Fuel Pump: Service and Repair

Fuel Pump Removal

Note : 1994 and 1995 740i, 740iL Models came with two different fuel pumps.


Early Design



REMOVE AND INSTALL

Fuel Pump Location:

1. Lift out the trunk insulation.
2. Remove the fuel pump cover plate screws and the cover plate.

Supply And Return Lines:

3. Mark the fuel lines and hoses for identification and remove.
4. Pull the slide on the electrical connector to one side and remove the connector.
5. Remove the fuel level sending unit retaining screws.

NOTE: If necessary, draw off some fuel with a scavenging pump.

In Tank Fuel Pumps:

6. Carefully remove the fuel level sender and lay it aside.
7. Compress the safety hooks on the fuel pump holder and pull out the pumps.
8. Remove the electrical connectors and fuel hoses and pull the pump out of the fuel pump console.
9. Remove the filter screen retaining screw and lift of the filter.
10. With a new seal reinstall in the reverse manner.

Late Design (Most E38 Chassis Use This Type).

- Suck the fuel out of the fuel tank. See: Draining and Filling Fuel Tank Service and Repair

- Remove right sensor for fuel level indicator.






CAUTION: Disconnect both plug connections (1) on the fuel pump.

- The retaining hooks on the plug connections (1) make disconnection more difficult. Separating them forcefully can cause damage.
- From 01/96, optimized plug connection (1) with black plastic housing. These automatically disconnect when the connector housing is pulled.






- Unfasten cable connector.






- Unfasten hose clip, pull spiral hose off carefully, taking care not to damage the connection.






Installation Note: In order to avoid twists, align the connector hose and cable (1) between the lid (2) and fuel pump (3) before installing.