Possible source of concern for BMW AG

[TerminatorX5]

I did not replace the mating connector as I have completed the work in the middle of a night (it would have been a cool fireworks show if the thing would go KABOOM!!! lol).

I will check the mating connector as soon as I get a chance, to see if it has any burn marks, and will see if i can replace it. I am sorry, jopecasa, I have mistakenly thought you suggested repairing the connector on the pump, but repairing/replacing mating connector makes sense.

I do not know the flash point of the 92 octane fuel with 10% ethanol, nor I am aware of the conditions needed for fuel to ignite, such as presence of oxygen/air in the tank. But still, the fact of electricity inside fuel tank got me to think if this idea safe in the first place. I am not sure if there any better engineering solutions to this submerged fuel pumps...

Once I get a chance, I will see what is needed to submit to the NHTSA, and to the BMW NA, or BMW AG. I don't want to get the BMW in trouble with authorities, so maybe it should go to the BMW first...

[CapeX5]

As far as pumps in the fuel tank, almost 100% of cars today go that route and have for many years. The pump completely immersed in the fuel doesn't allow oxegyn to be present, so the "sparks" of the motor running don't go anywhere. And actually there probably aren't any sparks because of what I said. So, by design it is fine and very dependable. Better to concentrate on the issue you found. I would be very surprised if you received any kind of response from any of those agencies you mentioned. But, please keep us posted.

[crystalworks]

Could the pump failing (motor) have been drawing too much current and caused the problem?

Conversely, perhaps the female connection was not as tight as normal/required and contributed to the pump's demise?

I think the first is more likely in this case though. Can't hurt sending info to BMW NA though I am not sure there is a design fault/safety issue. They should be able allay your concerns assuming they don't just respond with a "Thank you for contacting BMWNA" form letter.

[Deansbimmer]

Thread title is a stretch...

Their S54/S65/S85 rod bearing issues in hundreds, maybe thousands of ///M cars are barely tipping the scale as far as being a problem for them. I don't think they'll give an issue like this a second look, even if you weren't the only one to report a similar case.

My two cents...

[SlickGT1]

Damn, that sucks. Looks like another thing to check.

Glad everyone is ok.

[axgordon]

I would replace pump harness plug ASAP! Based on the picture, that pin reached pretty high temperature and most likely lost its silver coating and spring action causing point of high resistance. This pump could easily draw 10 Amp of current, which will cause overheat at the point of high resistance, possibly overheat and damaging connection pin on the new pump assembly. As for the cause of the problem in the first place – I would think that worn out pump caused higher current draw or possible issue with fuel pressure regulator, obstructed fuel filter, etc. All of this may cause fuel pump to draw excessive current. Good idea to check fuel pressure both at idle and under load.

[TerminatorX5]

Do you think this recall is talking about my issue? my year is not covered but symptoms are very close...

[itscoo2pyopants]

Sounds like it. Interesting...

[TerminatorX5]

Interestingly enough, the part number 16116768357 comes in RealOEM for 4.8is only, and not cross-referencing to any other models

The pump's screw ring is cross-referencing for many models (16116762417) from 1995 on some bimmers, to 2016 on some RR cars. I am not saying that the pumps are the same because the retaining ring is the same...

I need to put this on my to do list to get the info out to the BMW AG (or BMW NA) and give them the pictures of my pump, maybe I get lucky and recover my $300 I paid for the part...