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E46 Xi Forum
The E46 XI was produced from 01-05 in sedan and touring body styles. Powered by either a 2.5L inline 6 in the 325xi or a 3.0L inline 6 330xi. Discuss all thing about BMW AWD E46 'Xi' here.

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Old 08-28-2013, 10:31 PM   #1
frickengruvin
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Join Date: May 2012
Location: Norther Nevada
Posts: 12
My Ride: '04 325Xi
325Xi fuel pump install

I'm replacing the fuel filter and fuel pump on my '04 325Xi. Fuel filter replacement was pretty straight forward. I'm at the point of installing the new fuel pump now. I have installed the gasket on the new fuel pump as it is installed on the old one. The fuel pump is in the tank now, but I'm having a helluva time getting it to seat. Is there any "trick" to seating the fuel pump gasket? I don't want to break the pump housing. I'm exerting quite a bit of pressure in attempting to seat it, but no luck to this point.

Thanks for the advice in advance!
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Old 08-28-2013, 10:46 PM   #2
dgknight
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Join Date: Dec 2009
Location: Bay Area, CA
Posts: 184
My Ride: 02 325xi 5sp 120k
Yeah put the seal into the tank neck first (not on the pump). Then carefully thread the pump through without knocking the seal loose.

If you don't do it that way it could leak as well as being hard to seat. Ask me how I know...
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Old 08-28-2013, 10:57 PM   #3
frickengruvin
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My Ride: '04 325Xi
Thanks dg...I'll give that a try tomorrow...
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Old 08-29-2013, 07:33 AM   #4
Arnezie
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Join Date: Aug 2011
Location: Michigan
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My Ride: 04 325XI
325Xi fuel pump install

Yup what he said. The seal goes around the opening and kinda tucks into place then carefully insert pump


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Old 08-29-2013, 09:32 PM   #5
frickengruvin
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Join Date: May 2012
Location: Norther Nevada
Posts: 12
My Ride: '04 325Xi
Great advice...after seating the gasket in the fuel pump opening, the pump pretty much fell in. I've got about 5 hours in replacing the fuel filter, oil filter, fuel pump and battery, including test drive and clean up-not bad, considering my lack of experience working on these autos...
One note to those whose have never replaced the fuel pump. There is a glue "blob" that sets on the retaining ring and fuel pump housing. I carefully sliced that "blob" and doing that assisted the ease in which the ring was able to be removed....
It's a pretty simple job...By the way, I had 7/8 of a full tank and maybe lost a 3 or 4 tablespoons of fuel...

Thanks again for the advice and consideration!
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Old 08-30-2013, 01:34 AM   #6
dgknight
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Join Date: Dec 2009
Location: Bay Area, CA
Posts: 184
My Ride: 02 325xi 5sp 120k
Glad you got it figured out! Sounds like you've got it. If you want to be 100% sure the seal is good while its cool out rather than when the sun is blazing down, go ahead and run the engine for a few minutes and check for fuel spilling under the passenger side rear seat area.

The way the pump works it scavenges fuel from the left side of the tank and so the right will fill up after a few moments. If the seal is improper it will begin to spill out and is conveniently routed down the back of the tank and drips somewhat away from the hot exhaust, at least while the car is stationary.
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Old 09-12-2013, 12:19 PM   #7
sminnich
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My Ride: 04 325xi
It'll also overflow if it's not seated correctly haha
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