fuel pressure BMW 525i 2001 E39 Owner's Guide

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160 Fuel Tank and Fuel Pump
General ........................... .I6 0.2
Special tools ........................ .I6 0.2
Fuel pump ......................... .I6 0.3
Fuel tank evaporative control system ..... .I6 0.3
Evaporative system troubleshooting ..... .I6 0.4
Warnings and cautions ................ .I6 0.5
Fuel System Troubleshooting ...... .I6 0.6
Fuel pump fuse and relay .............. .I6 0.6
Operating fuel pump for tests ........... .I6 0.6
Fuel pump electrical circuit, testing ...... .I6 0.7
Fuel pump power consumption, testing ... .I6 0.9
Fuel pressure gauge, installing
(6-cylinder models)
................. .I6 0.1 0
Fuel pressure gauge, installing
(V-8 models) ....................... .I6 0.1 1
Fuel delivery, testing ................ .I6 0.12
Fuel Pump and Fuel Level Sender . . 160-15
Fuel level sender (right side) and
fuel pump. removing and installing
...... 160-15
Fuel level sender (left side).
removing and installing
............... 160-17
Siphon pump. removing and installing .... 160-1 9
Fuel Tank and Fuel Lines .......... 160-20
Fuel tank. draining ................... 160-20
Fuel tank. removing and installing ....... 160-21
Fuel expansion tank. removing
and installing
....................... 160-23
Activated carbon canister I fuel tank
leak detection unit
(LDP or DMTL).
removing and installing ............... 160-24
Running losses (312-way) valve.
removing and installing
............... 160-24

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This repair group covers service information specifically for the fuel supply system. Information on the fuel injection sys-
tem is covered in
130 Fuel Injection.
In the descriptions and procedures given below, engine and
engine management (DME) systems are referred to by man-
ufacturer code. If necessary, see
100 Engine-General for
model year, engine code, and DME applications.
NOTE-
Fuel filter replacement is covered in 020 Maintenance,
Special tools
Some of the procedures in this group require the use of
special tools.
I( Fuel line clamp 13 3 010 (Tool No. BMW 13 3 01 0)
4 Fuel pressure gauge T-fitting with shut-off valve
(Tool No. BMW 13
5 220)

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Fuel Tank and Fuel Pump
Fuel pump
The electric fuel pump is mounted in the fuel tank in tandem
with the right side fuel level sender. The fuel pump delivers
pressurized fuel to the fuel injection system.
A pressure regu-
lator maintains system pressure. The quantity of fuel supplied
exceeds demand, so excess fuel returns to the fuel tank via a
return line. See
130 Fuel Injection for more information.
NOTE-
Fuel pump removal procedures are given under Fuel level
sender (right side) and fuel pump, removing and install-
ing.
Fuel tank evaporative control system
Evaporative control, also referred to as running losses con-
trol, is designed to prevent fuel system evaporative losses
from venting into the atmosphere.
The components of this system allow control and monitoring
of evaporative losses by the on-board diagnostic
(OED II)
software incorporated into the engine control module (ECM).
NOTE-
1997 V-8 models (540i) with Bosch DME M5.2 are not
equipped with an
OBD I1 running losses monitoring system.
Fuel tank evaporative
control system
(models with
DME MS42.0)
4 The main components of the evaporative control system and
their functions:
Fuel overflow
tank acts as a liquidlvapor separator
Carbon canister stores evaporated fuel.
Plumbing ducts vapors from fuel tank to canister and from
canister to intake
manifold.
- Carbon canister purge valve is controlled by enginecontrol
module (ECM).
Running losses or 312-way valve (not shown) shunts ex-
cess fuel volume directly
back to fuel tank before it circu-
lates through injector fuel rail (models with Siemens MS42
or Bosch M5.2.1 engine management only).
Leak detection unit (LDP or DMTL) pressurizes fuel
tank
and evaporative system to monitor system leaks (models
with Siemens MS42 or Bosch M5.2.1 and later).
Leak detection systems vary among models and years, and
are further described in
130 Fuel Injection.
NOTE -
"3/2-way valve", 'tunning losses valve" and "fuel changeover
valve" are used interchangeably
in BMW technical literature.

