SM 13
SM 13
GENERAL
This repair group covers service information specifically for The cautions and warnings on this page should be ob
the fuel supply system . Information on the fue¡ injection sys- served when servicing the fuel system.
tem is covered in 130 Fuel Injection.
CAUTION-
NOTE- " Prior to disconnecting the battery, read the bat-
Fue¡ filter replacement is covered in 020 Maintenance tery disconnection cautions given at the front of
Program. this manual on page viü.
" Always unscrew the fuel tank cap to release pres- " Do not move the car while the fuel system is
sure in the tank before working on the tank or open.
fines .
" Avoid using high pressure compressed air to
" Do not use a work light near any fuel. Fuel may blow out fines and componente . High pressure
spray onto the hot bulb causing a tire. can rupture infernal seals and gaskets .
" Make sure the work area is properly ventifated. " Always replace seals and O-rings.
GENERAL
0011943
1. Filler pipe 10 . Fuel compensating siphon pump and hose assembly
2. Filler pipe grounding tab (models built from 1/95)
3. Vent pipe 11 . Fuel tank
4. Threaded collar 12 . Tank support strap
5. Rubber ring seal 13 . Bolt-tighten to 23 Nm (17 ft-Ib)
6. Fuel pump 14 . Fuel expansion tank
7. Left side fuel leve¡ sender (models built from 1/95) 15 . Fuel tank pressure sensor (OBD II)
8. Right side fuel leve¡ sender
9. Left side fuel leve¡ sender with fuel compensating siphon pump
(models built up to 1/95)
The plastic fuel tank is mounted beneath the center of the The fuel tank should be drained into an approved storage
car (beneath rear seat) . Mounted in the fuel tank are the fuel unit or another car's fuel tank.
pump and fuel leve¡ sending units . Connecting lines for the
evaporative emission control system and expansion tank are WARNING -
also attached to the tank. When performing the procedures " Before removing the tank, be sure that afl hot
that follow, refer to Fig . 1 . components such as the exhaust system, are
completely cooled down.
Fuel tank capacity for E36 modeis " Fuel may be spilled. Do not smoke or work near
heaters or other Pire hazards.
" All ex . 1996 M3 (3 .0 L) . . . . . . . . . . 65 liters (17 .0 gal)
" 1996 M3 (3 .0 L) modeis . . . . . . . . .62 liters (16 .4 gal)
1 . Disconnect negative (-) cable from battery.
CAUTION-
Prior to disconnectiog the battery, read the battery
disconnection cautions given at the front of this
manual on paga vi¡¡.
WARNING -
Fuel may be spilled. Do not smoke or work near
heaters or other fire hazards.
uui3140
CA UTION-
Fig. 2. Right side fuel tank access cover under rear seat cushion.
Before starting the engine, fill the fuel tank with at
least 1 .5 gallons (5liters) of fuel. The pump will be
4. Remove right and left access covers to expose fuel damaged if you run it without fuel.
hoses and electrical connections at tank .
5. Label fuel hoses. Then disconnect hoses and harness Fuel tank, removing and installing
connectors from fuel sending units and fuel pump. See
1 . Disconnect negative (-)cable from battery:
Fig. 3.
CAUTION-
Prior to disconnectiog the battery, read the battery
disconnection cautions given at the front of this
manual on page viii.
CAUTION-
" Before starting the engine, fill the fuel tank with
at least 1 .5 gallons (5 liters) of fuel to prevent
damaging a dry fuel pump.
" If the filler neck has been removed from the body,
be sure to reattach the neck's grounding screw
(where applicable). Check electrical resistance
between the ground tab and wheel hub. The re-
sistance should be no higher than 0.6 ohms .
Tightening Torques
" Fuel tank to body . . . . . . . . . . . . . . . . 23 Nm (17 ft-Ib)
" Hose clamps (10 mm-16 mm día .) . . 2 .0 Nm (18 in-lb)
NOTE-
0013143
On most early cars (1992-1995), the charcoal canister
Fig . 5 . After removing exhaust system, remove heat shield screws is in the engine compartment. On later cars, the char-
(arrows) and heat shield . coal canister is under the spare tire in the luggage com-
partment.
9 . Working underneath car, loosen hose clamp and dis-
connect filler hose.
FUEL LEVEL SENDERS
10 . Support tank from below . Remove tank strap mounting
bolts . Lower and remove tank, disconnecting right side The E36 model uses a two-lobed fuel tank and each lobe of
vent and other hoses/electrical connectors as neces- the tank has its own fuel level sending unit.
sary.
