Removing and Installing / Replacing Fuel Pump, E90/92/93 N51 only

REP-REP-RAE9016-1614010N51

Removing and installing/replacing fuel pump (US vehicles with engine N51)






Special tools required: SWZ-SWZ-SWZ00-9252 Extension
- 0490517 / 009252
- Replaced by 0496782
- Note: Flexible extension, 150mm replaced by 00 9 462 (0 496 782)










Prior to repair work on the fuel pump, follow repair instructions entitled Fitting Aid for Quick Connector/Retainer Fuel Pump Quick Connector/Retainer Repair Kit - US N51
- Ensure adequate ventilation in the workbay!
- When performing repair work on the open fuel tank, work with a clean environment.
- Dirt contamination in the fuel tank can lead to driving impairments or to vehicle failure.

Necessary preliminary tasks:
- Draw off fuel from fuel tank (hyperlink)





- Remove rear seat bench
- Removing and installing/replacing rear seat
- Removing and installing/replacing rear seat (through loading) Rear Seat, Through-Loading
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Release screws (1) and remove cover (2) from right side of fuel tank.






Disconnect plug connection (1).
Release union nut (2) and move fuel delivery line slightly to one side.
Important!
- Always hold union nut (2) at hexagon head (3).
- Ensure that sealing surfaces are clean.
- Capture draining fuel.
Installation note:
- Tightening torque 30 +/- 6 Nm; Ensure precise alignment between ball and taper.
Unlock and disconnect snap fastener of tank ventilation line (4).





Lever out rest of torque sheer head (1) (if present) in the direction of the arrow using a screwdriver.
Fully detach hose clamp of clamping ring (2).
Note:
- To release the hose clamp, a flexible extension can be used. For example, special tool 00 9 252

Press clamping ring (2) apart at open end in direction of arrow and remove.






Installation note:
- Make sure that service cover is installed in correct position.
- Indentation (2) on clamping ring must line up with raised section (1) of tank.
- Pin on service cover (3) must line up with indentation on clamping ring.
- Hose clamp with torque sheer head (4) always needs to be replaced.
- Tighten hose clamp until torque sheer head (4) breaks off.






Carefully raise service cover.
Unlock and disconnect tank ventilation line and fuel delivery line (1).
Unlock retaining lugs (2) on both sides of connector housing (3) and detach connector housing (3) from service cap.
Installation note:
- When installing service cap, ensure that gasket (4) is correctly seated in tank opening.
- Seal (4) must always be replaced!
Remove service cap






Disconnect plug connections (1) for both fuel level sensors.
Disconnect plug connection (2) for grounding cables.
Important!
The ground cable on the filter box must not be released.






Unlock and disconnect fuel delivery line (1).
Important!
Do not use any tools to release the fuel feed line.
Turn fuel pump in direction of arrow (anticlockwise) and remove.
Installation note:
Ensure that the parts are correctly engaged