       



      Access cover/protector
       
      Fuel pump wiring
       
      Return hose and high pressure fuel hose
       

    4.  
    5. For 1999-00 vehicles, remove the fuel pump nuts and pump
    6.  
    7. For 2001-05 vehicles, use special Tool No. MB991480, or equivalent to remove the fuel pump module.

      Click image to see an enlarged view

      Fig. Fuel pump special tool and mating marks



      Click image to see an enlarged view

      Fig. Fuel pump packing

    8.  

    To install:

    1. For 1999-00 vehicles, align the seal position projections with the holes in the fuel pump assembly. Install the fuel pump assembly and torque the nuts to 22 inch lbs. (2.5 Nm)
      WARNING
      Install the packing to the fuel tank, then install the fuel pump module in the tank. Install the packing to the fuel pump module will damage the packing lip when installing the fuel pump module to the fuel tank and fuel leakage will occur.

    2.  
    3. For 2001-05 vehicles, perform the following:
      1. Check that the fuel tank is not damaged or deformed, then securely install the packing to the fuel tank. Replace the packing if it is damaged or deformed.
        WARNING
        Do not tilt the fuel pump module during installation.


        WARNING
        The packing should not be folded over as shown by "A" in the illustration

      2.  
      3. Apply soapy water to the inside of the packing, then install the fuel pump module.
        WARNING
        When tightening, be careful not to let the fuel pump module turn together with the cap. If the mating marks are misaligned, the float may measure a remaining amount of fuel incorrectly, causing the low fuel warning light to malfunction.

      4.  
      5. Use special Tool No. MB991480 to align the mating marks on the fuel tank and fuel pump module, then tighten the cap.
      6.  

    4.  
    5. Install or connect the following:

      High pressure hose, return hose and fuel pump wiring
       
      Negative battery cable
       

    6.  
    7. Check the fuel pump for proper pressure and inspect the entire system for leaks.
    8.  
    9. Apply sealant to the access cover and install the cover.
    10.  
    11. Install the rear seat cushion.
    12.  
    13. Pressurize the fuel system by turning the ignition key to the ON position.
    14.  
    15. Start the engine to verify proper fuel pump performance.
    16.  

    The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure to approximately 49 psi (337.8 kPa). Voltage to the fuel pump is supplied through the fuel pump relay.

    The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections and the pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module.

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the negative battery cable from the left shock tower.
      NOTE
      The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

    4.  
    5. Remove the fuel filler cap and relieve the fuel system pressure using the recommended procedure.
    6.  
    7. Remove or disconnect the following:

      Fuel pump harness electrical connector on the left side of the trunk near the base of the shock tower
       
      Fuel pump harness grommet and push the harness through the hole
       

    8.  
    9. Raise the vehicle and drain the fuel tank.
    10.  
    11. Remove or disconnect the following:

      Fuel tank inlet and from the filler hose
       
      Fuel tank straps. Support with a jack prior to loosening the straps.
       

    12.  
    13. Carefully lower the tank.
    14.  
    15. Clean the top of the tank to remove any loose dirt.
    16.  
    17. Remove or disconnect the following:
      CAUTION
      The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.



      Fuel lines from the fuel pump module
       
      Fuel pump locknut using Spanner wrench tool 6856
       



      Fuel pump
       
      Fuel tank O-ring and discard it

      Click image to see an enlarged view

      Fig. Removing the fuel pump module lock ring using special tool 6856

       

    18.  

    To install:

    1. Thoroughly clean all parts. Wipe the seal area of the tank clean.
    2.  
    3. Install or connect the following:
      NOTE
      Be sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.



      New O-ring onto the fuel tank
       
      Fuel pump module in the tank
       



      Locking ring and torque it to 41 ft. lbs. (55 Nm), using Spanner Wrench Tool 6856
       
      Fuel tank assembly
       
      Negative battery cable
       

    4.  
    5. Refill the fuel tank.
    6.  
    7. Turn the ignition switch ON to pressurize the system. Check the fuel system for leaks.
    8.  

    1. Remove the fuel filler cap and perform fuel system pressure release procedure.
    2.  
    3. Disconnect negative cable from battery.
    4.  
    5. Drain fuel tank dry into holding tank or a properly labeled gasoline safety container.
    6.  
    7. Raise vehicle on hoist and support.
    8.  
    9. Use a transmission jack to support fuel tank. Remove bolts from fuel tank straps.
    10.  
    11. Lower tank slightly.
    12.  
    13. Disconnect the fuel filler vent tube.
    14.  
    15. Disconnect fuel line and vapor line.
    16.  
    17. Disconnect the vacuum line from the LDP.
    18.  
    19. Disconnect fuel filler tube by loosing the clamp and removing hose.
    20.  
    21. Slide fuel pump module electrical connector lock to unlock. The fuel pump module electrical connector has a retainer that locks it in place.
    22.  
    23. Push down on connector retainer and pull connector off module.
    24.  
    25. Lower tank from vehicle.
      CAUTION
      The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.

    26.  
    27. Disconnect fuel line from fuel pump module by depressing quick connect retainers with thumb and forefinger.
    28.  
    29. Slide fuel pump module electrical connector lock to unlock.
    30.  
    31. Disconnect the electrical connection from the fuel pump module, by pushing down on connector retainer and pulling connector off of module.
    32.  
    33. Mark fuel pump location.

      Click image to see an enlarged view

      Fig. Use a brass punch and hammer to remove fuel pump module lock ring

    34.  
    35. Use a brass punch and hammer to remove fuel pump module lock ring.
    36.  
    37. Remove the fuel pump and O-ring seal from tank. Discard old seal.

      Click image to see an enlarged view

      Fig. Fuel pump location

    38.  

    To install:

    1. Wipe seal area of tank clean and place a new seal in position in the tank opening.
    2.  
    3. Position fuel pump in the tank.
    4.  
    5. Position the lock ring over the fuel pump module.
    6.  
    7. Tighten the lock ring using a brass punch and hammer.
    8.  
    9. Connect the electrical connector.
    10.  
    11. Connect the fuel line to the fuel pump.
    12.  
    13. Position fuel tank on transmission jack.
    14.  
    15. Raise tank into position and carefully work filler tube onto the fuel tank. A light coating of clean engine oil on the tube end may be used to aid assembly. Connect fuel filler tube hose and tighten clamp.
    16.  
    17. Connect fuel pump/module electrical connector. Place retainer in locked position.
    18.  
    19. Connect the EVAP, vapor, and vacuum lines.
    20.  
    21. Lubricate the fuel supply line with clean 30 weight engine oil, install the quick connect fuel fitting.
    22.  
    23. Attach filler vent line to filler tube. Pull on connector to make sure of connection.
    24.  
    25. Place NVLD air filter under right rear tank strap before tightening.
    26.  
    27. Tighten strap bolts to 40 ft. lbs. (54 Nm).
    28.  
    29. Remove the transmission jack.
    30.  
    31. Tighten filler hose clamp to 32 inch lbs. (3.6 Nm).
      WARNING
      Ensure straps are not twisted or bent before or after tightening strap nuts.

    32.  
    33. Fill fuel tank, replace cap, and connect battery negative cable.
    34.  
    35. Use a scan tool to pressurize the fuel system. Check for leaks.
    36.  

     
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