BMW 330i ZHP fuel pump DIY doityourself

[danewilson77]

Time: 1 hour

Parts: fuel pump 16146766942

Tank level: I had 7/8 tank and spilled maybe 1/4 cup...if that.

http://www.realoem.com/bmw/showparts.do?model=EV53&mospid=47725&btnr=16_0373& hg=16&fg=15





Tools:
1. 10mm socket, 1/4" ratchet
2. Rags
3. 2 small tweakers (screwdrivers)
4. Wheel alignment tool (to plug supply tubing)
5. Hammer and large screwdriver.

***ENSURE CAR IS IN WELL VENTILATED AREA***

STEP 1 - Disconnect negative terminal on battery. Use 10mm socket here.

STEP 2 - Pull up on front edge of back seat to release clips. Set backseat aside.

STEP 3 - Remove sound damping material around fuel pump access plate. Mine just crumbled.

STEP 4 - Remove access plate by removing 4 10mm nuts. Slide electrical wiring up plate and set aside. Yes..you will likely see an unplugged connector. Some say this is used as a tamper kill switch during shipping...don't worry about it.



STEP 5 - Disconnect electrical connection by pulling lock clip toward passenger side of car. As it unlock//slides...the connection will become disconnected.

STEP 6 - Disconnect supply tubing by releasing hose clamp. Use a small socket or screwdriver here. Have your tubing plug ready...then plug hole after disconnection. This was the biggest pita for me. I used the two small tweakers to work in along the side of the hose, to break the seal. There may be enough extra hose to just cut it, but I wasn't taking any chances.

STEP 7 - Using hammer and large screwdriver hit locking ring smartly at various opposite locations to rotate and loosen lock ring. Remove lock ring and set aside.

STEP 8 - Pull pump up and out slowly, allowing pump to drain off into tank. Some finagling has to occur here due to the way the level sender is designed. Remove blue lock gasket with the pump and do not drop in tank. I cleaned up the used gasket here and re-used. It looked brand new.

Gas level is right at the rim.


STEP 9 - Re-assembly is in reverse of above direction. Ensure car smells of zero gas before making the connection at the negative battery terminal.

Also..do not install metal cover or backseat, until you turn key, wait 15 seconds, start car, and inspect for leaks.

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[johnrando]

Was just thinking something good had to come from all your efforts, and here it is!

[danewilson77]

Was just thinking something good had to come from all your efforts, and here it is!

Thanks.

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[Oli77]

Thanks Dane.

I put one of your ZHPmafia business card on the windshield of a beautiful black M3 parked next to me today.

Told him/her to join us.

[danewilson77]

Thanks Dane.

I put one of your ZHPmafia business card on the windshield of a beautiful black M3 parked next to me today.

Told him/her to join us.

Thanks Oli.

HTC Thunderbolt+TT

[quikryptonite]

Thanks for the post Dane. I got mine replaced today. Besides removing the old hose clamp, the only other part I found to be difficult was reiinstalling the electrical connection to the top of the fuel pump. Here is a video I found that helped me out, and may help out some others. Start at the 4:14 mark. You need to pull the connection out of the housing, push it on, then slide the assembly forward.