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General E46 Forum
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Old 12-12-2013, 04:21 PM   #1
clyde howard
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My Ride: 2002 BMW 325 CI
2002 BMW 325 ci fuel pump keep going out

I am on 4th fuel pump in 2 mo. BMW dealer replaced the first one and fuel filter , and fuel relay, cost $1,200.00 and has replaced 3 more since then, at no charge, but they say its just bad pumps, car will be fine for a few days, then wont start due to fuel pump bad, send to BMW dealer, they replace pump, car ok till next week, then repeat the process. any Idea's....2002 BMW 325 ci.
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Old 12-12-2013, 04:47 PM   #2
jfoj
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Sounds like it may not be a fuel pump problem?

Hard time believing there have been 4 bad pumps in 2 months.

I have only heard of a single replacement OE Siemens/VDO pump failure just past 2 years.

I would question the key, ignition switch or and electrical problem.

Probably the very first thing I would do is to replace Fuse #54 in the glove box and replace or swap Fuse #3 in the DME box.
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Solve your misfires, lean codes, rough idle - http://forum.e46fanatics.com/showthread.php?t=897616

Fuel pump failures - http://forum.e46fanatics.com/showthread.php?t=929501

Temp Info - http://forum.e46fanatics.com/showthread.php?t=964491

Hidden OBC Menu - Check Voltage, Temps, Fuel Level - http://forum.e46fanatics.com/showthread.php?t=239619

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Lower hose fan switch O-ring - BMW #13621743299

Last edited by jfoj; 12-12-2013 at 04:51 PM.
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Old 12-12-2013, 07:13 PM   #3
lszlszx
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How long have you owned the car, anybody messed with the wiring?
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Old 12-12-2013, 08:38 PM   #4
clyde howard
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had 2 mo. all fuses and relays have been changed by BMW dealer, Thinking Jet Pump mabey
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Old 12-12-2013, 08:48 PM   #5
jfoj
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Jet pump is SUPER easy to rule out and they rarely have problems.

Read the 2nd link below in my signature.

You can bring up the Hidden OBC Menu and read how much fuel is in each 1/2 of the fuel tank.

Tank levels should be even until about 1/2 thank the drivers side should empty.

Is there a certain fuel level where you keep having problems?

I might be thinking there is some screwed up EWS? Key is far fetched as compared to the EWS, the EWS does have control over the fuel pump as I recall? If I am wrong, I am sure Scott or someone will confirm if the fuel pump is EWS controlled.

Ignition switch is something I might consider?

Describe in detail what happens when you have the no start situations.

Use the terminology below.

Cranking means starter is spinning the engine, but engine will not start or kick.

No cranking means the starter does not spin the engine, basically silence when turning the key.

Cranks, starts then engine dies means the engine will initial start then quit.
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Solve your misfires, lean codes, rough idle - http://forum.e46fanatics.com/showthread.php?t=897616

Fuel pump failures - http://forum.e46fanatics.com/showthread.php?t=929501

Temp Info - http://forum.e46fanatics.com/showthread.php?t=964491

Hidden OBC Menu - Check Voltage, Temps, Fuel Level - http://forum.e46fanatics.com/showthread.php?t=239619

E46/E39 GM5 Door Lock Info - www.bmwgm5.com

Lower hose fan switch O-ring - BMW #13621743299

Last edited by jfoj; 12-12-2013 at 08:55 PM.
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Old 12-19-2013, 06:29 PM   #6
clyde howard
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it cranks but no start, replace fuel pump, car will start ever time, car seems ok till about 1/2 tank, if you kill car , you will need to replace fuel pump..
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Old 12-19-2013, 06:44 PM   #7
bmwbob89
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Try my usual test for fuel pumps to get them going again. This way no wires are touched and it verifies it is the pump and nothing else:
Pull the rear seat and fuel pump cover. Have someone crank the engine while you tap the fuel pump assemble with a small piece of wood. If it starts the fuel pump is bad. Common problem for no starts. Don't hit it too hard as you just want to shock the pump and not break anything. You can actually do it yourself you just have to operate the key with your left hand while whacking the pump with your right.
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Old 12-19-2013, 07:13 PM   #8
bmwbob89
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I know that will not fix the problem but may narrow it down a little. What kind of gas are you using? Back when they first started putting ethanol in the fuel we had a rash of pumps fail. All of the water in the fuel tanks was getting in the cars. You might want to have the fuel pumped out of the tank in case its a contamination issue.
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Old 12-19-2013, 07:41 PM   #9
Stinger9
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Quote:
Originally Posted by jfoj View Post

