Updated: High Pressure Fuel Pump (Failures): 335/135 (Updated pics)

Twinz

Forum - Support
Staff member
I hope my next comments will not put you off from purchasing a 335/135...but at least I can say...I told you so.:pimp:

By now, we all know that the 335/135 is destined for cult status whether in N54 or N55 guise.:clap::clap:
I love this car, like I have never loved a car...period...of course there has been many cars that made my heart race, very fast, but none that I actually (loved)...well there was the e30 325is...:dropjaw:

Anyway, there has been many reviews and I mean many reviews of the twin turbo N54 engine and rewards for being engine of the year in 2007/8/9 (I think). :thumbsup::thumbsup::clap::clap::clap:

There are also many, and I mean, many reviews and forum threads and articles about its biggest weakness...its High Pressure Fuel Pump (HPFP).:bawling:

On most bimmer forums there are “sticky’s” devoted to this issue and even a question and answer (Q&A) thread devoted to the HPFP.:google:

The thing is fuel pumps do fail and can fail on any car...but on the 335/135 it is a major defect, that has not been resolved and have exposed BMW to class action as we see in the US. :nono:

BMW is aware of this problem and has even extended the warranty on the HPFP to 10 years in some countries.:werd:

The symptoms of a failing HPFP pump, is well documented on the internet but includes:
*Long cranks (hard starting) especially on cold start up
*Long or delayed cranks anytime when the car is started
*Misfiring
*Stutter/sputtering
*Inconsistent speedo whilst driving
*Fuel starvation and the car stutters forward and stops
*Rough idling
*The worse experiences recorded is the car stop dead in its tracks on the highway for no reason.:wtf:

Now why does the HPFP fail? :thinking:

Before I answer let me highlight some other common "faults" that you WILL experience when you drive or purchase a 335/135.
Ps. I hear that the 535 twin turbo models experience similar problems as the N54 platform. Eish :shocked:

1. CEL:
You will get a limp mode or Check Engine Light (CEL) sometime while having this car and it can happen under any circumstances but mainly when it is hot or driving under heavy load/spirited driving/WOT, when heat soak shuts down the turbos from full boost. :thumbdown:

2. Spark Plugs:
Your plugs are meant to last 20 000km according to BMW. But it will not; you will probably have to change it twice in that time and if you run a tune expect to replace it more than often. Bad race fuel; over boost; WOT; Tracking or dragging all can contribute to the plugs just loosing their spark. Fortunately, the plugs are cheap but the labour to replace and install them could be expensive in the long term. :hammerhead:

2. Fuel injectors:
Sooner or later one or all of the 6 injectors will need replacing. It may be done when a new HPFP is installed or if the car backfires on cold starts or for some unknown reason during spirited driving. I am not saying that backfires are necessarily related to failing injectors but they are symptomatic of such. These are also very, very expensive to replace out of warranty. Expect to pay (R4,900) for one of these. :cursin:

3. Ignition Coils:
Another expensive part but not so common, but when you hold it in your hand you realise it is a “cheap” Bosch product. I have not heard of these failing (all) at the same time but one after the other...yes! A failing coil could also throw a check engine light (CEL). :thumbdown:

Now back to the question: Why does the HPFP fail?

The answer is we don’t know other than the fact that it is a defect inside the pump.
#Some had HPFP failures after using bad race fuel or the pump being starved of fuel or bad fuel contaminants
#Some claim it is tune related and the HPFP cannot handle boost higher than stock boost
#Some have not had HPFP failures at all
#Some claim it is the low octane/low fuel quality at our fuel stations etc etc....it could be any of these or none of these.

So should you - tune or not tune? Does this increase the risks?

There are always risks with tuning but there are so many cases of HPFP failures on complete stock 335/135s and then there are also cases of zero failures of the HPFP on tuned cars. So....:dunno:

I believe the problem is the HPFP itself that is defected and BMW has not found a solution to the problem.

The first 335/135s came out with the:
1351 7 537 320 HPFP
followed shortly by
1351 7 585 655 HPFP
and my 2009 model had this one:
1351 7 592 881 HPFP
Followed by:
1351 7 596 123 HPFP
These pumps were updated and replaced again due to the high rate of failure with:
1351 7 594 943 HPFP
But these also started to fail and got updated and replaced a couple of months ago (May 2010) with a brand new remanufactured pump:
1351 7 613 933 HPFP

Time will tell if this replacement will endure.

For the DIY types...yes you can install the HPFP yourself. It is pretty straight forward and there are guides available online as well as a youtube guide.The HPFP is located on the right hand side of the engine under the airfilter box and then immediately underneath/next to the throttlebody connection, in case you were wondering.:thumbsup: See the last pictures in this post.

NB. A HPFP replacement is normally accompanied with a software update at the dealership.

Now for those pictures:

Pictures of the first version pump on the 2009 models:1351 7 592 881 HPFP

DSC03035.jpg


DSC03041.jpg

DSC03043.jpg


DSC03038.jpg


Then another revision on the 2009 models:1351 7 594 943 :hammerhead:
DSC03030.jpg

DSC03031.jpg

DSC03045.jpg

Here are some pics of the HPFP on the inside.

