richie281vn

I drive a 06 525i at 80k miles.

Yesterday when I was cruising, the car stalled and then engine shut off. I tried cranking the car again but no luck. Idrive showed fuel pump error (6294 - low current fuel pump).

I got the car towed back home and replaced the EKPS module, program it and still no luck.

Then I checked on the fuel pump and realized the tank was empty while the cluster gauge shows more than 1/4 of fuel left. I put in some gas and the car cranks ok. The Idrive error still intermittently shows fuel pump error but car runs ok.

I recently replaced both fuel filter and fuel pumps 3 months ago with Bosch OEM.

This fuel pump error message has shown sporadically since I replaced the fuel pump and loss of acceleration here and there but never to this extend i.e. car shut off due to fuel empty. I normally refill at 1/4 mark but had previoysly drove to an empty tank once (still make it to station)

What could be the culprit and how to best fix it?

Thanks

seanjordan20

My next step after replacing the pump and having issues would of been returning it. I do not know what forced you to change your pump in the first place but there is obviously something wrong with the pump or the install if you had issues after your initial fix. What made you change you pump and filter initially? Double check your work. The level is off and circuit is bad.

Assembly needed

richie281vn

I replaced the fuel pump as preventive maintenance only. I agreed that it is likely the pump itself or installation since i only got this after the replace.

Claiming warranty is gonna be a pain since I am far away so i am trying to figure out if the install went correctly.

Do you have any tips of common error on fuel pump installation?

seanjordan20

06 525i at 80k was way to preemptive. If you are running 91 and keep your system clean you would of at least made it to 160k at a minimum. The install should of been straight forward. All I can think of is the hitting the leveler while putting it in. Did you replace just the pump or both sides.

richie281vn

I replaced both fuel pump and filter (with level sending unit) with Bosch Oem. I agreed it is a bit preemptive but where I live the fuel quality is not as good. Also I bought the car used and have no idea how the previous owner treated it. So all the preventive maintenance so far are mostly for peace of mind. Yet it still got me stranded :-(

I will check the level sender units since i do not always have this problem. But if the tank is empty on the passenger side, it is the level sensor on this side or the other gone bad?

seanjordan20

I do know the operations of the fuel system so I can not answer your question. I have changed 2 of my friends and never had the issue you are having. I would say it is pointing to an install error. Connectors not plugged in all the way or something. You should not have this issue if the product was new. I believe if you check your work everything will start working as it should. With pumps and senders it either works or it doesn't this is why I believe it is an instal issue. Just make sure the connectors are clicked in.

It's good doing preventive maintenance but the pump is something I would only doing if it goes out. Prior maintenance doesn't effect the pump. Some SL1 ran though the system would of clear any thing up. I probably would have bought it and had it on standby just in case but not change it. I do get where you are coming from because I change things preemptive for peace of mind too.

richie281vn

I replaced the pump with another one today. Akso pulled out and checked the sender to ensure everything is ok and putnit back.

Car drove smoothly for half a day and then started to stutter again. And then that Fuel pump problem showed up in idrive and car shut off itself.

I could start the car again after few attempts and drove to gas station to fill up (gauge still showed half tank fulled). Funnily I could only fill up 2 litres then gas is full (nozzle shut off and gas overfilled). Gauge still shows half tank afterward.

I guess this round the pump size is full and the filter size is damn empty. What can indo to address this issue?

seanjordan20

Try these methods:

Refuel at slow speed
Putting the pump in half way
Fueling with the pump upside down

Or your tank purge valve is not working. To much pressure building up as you pump which would also give you the pump error while driving. Check that the purge valve connector is clean and completely plugged in.

richie281vn

Thanks. I tried the half nozzle and was able to fill the tank.

Now the big issue is the fuel pump. Apparently I got the EKPS - 006924 error quite often (low current to fuel pump).

I replaced the EKPS so this is not the issue. Then I trace to the only 2 options that might impact the current ampere to fuel pump

1. The wiring from EKPS to fuel pump and/or the connector itself
2. The CAN wire in my car is playing funny and send wrong signal to the pump with regard to pump speed.

ISTA and INPA show my fuel pump only has 11.9V at fuel pump (ignition on) and 4.5amp only. Fuel pump speed is 6738/min

Any idea on this?

seanjordan20

Ok your voltage levels seem to be fine. If I'm reading it correctly 12v while on 4.5v off.

Is your level issue corrected? Now you need to try and see why it's saying low voltage. Have you check you battery level? Have you reset the car ( clear codes and keep unplugged for 30 mins ). Check your relay (swap your horn with pump relay) check fuses. If the wiring is correct in the tank then one of the above is your issue. I don't understand if it was not happening before the change why would it be doing it now. Especially if you are using OE. While troubleshooting you have to have you battery charged as this can give you false negatives.