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Thread: 2004 BMW X3 fuel pump

  1. #1
    Join Date
    Sep 2017
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    2004 x3

    2004 BMW X3 fuel pump

    I'm replacing my fuel pump, but the new pump doesn't have the small black hose attachment like the old one, pumps look identical other than that.....any thoughts. I checked all of the install posts and no one else seems to have an issue.

  2. #2
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    Please tell us the last seven digits of your VIN, and also the part number of the fuel pump unit you bought.

    Where did you buy the fuel pump? If you bought it from a local generic supplier like Autozone or something, return it immediately, and buy a genuine VDO unit from a good BMW specialist supplier. You also will need a new top seal for the fuel tank, of course.

    The correct part number for the fuel pump unit will be 16117159604.
    Here it is at ECS Tuning : https://www.ecstuning.com/Search/Sit...h/16117159604/

    Here it is from getbmwparts.com (They are a BMW dealership) : https://www.getbmwparts.com/parts/in...&siteid=214672
    Last edited by bmwdirtracer; 09-22-2017 at 09:10 PM.

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

  3. #3
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    Yes to everything Chris said, and you'll probably also need a new screw cap/lock ring for the pump.... or at least I always do even when I use the proper tool, they are easy enough to damage that I always just suggest them.

    link to parts - https://www.ecstuning.com/BMW-E83-X3...aign=postreply



    -James

  4. #4
    Join Date
    May 2012
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    Clarkson Valley, MO, USA
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    My Cars
    1995 540i 6 speed
    2005 X3 fuel pump - I'm down to trying to get the fuel pump itself out and cannot figure out how to release the fuel pump assembly from the tank. I have the round access panel off, have taken the two fuel lines off of the top cover, removed the top cover and am looking down into the tank at the fuel pump. There are evidently one or two tabs that need to be moved out of the way, but I cannot see them. Anyone done this before?

    Tom

  5. #5
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    Hi Tom,
    It's not easy, unless you've been there before.

    If you're looking down into the tank full of fuel, you'll likely be seeing a couple of electrical plugs, and a couple of hose fittings. The pump assembly should have moved upwards when you released the top ; it's all connected to the white plastic top unit. You DID but a genuine BMW / VDO assembly, not just an Autozone pump, right? You will, of course, need a new gasket, too....comes with the genuine BMW / VDO unit.

    You'll have to release several hose assemblies and electrical plugs which live underneath the gasoline; they are connected to the passive assembly in the other side of the tank.

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

  6. #6
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    1995 540i 6 speed
    Chris,

    I bought the fuel pump and fuel filter from BMA Parts in California - the fuel pump is part no. 16 11 7 159 604, fuel filter is part no. 16 14 6 766 158. My problem is - I do not see the tabs that must be leased in order to lift the fuel pump out. I'm guessing that the fuel filter is removed separately from the fuel pump and they do not come out at the same time. The whole fuel pump installation seems awkward as the fuel pump sits back toward the rear from the opening in the top of the fuel tank and not directly below the opening as is the case on my 1995 540i. Also, I found a plastic piece rolling around on the bottom of the fuel tank - it is about 7/8" dia. and 1-7/8" long and looks like a check valve - when you shake it, a piece moves up and down inside this little cylinder of mystery.

    Tom

  7. #7
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    I've never actually done an X3 pump, I guess. I looked it up for you on the pro website I use. I will say that I've never had to look up how to do a fuel pump, but this one is certainly different.

    I'm not going to try to figure it out right now...let's just say I've been celebrating the New Year for a couple of hours already.

    However, I'm going to try to copy the instructions for you. I am skipping the first few photos and all the warnings, because you're already there. I have had to copy each picture to my computer, and label them separately....let's just hope I can stick them into the correct spot in the verbal directions,,,ten times.


    Hmm, maybe I'll just insert a label in each spot....bear with me, I'm not good at these computer tricks.


    --------



    Necessary preliminary tasks:

    Draw off fuel from fuel tank See: Fuel Tank\Service and Repair\Procedures
    Remove rear seat bench See: Body and Frame\Seats\Service and Repair\Removal and Replacement\Rear Seat, Through-Loading



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



    Unlock and detach plug (1), fuel feed line (2) and service vent line (3).



    Release screw cap with special tool 16 1 020 See: Tools and Equipment\16 1 020 Pin Wrench and remove service cap.

    Installation:
    Tightening torque 16 14 2AZ See: Specifications\16 14 Fuel Pump.



    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.

    During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment (4) on fuel tank.

    Replace rubber gasket.

    PHOTO 1

    Important!
    Make sure that tab (1) of adapter ring lies completely in recess (2).