The right side fuel leve¡ sender is integrated with the fuel
11 . Installation is reverse of removal . pump . Each sender has a float connected to a variable resis-
" Always use new seals, gaskets, O-rings, and hose tance for fuel leve¡ . When replacing the sender/pump assem-
clamps. bly always replace hose clamps, gaskets and O-rings .
" Inspect hoses and replace any that are chafed, dried
out or cracked . WARNING -
" Inspect heat shield and replace if corroded . When removing the fuel level sender or the fuel
" Inspect rubber buffers and liners on fuel tank, support pump, the fuel tank should be emptied.
straps and on underside of body. Replace rubber
parts that are hardened or damaged .
WARNING -
Always unscrew the fuel tank cap to release pres-
sure in the tank before working on the tank or fines.
Table a. Fuel Leve¡ Sender Resistances 8. Reconnect harness connector and hoses. Fill tank and
check for leaks by running engine . Insta¡¡ access cover
Float position Test result (ohms) and its mounting screws . Reconnect negative (-) cable
Right side empty 10 ohm t 2 to battery.
Fuel DM E
PUMP main
re ay relay
aoo o ~a
0
aao ó
0013034,
The DME engine control module (ECM) and the DME main
relay supply powerto the coi¡ side of the fuel pump relay. Dur-
ing starting, the fuel pump runs as long as the ignition switch is
in the start position and continues to run once the engine
starts . If an electrical system fault interrupts power to the fuel
pump, the engine will not run .
0013142
Fig. 7. Fuel sender and pump assembly. Operating fuel pump for tests
To operate the fuel pump for testing purposes without hav-
Fuel leve¡ sender (left side), ing to run the engine, the fuel pump relay can be bypassed to
removing and installing powerthe pump directly.
The procedure for removing and replacing the left side fuel To run the fuel pump, remove the relay and connect the
leve¡ sender is similar to that used for the right side . There is socket for relay terminal 30 to the socket for relay terminal no.
no fuel pump on the left side. 87 with a fused jumper wire . Relay terminal identification is
shown in Fig. 9. After completing the tests, remove the jumper
wire .
FUEL PUMP
CA UTION-
The electric fuel pump ís mounted in the fuel tank in tandem Relay locations may vary. Use care when identify-
with the right side fuel leve¡ sender . The fuel pump delivers ing relays and when troubleshooting the electrical
fuel at high pressure to the fuel injection system . A pressure system at the fuselrelay panel. The fuel pump re-
regulatormaintains system pressure . The quantity of fuel sup- ¡ay is a four pin relay and has a 1 .5 mm2 red wire
plied exceeds demand, so excess fuel retums to the fuel tank at terminal 30 in the relay socket, lf in doubt, con-
via a retum líne . See 130 Fuel Injection for more information sult an authorized BMW dealer.
on system pressure and the fuel pressure regulator.
NOTE-
NOTE - Thejumper wire should be 1 .5 mm2 (14 ga.) and in-
Fuel pump removal procedures are given earlier under clude en in-fine fuse holder with a 16 amp fuse. To
Fuel leve¡ sender (right side) and fuel pump, remov- avoid fuselrelay panel damage from repeated connect-
íng and installing . íng and disconnecting, also include a toggle switch . A
heavy-duty jumper, BMW tool no. 613 050, fs also
available from en authorized BMW dealer.
Fuel Pump Fuse and Relay
If the pump does not run with the jumper installed, the fault
The fuel pump is operated by a fuel pump relay located ín could be in the fuel pump or the wiring to the pump . Check the
the power distribution box . The fuel pump circuit is protected pump and its wiring as described below.
by fuse no . 18 located in the power distribution box. See Fig 8.
FUEL PUMP
30
-~ Fuel Pump
Relay
8~T
1 .5 GNNI
2 .5 GNNI
WIRING
Fig. 9. Fuel pump relay terminal identification . COLOR CODE
BK - BLACK
BR - BROWN
Fuel Pump Electrical Tests Fuel Pump M
RD
YL
- RED
YELLOW
(in-tank)
GN - GREEN
BU - BLUE
Troubleshooting of any fuel pump fault should begin with 1 VI - VIOLET
GY - GREY
checking the fuel pump fuse and the fuel pump relay. The WT - WHITE
DME main relay should also be checked. PK - PINK
NOTE- Ground
(below center console) 0011946
Special tools are requíred for some of the tests de-
scribed here .
Fig. 10. Fuel pump electrical circuit.