Tank levels should be even until about 1/2 thank the drivers side should empty.
I checked; this is not the way the sucking jet pump works. I plotted the levels by taking OBC readings every thirty miles.
First the fuel level completely empties from the driver's side while the passenger side stays full at about 33 liters. Only when the driver's side level goes to zero does the passenger side start to lower.
A properly working pump and sucking jet keeps filling the passenger side from the driver's side.
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Old 12-20-2013, 04:34 AM   #10
jfoj
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Quote:
Originally Posted by Stinger9 View Post
I checked; this is not the way the sucking jet pump works. I plotted the levels by taking OBC readings every thirty miles.
First the fuel level completely empties from the driver's side while the passenger side stays full at about 33 liters. Only when the driver's side level goes to zero does the passenger side start to lower.
A properly working pump and sucking jet keeps filling the passenger side from the driver's side.
I think you did not understand my statement, I did have a typo in the statement. What I stated was, "Tank levels should be even until about 1/2 thank the drivers side should empty." What it should have stated is "Tank level should be even until about 1/2 tank, then the driver side should empty". But I believe we are saying the same thing?

From a full tank, the fuel level drops evenly until somewhere around 1/2 of a tank (I have not checked the level specifically, probably the 33 liters you mention). The sucking jet pump is CONSTANTLY transferring fuel from the drivers side to the passenger side buy using return fuel from the fuel filter/pressure regulator to siphon fuel from the drivers side to the passenger side. The return fuel from the filter/pressure regulator technically is sent to the passenger side of the tank, not the drivers side.

Once the fuel level has dropped below the center raised part of the tank, you will see the driver side continue to empty (fuel being transferred into the passenger side), unless you corner hard and slosh fuel back into the drivers side of the tank, which will quickly be transferred back to the passenger side of the tank. During this time the passenger side of the fuel tank will appear to stay somewhat constant.

Of your passenger fuel level is EVER lower than the drivers side, you have a problem. Most likely a fuel soft fuel pump or a sending unit issue.

Note this behavior is referenced for Left Hand Drive vehicles.
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Solve your misfires, lean codes, rough idle - http://forum.e46fanatics.com/showthread.php?t=897616

Fuel pump failures - http://forum.e46fanatics.com/showthread.php?t=929501

Temp Info - http://forum.e46fanatics.com/showthread.php?t=964491

Hidden OBC Menu - Check Voltage, Temps, Fuel Level - http://forum.e46fanatics.com/showthread.php?t=239619

E46/E39 GM5 Door Lock Info - www.bmwgm5.com

Lower hose fan switch O-ring - BMW #13621743299
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Old 12-20-2013, 08:01 AM   #11
markusmarkus
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2002 BMW 325 ci fuel pump keep going out

Did the dealer ever test any of the "failed" pumps? As was noted, VDO pumps rarely fail except from "exhaustion."


Sent from BimmerApp mobile app
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Old 12-20-2013, 09:14 AM   #12
Stinger9
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Quote:
Originally Posted by jfoj View Post
From a full tank, the fuel level drops evenly until somewhere around 1/2 of a tank (I have not checked the level specifically, probably the 33 liters you mention). The sucking jet pump is CONSTANTLY transferring fuel from the drivers side to the passenger side buy using return fuel from the fuel filter/pressure regulator to siphon fuel from the drivers side to the passenger side. The return fuel from the filter/pressure regulator technically is sent to the passenger side of the tank, not the drivers side.

Once the fuel level has dropped below the center raised part of the tank, you will see the driver side continue to empty (fuel being transferred into the passenger side), unless you corner hard and slosh fuel back into the drivers side of the tank, which will quickly be transferred back to the passenger side of the tank. During this time the passenger side of the fuel tank will appear to stay somewhat constant.
I said it pretty clearly the first time. Passenger level stays totally full at 33 liters until the driver's side is totally drained.
Levels never drop evenly, and there is no effect from the crossover.
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