    PHOTO 2

    Carefully raise service cap (4) on right.

    Unlock and detach fuel line (2).

    Detach vent line (3).

    Disconnect connector (1).

    Important!
    Carefully release quick-release fasteners and detach.

    Make sure quick-release fasteners are correctly engaged.

    Test the quick-release fasteners by pulling on them.

    PHOTO 3

    Installation:
    Cable (1) must be laid in a loop around the corrugated tube (2).

    Cable must not restrict freedom of movement of lever-type sensor!

    PHOTO 4

    Unlock and disconnect plug housing (1) using a screwdriver (2).

    PHOTO 5

    Disconnect plug connection (1).

    PHOTO 6

    Press retaining lug (2) together simultaneously in direction of arrow and detach fuel line (1) from pressure regulator.

    PHOTO 7

    Detach line (1) in direction of arrow from surge chamber.

    Installation:
    Line (1) must snap audibly into place.

    PHOTO 8

    Press retaining lug (1) in direction of arrow towards rear and lift out fuel pump with surge chamber (2).

    Installation:
    Fuel pump can only be installed in one position.

    Make sure lug (4) of mounting engages opening in fuel pump.

    Make sure fuel pump (2) is correctly positioned in guides (3).

    © 2017 ALLDATA LLC. All ri





    I'll post the other 4 pictures on an additional post; or I'll run out of permitted attachments.
    Attached Images Attached Images
    Last edited by bmwdirtracer; 12-31-2017 at 08:46 PM.

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

  8. #8
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    Okay, the other 4 pics: Hope this all helps !
    Attached Images Attached Images

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

  9. #9
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    Clarkson Valley, MO, USA
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    1995 540i 6 speed
    Chris - thank you ever so much. Photo #8 is the sequence I did not understand. The retaining lug is pretty much hidden under the top of the fuel tank - BMW did a good job of making a simple procedure difficult. I've been working on cars (MGA, Datsun 510, BMW 318i, Lotus Europa, Miata, BMW 540i, BMW X3) since 1959. The only ones I no longer have are the Datsun 510 and BMW 318i. I have rebuilt engines and gearboxes on the MGA, Lotus Europa and Miata. My current project is a frame off restoration of the Lotus Europa. My Bentley X3 manual should be here tomorrow. I've also ordered a new screw cap and the tool for removing and replacing it as the punch and hammer method of removing the screw cap really damages the little lugs on the screw cap. The Lotus is so much easier to work on - you can stand inside the engine bay straddling the transaxle and work on anything. Also, no circuit boards, no electronics (except the ignition system) - a simpler world.

    Tom

  10. #10
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    Chris,

    OK - the fuel pump is out - easy when you know where the magic 'tab' is located. I used a pair of needle nose vise-grips to grab the side of the fuel pump to pull it out - not enough working room for two hands in the access opening. Now, I'm stumped in getting the fuel filter/pressure regulator out. Can you help? The Bentley shop manual says the fuel filter is a 'lifetime filter', thus does not need service - what kind of nonsense (aka BS) is this?

    When I first looked down into the fuel tank (full of fuel - had to siphon it out), I saw a plastic piece rolling around in the bottom of the tank - it had Patent 5313977 embossed on it - no BMW Part No. - I Goggled the Patent No. and found the part is a 'fluid responsive vent control valve' - I think it is part of the fuel vapor removal system - sounds like a check valve when you shake it. It must have come loose when I was hammering in the fuel pump service cap with a punch and hammer. I have since gotten a new service cap and the BMW tool to tighten it. Anyway, can you explain how to remove the fuel filter/pressure regulator and where does the part goes I found rolling around in the bottom of the fuel tank?

    Tom

  11. #11
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    1995 540i 6 speed
    Chris,

    OK - the fuel pump is out - easy when you know where the magic 'tab' is located. I used a pair of needle nose vise-grips to grab the side of the fuel pump to pull it out - not enough working room for two hands in the access opening. Now, I'm stumped in getting the fuel filter/pressure regulator out. Can you help? The Bentley shop manual says the fuel filter is a 'lifetime filter', thus does not need service - what kind of nonsense is this?

    Also, when I first looked down into the fuel tank (full of fuel - had to siphon it out), I saw a plastic piece rolling around in the bottom of the tank - it had 'Patent 5313977' embossed on it - I Goggled the Patent number - it is a 'Fluid-Responsive Vent Control Valve' - probably part of the fuel vapor removal system, but I don't know where is should be located inside the tank - do you have any idea where it belongs? I may have jarred it loose when I removed the service cap with a punch and hammer - a lot of hammering. I have since gotten a new service cap and the BMW tool to re-install the cap.