CAUTION-
Fuseandrelaylocationsmayvary. Usecara when Fuel pump power consumption, testing
troubleshooting the electrical system at the
fuselrelay panel. To resolve problems in identify- NOTE-
ing a relay, see en authorízed BMW dealer. " To achieve accurate test results, fhe battery voltage
at the connector should be approximately 13 volts.
1 . Remove rear seat cushion, pull right side insulation mat Charge the battery as necessary.
back to expose fuel tank access cover. Remove cover . q higher than normal power consumption usually fin-
to expose wiring connections . dicates a worn fuel pump, which may cause intermit-
tent fuel starvation due lo pump overheating and
2. Remove fuel pump relay and opérate fuel pump as de- seizure. The only remedy is pump replacement. Be
scribed under Operating fuel pump for tests earlier. sure to check that the return fine and the pump pickup
Pump should run. Disconnect jumper wire when fin- are not obstructed before replacing the pump.
ished.
1 . Remove rear seat cushion, pull right side insulation mal
3. If fuel pump does not run, disconnect black harness back to expose fuel tank access cover. Remove cover
connector from tank sender unit . With jumper wire con- to expose wiring connections .
nected as described in step 2 above, check for positive
(+) battery voltage at harness connector terminals. See 2. Disconnect (black) harness connector from fuel pump .
Fig. 11 .
3. Connect an ammeter and an insulated jumper wire be-
tween terminals in connector and corresponding pump
terminals. See Fig. 12 .
FUEL PUMP
160- 8 FUEL TANK AND FUEL PUMP
WARNING -
" Gasoline is highly flammable and its vapors are
explosive. Do not smoke or work on a car near
heaters or other fire hazards when diagnosing
and repairing fuel system problems. Have a fire
00131ts7
extinguisher available in case of an emergency.
Fig . 12 . Test fuel pump for current draw by attadhing ammeter and
jumper wire as shown . " When working on an open fuel system, wear suit-
able hand protection . Prolonged contact with fuel
can cause iflnesses and skin disorders.
CAUTION-
Do not allow the test leads to short to ground.
CA UTION-
Cleanliness is essential when working with fuel
NOTE-
circuit components. Thoroughly clean the unions
See 600 Electrical System-General for information before disconnecting fuel fines
on electrical tests using a digital multimeter (DMM) .
FUEL PUMP
FUEL TANK AND FUEL PUMP 160-9
NOTE- NOTE -
On 1996 and later 4-cylinder cars, use BMW special " Use BMW pressure gauge Part No. 133 060, or an
tool 13 6 051 (hose with quick release coupling) to at- equivalent. The fuel pressure gauge should have a
tach pressure gauge to Shraeder valve fitting on top of range of 0 to 5 bar (0 to 75 psi) and must be securely
the M44 fuel rail. See Fig . 13. connected to prevent it from coming loose under pres-
sure .
u012503a
Fig . 13 . Fuel rail showing location of Shrader valve fitting on M44 en-
gine (arrow) .
CAUTION-
The fuel pump is capable of developing a higher
pressure than that regulated by the pressure reg-
ulator. In the event the fuel pump check valve is
faulty (stuck closed), make sure the fuel pressure
0012699
does not rise aboye 6.0 bar (87 psi) . Damage to
the fuel fines or fuel system components could re-
Fig . 14. Fuel lines at rear of íntake manifold on M52 engine . Use BMW
sult.
special tool 16 1 050 to release fittings .
FUEL PUMP
160- 1 0 FUEL TANK AND FUEL PUMP
3. Operate fuel pump as described earlier under Operat- Fuel delivery volume, testing
ing fuel pump for tests. Check that fuel pressure cor-
responds to specifications listed in Table c. 1 . Disconnect return line from fuel rail in engine compart-
ment.
" If system pressure is low, repeat test while gradually
pinching off return hose . Pressure should rise rapidly. 2. Connect a length of hose to fitting on fuel rail and place
If not, fuel pump is most likely faulty. open end of hose in a suitable container for catching
" If system pressure is too high, check return line from fuel (2-quart capacity).
pressure regulator to tank. Check for kinks in hose .
Blow compressed air through line to check for block- 3. Run fuel pump for exactly 30 seconds as described
ages . If no faulty can be found, pressure regulator is earlier under Operating fuel pump for tests and mea-
most likely faulty. See 130 Fuel Injection for testing sure fuel collected . Refer to Table d.
and replacement procedures .
NOTE-
CA UTION- It is common practice to replace the fuel filter any time
Do not use compressed air above 40 psi to blow the fuel pump unit is replaced.
out fines or components. Interna¡ damage to com-
ponents may result.
FUEL PUMP