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post #1 of 24 Old 6th July 2019, 01:47 AM Thread Starter
MMMotorsport
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Fuel Pump Preventive Maintenance?

So recently I was left stranded with what appears to be a bad fuel pump relay (after Terrabass's useful video on testing it seems to point to the relay and not the pump):

https://www.youtube.com/watch?v=apOHpW_K_Lk&t=57s

Fortunately it was at a friend's house, so I plan to make the repair on site. Ordered the relay and will install when received. The problem with a fuel pump relay or fuel pump failure is that you are screwed. There is no "limp mode" to get you home when the engine is not getting fuel. I had a fuel pump failure at 126,000 miles. Now at 255,000 I am thinking to just go ahead and replace the pump (and fuel filter) as well.

Anyone on the board subscribe to fuel pump replacement even if it has not failed?
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post #2 of 24 Old 6th July 2019, 04:37 AM
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Quote:
Originally Posted by MMMotorsport View Post
So recently I was left stranded with what appears to be a bad fuel pump relay (after Terrabass's useful video on testing it seems to point to the relay and not the pump):

https://www.youtube.com/watch?v=apOHpW_K_Lk&t=57s

Fortunately it was at a friend's house, so I plan to make the repair on site. Ordered the relay and will install when received. The problem with a fuel pump relay or fuel pump failure is that you are screwed. There is no "limp mode" to get you home when the engine is not getting fuel. I had a fuel pump failure at 126,000 miles. Now at 255,000 I am thinking to just go ahead and replace the pump (and fuel filter) as well.

Anyone on the board subscribe to fuel pump replacement even if it has not failed?
I haven't but at that mileage, I would. How often have you replaced the fuel filter? ("Lifetime" per BMW .)

Kevin

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post #3 of 24 Old 6th July 2019, 01:26 PM
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To answer your question directly first, there is no PM you can do for the pump. People will say don't run the tank down to low but I've never subscribed to that theory and I got more than 130k out of a replacement pump before it went.

For your situation, you should probably start thinking about replacing the pump. 100-130k miles is pretty typical lifespan. The relay may have gone bad because the pump is making it work harder all the time... gets hot and eventually died.

You could be weird like me and just keep a pump and a few tools in the trunk to change the pump where ever it dies... including on the side of I-90! If you've "been in there" before then you really don't need much... flatblade screwdriver, a hammer or in my case a small block of wood I keep to use with the scissor jack, and a razor blade from your temporary flat repair kit if you keep one. In order for this to work you need to just replace the pump itself. I've been running a Walbro. You have to change the connectors but once done, it's plug and play for another Walbro or the factory Pierburg.

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post #4 of 24 Old 6th July 2019, 07:27 PM Thread Starter
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Yes, once I get it home, I am now thinking of replacing the pump anyway. I might keep the old one in the trunk per your suggestion. Still shopping for that since their seems to be significant cost differences and am curious if it is justified by performance or longevity.

A curiosity: When I go to realoem.com it shows the relay behind the glovebox as a normal 5 prong 86/87/30 relay. These are relatively cheap--generally a few dollars. But when I went to order, of course, the BMW one is special with 8 prongs and a $110 - $140 price tag. Example at FCP:

https://www.fcpeuro.com/products/bmw...m3-61357892976


But realoem.com is showing the 5 prong version here:

https://www.realoem.com/bmw/enUS/sho...diagId=61_4007

When I get back to my car with the part, am I going to be surprised when I drop the glovebox with the wrong relay?

Last edited by MMMotorsport; 6th July 2019 at 08:15 PM.
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post #5 of 24 Old 6th July 2019, 10:09 PM
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Quote:
Originally Posted by MMMotorsport View Post
.... A curiosity: When I go to realoem.com it shows the relay behind the glovebox as a normal 5 prong 86/87/30 relay. These are relatively cheap--generally a few dollars. But when I went to order, of course, the BMW one is special with 8 prongs and a $110 - $140 price tag. Example at FCP:
https://www.fcpeuro.com/products/bmw...m3-61357892976

But realoem.com is showing the 5 prong version here:
https://www.realoem.com/bmw/enUS/sho...diagId=61_4007

When I get back to my car with the part, am I going to be surprised when I drop the glovebox with the wrong relay?

If you drop the glovebox, you will find the relay that was pointed to in your realoem link, but you will be disappointed if you buy a new one of this type of relay and install it: It is not the real EKP-relay (K96)! The EKP-relay (K96) is in the trunk, the big black one behind the right cover with 8 pins. The fcpeuro link shows the correct relay, only their price isn't right and that of several other providers ...

The EKP-relay is a PWM (pulse width modulation) controlled relay. I have to look up which of the smaller pins receives the PWM-signal. The flow of your fuel pump is controlled with it. Another small pin receives a signal from the DME (engine management unit) if the EWS (drive away protection) allows it. A missing signal there or a missing pin, if you would insert a standard 5-pin relay, will prevent your car from starting ...

On realoem the right (8-pins) EKP-relay (K96) can be found here:
http://www.realoem.com/bmw/enUS/show...92#61357892976

My remark above about the 'wrong' price, is based on the realoem price for a K96 relay, BMW no. 61357892976, of $40.25 and the experience that realoem-prices are always above actual prices. Things have changed now obviously, if I look at prices of other suppliers on the web ...

Last edited by Freude_am_Fahren; 6th July 2019 at 10:57 PM.
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post #6 of 24 Old 6th July 2019, 10:39 PM Thread Starter
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All,

Thanks for the help!

OK, so from the research it seems that for 2001 and later (mine is a 2002) the relay is behind the glovebox--not in the trunk. Not sure that was an improvement.

Once the glovebox is dropped, will the 8 pin relay plug in there?

Thanks
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post #7 of 24 Old 6th July 2019, 11:18 PM
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Quote:
Originally Posted by MMMotorsport View Post
All,

Thanks for the help!

OK, so from the research it seems that for 2001 and later (mine is a 2002) the relay is behind the glovebox--not in the trunk. Not sure that was an improvement.

Once the glovebox is dropped, will the 8 pin relay plug in there?

Thanks
Nah, pretty sure the fuel pump relay you're looking for is in the trunk. I remember there being confusion regarding WDS and its location.

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post #8 of 24 Old 6th July 2019, 11:25 PM
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Quote:
Originally Posted by MMMotorsport View Post
... OK, so from the research it seems that for 2001 and later (mine is a 2002) the relay is behind the glovebox--not in the trunk. Not sure that was an improvement. Once the glovebox is dropped, will the 8 pin relay plug in there?
Thanks
If you click the part number 61357892976 behind the 8-pin K96 relay, you should see the reference 10/1997 - 06/2003. That gives reason to think that the same 8-pin K96 relay is used for all years of build. Maybe M5's before 2001 are different, but not later versions like your 2002 (and mine 2003).
Before uninstalling the glove box, I would first have a peek behind the right cover in the trunk. If there's no big black relay in there, then have a look behind the glove box ...

Last edited by Freude_am_Fahren; 6th July 2019 at 11:28 PM.
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post #9 of 24 Old 6th July 2019, 11:32 PM Thread Starter
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post #10 of 24 Old 7th July 2019, 12:02 AM Thread Starter
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Confusing literature.

Manuals online states it is in the trunk:

https://workshop-manuals.com/bmw/5_s...el_pump_relay/

Realoem shows it behind the glovebox. This is after putting in the last 7 digits of my VIN--so it would seem this is most accurate. Again showing a standard relay:

https://www.realoem.com/bmw/enUS/sho...diagId=61_4007

What?!
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