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Fuel Tank and Fuel Pump
Warnings and cautions
Observe the following warnings and cautions when servicing
the fuel system.
WARNING-
* The fuel system is designed to retain pressure even when
the ignition is off. When working with the fuelsystem, loos-
en the fuel lines slowly to allow residual
fuel pressure to
dissipate. Avoid spraying fuel. Use shop rags to capture
leaking fuel.
Before beginning any work on the fuel system, place a
fire extinguisher in the vicinity of the work area.
Fuel is highly flammable. When working around fuel, do
not disconnect any wires that could cause electrical
sparks. Do not smoke or worknearheaters or other fire
hazards.
* Always unscrew the fuel tank cap to release pressure
in the
tanlc before working on the tank or lines.
When disconnecting a fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
Do not use a work light with an incandescent bulb near
any fuel. Fuel may spray on the hot bulb causing a fire.
0 Make sure the worlc area is properly ventilated.
CAUTION-
- Prior to disconnecting the battery, read the battery discon-
nection cautions given in
001 General Cautions an4
Warnings.
Before
making any electrical tests with the ignition
turned on, disable the ignition system as described in
120 Ignition System. Be sure the battery is discon-
nected when replacing components.
To prevent damage to the ignition system or other DME
components, including the engine control module
(ECM), always connect and disconnect wires and test
equipment with the ignition off.
Cleanliness is essential when
worl~ing with the fuel sys-
tem. Thoroughly clean the fuel line unions before dis-
connecting any of the lines.
Use only clean tools. Keep removed parts clean and
sealed or covered with a clean, lint-free cloth, especial-
ly if completion of the repair is delayed.
Do not move the car while the fuel system is open.
Avoid using high pressure compressed air to blow out
lines and components. High pressure can rupture inter-
nal seals and gaskets.
Always replace seals, O-rings and hose clamps.

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I Fuel Tank and Fuel Pump --
Fuel pressure gauge, installing
(6-cylinder models)
4 Remove fuel rail cover by prying off trim covers (arrows) and
removing nuts.
4 If equipped, remove schraeder valve cap (arrow). Blow fuel
back through feed line using a brief burst of compressed air
(maximum
3 bar or 43.5 psi).
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or 45 -
75psi) andmay be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines.
4 Attach fuel pressure gauge to BMW special tool 13 5 220
(T-fittlng) or equivalent and attach to schraeder valve.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from
coming loose underpressure.
CAUTION-
When using the BMWspecial tool, use care when turning the
T-handle in to open the schraeder valve. Screw the handle in
just until the schraeder valve opens. Turning the handle in too
far will damage the schraeder valve.
NOTE-
* The schraeder valve must be opened to the fuel pressure
gauge connection. Either remove the valve using a stan-
dard tire valve removal tool or use the BMW special tool
15 5 220.
* The fuel pressure gauge should have a minimum range of
0 to 5 bar (0 to 75 psi).
- For vehicles without the schraeder valve on the fuel rail, at-
tach the fuel pressure gauge in line with the fuel supply line
to the fuel rail.

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Fuel Tank and Fuel Pump
Fuel pressure gauge, installing
(V-8 models)
Remove engine cover by pressing down on pins (arrows) to
release cover locks.
4 Disconnect and remove fuel supply line from lefl side of fuel
rail by sliding
loclting collar in (arrows) and pulling lines
apart.
NOTE-
* ME2 TU and MS43 vehicles (1999 and later models) use a
non-return fuel line with only one line to the fuel
rafl.
BMW uses three styles of fuellfne connections; a one-use
clamp, a locking fitting that uses
BMWspeclal tool 16 1 050
to release, and a quick release sleeve (above) that discon-
nects the line when depressed.
WARNING -
* Fuel In fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any
lealiing fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before workina on the tank or lines.
< Install inline fuel pressure gauge.
WARNING -
The fuel pressure gauge must be securely connected to pre-
vent it from coming loose underpressure.
NOTE-
The fuel pressure gauge should have a minimum range of 0
to 5 bar (0 to 75 psi).

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Fuel Tank and Fuel Pump
Fuel delivery,
testing
Checitino fuel delive~ is a fundamental oart of troubleshoot- .. ing and diagnosing thk DME system. ~ukl pressure directly
influences
fuel delivery. An accurate fuel pressure gauge will
be needed to make the tests.
There are two significant fuel deliveryvalues to be measured:
* System pressure - created by fuel pump and maintained
by pressure regulator
Residual pressure
- pressure maintained in closed sys-
tem after engine and fuel pump are shut off
if proper system pressure and residual pressure are present,
also check for problems in fuel delivery volume, which can be
affected by restrictions such as clogged fuel filter or fuel pick-
up port in the fuel tank.
System pressure, testing
1. Fuel pressure regulator outer seal
4 System pressure is created by the fuel pump and maintained
2. Vacuum line connection.
3. Fuel pressure regulator Inner seal.
4. Fuel flow back to fuel tank.
5. Fuel flow from fuel pump.
Fuel pressure
regulator
Fuel pressure regulator locations
M52 In fuel injector rail, in engine
compartment
M52 TU In 312 way valve, below vehicle under
driver seat
by the pressure
regulator. System pressure is not adjustable.
M54 In fuel filter
M62 to 9/97 In fuel injector rail, in engine
compartment
M62 from 9/97 to 9/98 In 312 way valve, below vehicle under
driver seat
M62 TU from 9/98 In fuel filter, below vehicle under driver
seat

