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<!-- from fixya rte -->HOW TO CHANG A FUEL PUMP ON 2002 BMW X5 3DI - BMW Cars & Trucks

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BMW has a unique habit, the automaker has, for years, used the rear passenger area of its cars to mount items like batteries, fuel pumps and fuel pump sender units. It makes sense in a weird way as it does keep wire runs short and makes access to the fuel pump and the sender unit more convenient than in other vehicles. The downside is that you have to disassemble the passenger seat to gain access to the fuel pump and the fuel pump sender.

To replace the fuel pump, you have to remove the rear seat starting with the child safety seat holddown covers. The child seat holddown covers simply unclip and slide away.

Next, you have to remove loosen the rear seat back so you can remove the rear seat bottom. The rear seat back slides up slightly so the seat bottom can be removed. You remove the rear seat bottom, being careful to watch the seatbelt lap attachment units, by moving it out and forward. It may take several movements to do this. Once the seat is free, swing it vertical and out of the way.

With the rear seat out of the way, you will see the fuel pump and fuel pump sender access cover panel. It is a sheet of composite material with four access holes per side. Remove any holddown clips or nuts that you find in the access cover panel, being careful to leave it in place, for the moment. Once you have removed the clips or nuts that are used to hold down the access cover panel , place them in a secure spot out of the way, such as an ashtray or one of the cargo trays to ensure you that the clips or nuts don't become victims of the repair (they are easily lost).

Now, it's time to orient yourself to the fuel pump and fuel sender sites. Looking toward the rear of the BMW, you will find the fuel pump on the left (passenger side) of the vehicle and the fuel pump sender unit on the right (driver side).

Next, find the access holes in the fuel pump cover seal plate. Insert a 10 mm ratchet socket and drive arm and remove the fuel pump cover plate access screws.

Since you have already loosened the fuel pump and fuel pump sender access cover panel, simply remove the sheet of composite material and expose the fuel pump cover seal plate. Now, remove the metal fuel pump cover seal plate.

On removing the fuel pump cover seal plate, you have access to the fuel pump assembly. Looking at the top of the fuel pump assembly, you will see the power plug and fuel line.

Next, remove the power plug from the left hand side of the fuel and loosen the fuel line clamp. After loosening the fuel line clamp, remove the fuel line and place it in a small metal container to trap any fuel that might leak out.

Next, remove the fuel pump retaining ring. There is a special tool available from BMW to handle this chore. Or, if you take a flat-bladed screwdriver and a small hammer and place the blade of the screwdriver against one of the raised nubs on the retaining ring, you can gently tap the screwdriver, exerting pressure toward the rear of the X5, to loosen the retaining ring. Once it is loosened, unscrew the ring by hand.

Now, remove the fuel pump assembly and place it on a cloth on the ground. The cloth is there to absorb any leakage.

Now, take the replacement fuel pump and insert it into fuel pump site and replace the retaining ring, spinning it tight by hand. Then, take the screwdriver and hammer again and gently tap the ring, exerting pressure toward the front of the vehicle.

Reattach the power lead and fuel line, tightening the fuel line clamp, and you are finished.

Clean up and complete the repair by replacing the fuel pump cover seal plate and fuel pump access cover panel. Reinsert any clips or nuts to hold down the fuel pump access cover panel. And, reinsert the four 10 mm nuts for the fuel pump cover seal plate through the access cover panel and torque them down.

Finish up by reversing the seat removal steps.

That's it, you have just finished removing and replacing the fuel pump.

Posted on Nov 22, 2014

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