    Tom

  12. #12
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    Chris,

    This is the part I found in the fuel tank.

    Found in Fuel Tank.JPG

    Tom

  13. #13
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    I'll try:



    Installation:
    Service cap can only be installed in one position.

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

    During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment (4) on fuel tank.

    Always replace seal (2).



    Press retaining lugs (2) together simultaneously in direction of arrow and detach fuel line (1) from pressure filter.



    Unlock line connection (1) and detach from pressure regulator.



    Remove fuel filter with pressure regulator (1) from mounting in direction of arrow.



    Installation:
    When installing, make sure that turning lock (1) on fuel filter engages opening (2) on fuel filter holder.



    Disconnect grounding cable (1) from pressure regulator and fuel filter.

    - - - Updated - - -

    More.....insert photos where you see breaks in the text: Wish I could give personal experience, but I can't....looks like a pain in the ass.
    Attached Images Attached Images

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

  14. #14
    Join Date
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    1995 540i 6 speed
    Chris,

    Do you have any idea what the part may be that I found rolling around in the bottom of the fuel tank? See my earlier reply about and a photo of the part and a bit more explanation.

    Tom

    Tom

  15. #15
    Join Date
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    1995 540i 6 speed
    Chris,

    I figured out what the mystery part was I found rolling around in the bottom of the fuel tank. It plugs into a round 'receiver' in the bottom of the white plastic 'service cap' - it is evidently part of the 'fuel vapor recovery system'. I must have vibrated it loose when I removed the service cap nut with a punch and hammer - a lot of banging went on to remove the nut. I installed a new nut and tightened it with the 'proper' BMW tool I bought. Also got the new fuel filter/pressure regulator installed. I have worked on a lot of car over the years - this was a PITA - working blind and by feel most of the time. My car must have been an early 1995 as I found that later X3's had a different fuel system with the fuel pump directly below the hole in the fuel tank (not off to the rear of the tank), the fuel filter installed under the car on the unibody and the pressure regulator installed under the hood. Car now runs fine. Thank you for your help.

    Tom

  16. #16
    Join Date
    Oct 2018
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    Tamps, Fl
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    1997 BMW X3

    Help

    Quote Originally Posted by BMW63005 View Post
    Chris,

    I figured out what the mystery part was I found rolling around in the bottom of the fuel tank. It plugs into a round 'receiver' in the bottom of the white plastic 'service cap' - it is evidently part of the 'fuel vapor recovery system'. I must have vibrated it loose when I removed the service cap nut with a punch and hammer - a lot of banging went on to remove the nut. I installed a new nut and tightened it with the 'proper' BMW tool I bought. Also got the new fuel filter/pressure regulator installed. I have worked on a lot of car over the years - this was a PITA - working blind and by feel most of the time. My car must have been an early 1995 as I found that later X3's had a different fuel system with the fuel pump directly below the hole in the fuel tank (not off to the rear of the tank), the fuel filter installed under the car on the unibody and the pressure regulator installed under the hood. Car now runs fine. Thank you for your help.

    Tom
    Is there any way you can tell me when you say service cap where that is or what part that is I'm a female trying to do my own fuel pump.

  17. #17
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    Hi Amanda, and welcome to the forum. And, a special welcome, because you're "a female trying to do your own fuel pump".

    As you can see from the above directions I posted a while back, the X3 isn't the easiest fuel pump job, compared to other BMWs. The directions I gave are copied from a pro website, which copied factory directions. For this and future work on your car, here's a link to the factory wiring diagrams, and the factory workshop manuals:

    https://www.newtis.info/tisv2/a/en/

    To answer your question, the "service cap" to which Tom is referring is the metal, screw-on ring which holds the fuel filter in place in the top of the tank. It is shown in the second picture from James (ECS Tuning), next to the factory-type tool for removing it.

    I will, however, tell you that I've never ruined one, nor have I ever used the factory tool. That said, using a large screwdriver and a 3-pound hammer to remove and install that ring does take a little bit of experience. Truly, so does the rest of this job, on this particular model. Everything is plastic and fragile - if you use tools to release the plastic quick connect fittings, you may damage them irreparably. Furthermore, you will be working with your hands under gasoline a fair bit....well, one hand...there's not room for 2...

    Don't buy a cheap imitation. Buy only a genuine VDO unit from a reputable BMW supplier, like FCP Euro, or ECS Tuning.

    Chris Powell
    Racer and Instructor since, well. decades, ok?
    Master Auto Tech, owner of German Motors of Aberdeen
    BMWCCA 274412
    German Motors is hiring ! https://www.bimmerforums.com/forum/s...1#post30831471

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