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Fuel Tank and Fuel Pump
4 Relieve system pressure and attach a fuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
WARNING-
Fuel in fuel line is under pressure (approx. 3 - 5 bar or 45 -
75psi) and may be expelled underpressure. Do not smoke
or
worlc near heaters or other fire hazards. Keep a fire ex-
tinguisher handy Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any
leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
Always unscrew the fuel tank cap to release pressure
in the tank before
working on the tank or lines.
- Operate fuel pump as described in Operating fuel pump for
tests. Compare fuel pressure to specifications in accompa-
nying table.
Fuel pressure specification
All E39 vehicles 3.5 +0.2 bar (50.76 i2.9 psi)
- If pressure is low, repeat test while gradually pinching off re-
turn hose to fuel tank. Pressure should rise rapidly. If not, fuel
pump is most likely faulty. If pressure rises, the fuel pressure
regulator is most
likely faulty.
- If pressure is too high, checlc return line from pressure regu-
lator to tank. Check for
ltinks in hose. If no faults can be
found, pressure regulator is most likely faulty.
CAUTION-
The fuel pump is capable of developing a higher pressure
than that regulated by the pressure regulator. In the event the
fuel pump checlc valve is faulty (stuck closed), male sure the
I fuel pressure does not rise above 6.0 bar (87psi). Damage
to the fuel lines or fuel system components could result.
- Reassemble engine, noting the following:
Remove fuel pressure gauge and fittings.
Replace schraeder valve, if removed
Replace fuel pump relay.
Replace fuel filler cap.
Residual pressure, testing
For quick restarts and to avoid vapor lock when the engine is
hot, the fuel injection system retains fuel pressure after the
engine is shut off. This residual pressure is primarily
rnain-
tained by the fuel pressure regulator and a checlc valve at the
fuel pump
outlet.

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. .
I Fuel Tank and Fuel Pump I
4 Relieve system pressure and attach afuel pressure gauge as
described in Fuel pressure gauge, installing (6-cylinder
models) or Fuel pressure gauge, installing
(V-8 models).
WARNING -
Fuel in fuel line is underpressure (approx. 3 - 5 bar or45 -
75psi) and may be expelled underpressure. Do not smoke
or work near heaters or other fire hazards. Keep a fire ex-
tinguisher handy. Before disconnecting fuel hoses, wrap a
cloth around fuel hoses to absorb any leaking fuel. Catch
and dispose of escaped fuel. Plug all open fuel lines.
. Always unscrew the fuel tank cap to release pressure
in the tank before working on the tank or lines
- Start engine allow it to run for approximately one minute.
Note fuel pressure reading.
- Observe fuel pressure reading after approximately 20 mln-
utes. The pressure should not drop more than 0.5 bar from
system pressure listed in fuel pressure specifications in ac-
companying table.
Fuel pressure specification
Ail
E39 vehicles 3.5 i-0.2 bar (50.76 i2.9 psi)
- When finished, disconnect pressure gauge and fitting, and
replace schraeder valve, if removed.
- If fuel system does not maintain pressure:
Visually check for leaks in fuel lines and unions,
Check for leaking
injector(s).
Check for faulty fuel pump check valve.
- To test fuel pump check valve:
Repeat residual pressure test.
Immediately aftershutting off engine, pinch off fuel delivery
line using a fuel hose pinch clamp (BMW
13 3 010 or
equivalent).
If pressure is now maintained, fault is most likely at fuel
pump check valve.
If pressure again drops below specifications, fault is most
likely in fuel pressure regulator.

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.-
I Fuel Tank and Fuel Pump
- Expose right side access cover:
Peel forward lip of carpet.
Release rubber grommet from center of access cover insu-
lation.
Peel back insulation at
perforations to expose fuel tank ac-
cess cover.
Remove right side cover to expose electrical harness con-
nector.
WARNING -
Fuel may be spilled. Do not smolce or work near heaters or
other fire hazards.
When disconnecting fuel hose, wrap shop rag around
end of hose to prevent spray of fuel under pressure.
Remove
tank sending unit:
Release electrical harness by sliding lock back, then lifting
off connector.
a Disconnect hose (arrow).
Unscrew threaded collar from fuel
pumpifuel level sender.
NOTE-
BMW special spanner 16 1 020 should be used to remove
and install the threaded collar. Damage to the collar may re-
sult if the special tool is not used.
Slowly withdraw assembly from tank, allowing fuel to drain
off. If necessary, push level sender arm toward sending
unit to facilitate removal.
CAUTION-
Do not bend fuel level sender arm.
To remove fuel pump, press locking tabs (arrows) towards
pump body.
Lifl out pump, using care not to damage hoses.