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  #1  
Old 03-20-2016, 04:08 PM
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Possible source of concern for BMW AG

Hello folks. I have not been on this forum for a very long time, and stopped by just to make this post. There are so many things going on at this time, that i simply don't have time to come here as much as I wish I could.

So, long story short - my wife (yeah, I know, I know!!!) is driving my car last Thursday, and the car shuts off on her. she tries to restart it, to no avail, calls me in panic, I am coming home from work, find her stranded a mile away from home on a shoulder (some strangers pushed the car to the shoulder) with kids sitting on the side of the shoulder, waiting for me. I tried to start the car, the auto starter is cranking strong, nothing else is happening. Sounds as if engine is flooded or if there is no fuel coming. I can't listen to the pump priming, so I have the car towed home.

As I listen to the pump, I do not hear it priming, so I check fuse 47 in glove compartment, it is good (tested good), I dig into the glove compartment for the relay, swap it with other same relays, still, no priming.

pull the rear seat, cut the sound barrier, test the voltage on the pump pins, good voltage. Look at the pump's connectors, one connector is darker than the rest, and seems to have oil residue around it... hmmm..

it is middle of night on Thursday, going on to Friday, so I get on line, order a new pump from BMW of Fairfax for about $330 with the tax. Early in the morning call them, confirm they have the part, pick it up in the afternoon, come home and replace the pump in the late evening (spill total about 10mL of fuel!). Car starts right up, after test drive around house, still starts right up. All good!

Total cost is

$330 for the pump
$1 for a hose clamp from Home Depot
$5 for rubber mallet (that I can use for my work later)
$20 for shop towels (that I will use for my work later)

But the kicker is here... As I went to inspect the old pump, I see that one of the power pins has fallen into the opening of the plastic housing. What??!! Did not take a genius to realize, that the pin overheated and MELTED the plastic around itself and the pin fell through.

This is a serious reason for a concern - a HEAT source next to highly COMBUSTIBLE substance!!! I smelled gasoline inside the car for some time, and was "blaming" the fuel filter, but once the pump was replaced, there is no more gasoline smell. So, this plastic melting business was going on for some time.

Here are some pictures
Attached Images
    
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E53 X5 4.6iS
147K mi - Sold May 2013
Tireprints left in:
USA, Nicaragua, Costa Rica, Panama, Russia

E53 X5 4.8iS built 2005-10-17
66200 mi - June 2012
96000 mi - June 2013
112000 mi - June 2014
OEM fire extinguisher
OE first aid kit
OE tow hitch
OE TV module
OE aspheric mirror
K&N air filter
black/white badges
rear camera
4-channel video recorder

Here is the list of things I have done to the X

Last edited by TerminatorX5; 03-20-2016 at 04:17 PM. Reason: spelling
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  #2  
Old 03-20-2016, 04:17 PM
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Has the X been operated in a low voltage state (battery below 12.2v or alternator charging below 13.5 v)?

Just pointing out that as volts drop, amps increase (lots of heat).
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Last edited by TiAgX5; 03-20-2016 at 04:29 PM.
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Old 03-20-2016, 04:23 PM
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OBC shows 13.2 - 13.8V during driving, with occasional 14.1V. Car is driven at highway speeds for 40 miles one way about 4-5 times a week. This battery was changed for an AGM on 10/30/13, was strong then, still shows no signs of weakness. Load tested the battery, in rest state under load showed 11.9V, which is within specs of a good battery.

Nevertheless, I will continue watching the battery, just in case it has some issues.
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E53 X5 4.6iS
147K mi - Sold May 2013
Tireprints left in:
USA, Nicaragua, Costa Rica, Panama, Russia

E53 X5 4.8iS built 2005-10-17
66200 mi - June 2012
96000 mi - June 2013
112000 mi - June 2014
OEM fire extinguisher
OE first aid kit
OE tow hitch
OE TV module
OE aspheric mirror
K&N air filter
black/white badges
rear camera
4-channel video recorder

Here is the list of things I have done to the X
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Old 03-20-2016, 04:32 PM
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Please file a report with NHTSA. Every safety problem you have. I'm still dumbstruck my 01 was never recalled for the seat mat or ABS module.

https://www-odi.nhtsa.dot.gov/VehicleComplaint/
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Old 03-20-2016, 04:38 PM
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I've not experience this issue in any of our cars.

But I would cut and re-splice and source out new connectors and pins.

For peace of mind.
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Old 03-20-2016, 04:42 PM
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I am not going to reuse this pump, so no need to fix connector. Main concern is, source of ignition inside a gas tank.

Sent from my LG-E980 using Tapatalk
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E53 X5 4.6iS
147K mi - Sold May 2013
Tireprints left in:
USA, Nicaragua, Costa Rica, Panama, Russia

E53 X5 4.8iS built 2005-10-17
66200 mi - June 2012
96000 mi - June 2013
112000 mi - June 2014
OEM fire extinguisher
OE first aid kit
OE tow hitch
OE TV module
OE aspheric mirror
K&N air filter
black/white badges
rear camera
4-channel video recorder

Here is the list of things I have done to the X
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  #7  
Old 03-20-2016, 04:45 PM
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Wow that could have been really bad.. glad your family was ok. I've never seen that happen before.
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Old 03-21-2016, 01:07 AM
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WOW! I suppose the fuel wouldn't ignite unless there was some kind of spark (or the flash point of the fuel.) still scary stuff! definitely file a complaint with bmwna and send them a photo!!!!!
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Old 03-21-2016, 02:11 AM
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That level of heat shouldn't (can't) ignite fuel but why take the risk!!

Fuel pumps worry me; electric motors immersed in fuel. Yikes... I've replaced a few but never seen your issue. My motorcycle (a BMW) is known for breaking the wire that got hot in your car. Double yikes..

What did the mating connector look like? As it has the female pin, the issue could be there, with a loose fitting socket. The replacement pump connector may suffer the same fate. It might be a good idea to check the mating connector, retention the contacts with a small (jewelers) screwdriver or the like, and use a good contact treatment.

*edit* just re-read this thread realised that jopecasa suggested replacing the mating connector - good idea!
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Last edited by wpoll; 03-21-2016 at 02:26 AM.
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  #10  
Old 03-21-2016, 09:46 AM
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+1 for immediately checking the mating connector. The one you took a picture of looked fine, I bet you have a bad connection on the female end. I had this issue on a coil for the ignition. And, gasoline as a liquid isn't as flammable as the fumes. ANd if you were smelling gas, that was the fumes. Think of that connector/heat like a welder. The pump was calling for amperage, and the connection was weak. And like a welder, it was arcing and sparking(maybe not literally)trying to get the connection to that bullet connector. Good luck.
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