Bimmerworld E36 Fuel Upgrade, Stage II

Fuel will be present during installation. Install this kit only in a well ventilated area, free of any electrical motors, lights, or sources of spark.

Parts List:  2x fuel pump/sender assemblies  2x line adaptors – CHECK FOR  6” small fuel line – not cut to length TIGHTNESS  Electrical connector/plug  3’ large fuel line – not cut to length  7x hose clamps

Tools Required:  Fire extinguisher  Utility knife  Large flat screwdriver  Hammer  Medium flat screwdriver  Pliers  Medium Phillips screwdriver

1. Pull up on front edge of rear seat bottom to release clamps and then pull section forward and out of the car. 2. Remove 4 Phillips screws on each of the two 8” round black fuel pump access covers, pull covers off, and unplug wires from pump/senders. 3. Remove external hoses from the two sending units. Note the orientation of the return line (driver’s side) and sending line (passenger’s side). FUEL WILL BE PRESENT BEGINNING AT THIS STEP – DO NOT START A FIRE PLEASE! Do this in a well ventilated area, do not install in the presence of any electrical equipment or other source of a spark. Keep a fire extinguisher inside the car. 4. Place the tip of the large flat screwdriver on the large black plastic ring (holding the stock pump/senders in) and tap with the hammer to unscrew the ring counterclockwise. After approximately 1 turn, you will be able to unscrew completely with your hands. Repeat on other side. 5. Remove the fuel sending unit on the driver’s side and the pump/sending unit on the passenger’s side. Pull out hose inside the tank connecting the two units. This may require some force to break adhesive bond, cut line if needed to make this step easier – you will not reuse it. 6. Install the two included fuel pumps, one in each side of the tank. The passenger’s side is a direct replacement. On the driver’s side, the pump housing will need to be rotated. Note the movement of the fuel level float and position this pump so the float does not hit the side of the tank throughout the range of movement. Tighten black rings with screwdriver and hammer. 7. Fish the included section of large diameter fuel line between the two fuel pumps, between the top of the black plastic fuel tank and the metal seat bottom of the car. With a little effort, this can be done without dropping or removing the fuel tank. 8. Cut the return line (existing line on driver’s side) in order to install the step-up adaptor. Attach a short section of the included large diameter line to the other end and then attach to the same larger port on the pump used in the original configuration (noted earlier in step 3). 9. Connect the car’s fuel rail sending line (passenger’s side) to the smaller port on the new pump that was used in the old system (noted in step 3). 10. Connect the remaining ports of two fuel pumps together (small driver’s port to large passenger’s port) – use a short section of small diameter line included to run from the driver’s side pump to a step-up adaptor, then into the large diameter line installed in Step 7. 11. Run the provided wiring pigtail through the cover for the driver’s side sender.

540.639.9648 www.bimmerworld.com 12. The passenger side has a plug for both the fuel pump and the fuel sender which will only plug into the correct socket. Match the plug to the included wiring pigtail to determine the pump wire. Trace this pump wire back to the point that the wires split for the left and right sides and splice the pigtail provided into it, using the supplied splice connectors. The ground has been marked black and the positive is green. 13. Plug in the pump and sender wires, replace the metal covers and seat. 14. The kit is now fully operational; car may sputter momentarily while building fuel pressure.

540.639.9648 www.bimmerworld.com