DSC03191.jpg

DSC03185.jpg


DSC03197.jpg


DSC03199.jpg

DSC03194.jpg


The latest version: 1351 7 613 933 :thumbsup:

I hope this works:
DSC03154.jpg

DSC03153.jpg

DSC03152.jpg

DSC03155.jpg

DSC03156.jpg

Location:
Here are two pics of the new pump installed:
DSC03436.jpg

DSC03435.jpg

That is it and i sincerely hope that you will not be discouraged by this thread but stimulate discussion. :woot::woot::woot:
 

George Smooth

///Member
The majority of these failures have occurred in the States due to there high ethanol level in the fuel. I would not really be concerned about failure that much in SA. I would worry more about the rattling waste gates on the turbos.
 

Matt Q

///Member
Since running the charger I've gone through pumps on Jezzy.. I recon like most motors, pumps like to operate under pressure and if you are using the fuel at such a rate the pump is gonna take strain... then again as stated above the ethanol content may contribute as this would damage certain internals.... would it not be possible to run another in line pump??

Also beware.. if your pump fails during WOT.. you could get some nasty leaning occurring
 

George Smooth

///Member
Matt Q said:
Since running the charger I've gone through pumps on Jezzy.. I recon like most motors, pumps like to operate under pressure and if you are using the fuel at such a rate the pump is gonna take strain... then again as stated above the ethanol content may contribute as this would damage certain internals.... would it not be possible to run another in line pump??

Also beware.. if your pump fails during WOT.. you could get some nasty leaning occurring

These pumps are a bit different. The car does have a conventional pump in the tank going to the front running normal pressures. When the fuel reaches the motor there is another high pressure pump (200bar) that is driven of the camshaft sprocket. These are the ones that are fucking out. They are even using the same pump on the N55. Most the cases are in the States though where its not uncommon for every car to have the pump replaced several times. I court case was held and the pumps now carry a extended warranty.
I think when BMW tested the pumps in the states the economies where good and there was less ethanol in the fuel in the States. Things have changed a lot since then and probably the fuel they tested with is no longer the same.
 

Twinz

Forum - Support
Staff member
Okay i updated the pictures of the internals of the pump...interesting but i am none the wiser:mmm:

1. @Matt..."Also beware.. if your pump fails during WOT.. you could get some nasty leaning occurring"...Ya this was my biggest concern.

2. @George.....:cursin:...."high ethanol level in the fuel.".......this could have been the reason for my pump failing:pimp:...experimented with a new concoction of fuel, which i stopped after the pump failing....but time will tell if it is not just crappy pumps:pimp:
 

George Smooth

///Member
Twinz said:
Okay i updated the pictures of the internals of the pump...interesting but i am none the wiser:mmm:

1. @Matt..."Also beware.. if your pump fails during WOT.. you could get some nasty leaning occurring"...Ya this was my biggest concern.

2. @George.....:cursin:...."high ethanol level in the fuel.".......this could have been the reason for my pump failing:pimp:...experimented with a new concoction of fuel, which i stopped after the pump failing....but time will tell if it is not just crappy pumps:pimp:

You should find out from Terry if he increases the rail pressure at all for fueling. This could also be a possible cause but most likely ethanol in your case.
 

laloosh

New member
Hi guys just a noob question but what are the symtoms of a failing pump.thx

Also how would you no if u got a rattling/lose wastegate
 
A

anile8-zn

Guest
i had my fuel pump replaced twice !!!
both the high and low pressure.

u will get hard starting at first laloosh!
 

laloosh

New member
Thanks anile8.the reason why I'm asking is becos my cuz's car had no issues or symtoms and bmw reckon that his pump was failing.The only issue was the his power wasn't very consistant.
 

Kisho135i

New member
Twins i'm already having a bad day now hearing about all my cars defects lol. Hope my car is one of those without this problem. Under warranty you shouldnt have any problems? I still got 2-3 years will probably sell before warranty is over.
 

Twinz

Forum - Support
Staff member
@Laloosh: You will know when you have wastegate issues, the rattlling will get louder and annoying. The 2009 upward models don't seem to have this problem....BMW must have sorted it out but then again i won't stake my hopes on it.

@ Kisho...sorry to say but you WILL have problems with your 135...any of the ones i mentioned in the first post; it is just a matter of time. However there are many 335/135s that never had pump issues such as my first 335....so perhaps there are a selected few:)

I cannot see a 135/335 without warranty coverage...:nono: its a must and when the BMW warranty expires get an aftermarket one:thumbsup:
 

Kisho135i

New member
TWIN I GOT 335 E92 NOW, NOT THAT IT MAKES A DIFF. YA HEY WARRANTY IS A MUST, SO MUCH FAULTS FROM BMW, ITS ACTUALLY QUITE SHOCKING. GREAT POST THOUGH, ATLEAST I'LL KNOW WHATS UP IF ANYTHING DOES HAPPEN

GEORGE- rattling waste gates on the turbos? wHY DO THEY RATTLE, WHAT PROBLEM DOES THIS CAUSE.

--------------------------------------------------------------------------------
 

Twinz

Forum - Support
Staff member
I leave the explanation to George....but i will put up a few pics of the turbo so you can see the wastegate/rod/actuators....see tonight:wave:
 

laloosh

New member
Thanks for the input Twinz much appreciated.

I do get a rattle but me dealer says that its the normal sound of the exhaust.Is there any other way to find out????
 

dlk001

Member
Thank you Twinz for the informative post. I'm feeling better knowing what to expect from the ownership of the 335i. So far, mine has 50k mileage and all is still good. My previous 2005 E90 325i visited the dealer 64 times in 90 000kms. This 335i has only been at the dealer 3 times in 50 000kms. Maybe I'm lucky this time around.
 
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