Saturday, October 19, 2013
How to Replace the Fuel Pump on a 1991 525 BMW
The BMW 5 series of vehicles consists of midsize cars and has been in production since 1972. The 1991 BMW 525 has a BMW M50B25 engine, which is a 6-cylinder 2.5L engine generating 189 horsepower. This engine uses fuel injection, which requires the fuel pump to deliver fuel to the injectors under high pressure. The fuel pump in the BMW 525 is attached to the fuel sender, and is accessible from the trunk of the vehicle.
Instructions
- 1
Drain the fuel from the fuel tank, so that the tank is no more than 1/4 full. Remove the panels in the trunk to expose the access cover in the front right corner of the trunk. Unfasten the mounting screws for the access cover with a socket wrench, and remove the access cover. Disconnect the fuel lines and the electrical connector from the fuel sending unit.
2Attach tool 16 1 020 to a socket wrench and use it to turn the large mounting ring on the fuel sending unit counterclockwise. Remove the mounting ring from the fuel sending unit. Discard the gasket on the fuel sending unit.
3Pull the fuel sending unit from the fuel tank without spilling the fuel in the fuel sending unit. Squeeze the mounting hooks on the fuel pump to remove it from the fuel sending unit. Disconnect the fuel hoses and electrical wiring from the fuel pump. Turn the pressure damper on the fuel pump counterclockwise, and remove it from the fuel pump. Remove the fuel pump from its holder. Loosen the mounting screw for the fuel filter, and remove the fuel filter from the fuel pump.
4Connect the fuel filter on the bottom of the new fuel pump, and place the fuel pump into its holder on the fuel sending unit. Connect the pressure damper to the fuel pump. Attach the fuel lines and electrical wiring to the fuel pump. Attach the fuel pump to the fuel sending unit by securing the fuel pump with the mounting hooks.
5Install the new gasket for the fuel sending unit and mount it to the fuel tank. Attach the mounting ring to the fuel sending unit, and tighten the mounting ring to between 27 and 31 foot-pounds with tool 16 1 020. Connect the fuel lines and electrical wiring to the fuel sending unit. Replace the trunk access cover and trunk panels.
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