2001 BMW 3 Series Fuel System Problems

WHILE DRIVING DOWN THE HIGHWAY, THE PASSENGER-SIDE FUEL TANK RETAINING STRAP BRACKET BROKE FROM THE FLOOR PAN OF THE CAR. IT WAS NOT ENTIRELY CLEAR TO ME IF IT WAS STRUCK BY SOMETHING ON THE ROAD OR IF THE WELDS JUST FAILED, HOWEVER I DO KNOW THAT I DIDN'T HIT A POTHOLE OR OTHER ROAD IRREGULARITY. I'VE DONE SOME RESEARCH AND FOUND THAT THIS IS NOT AN UNCOMMON PROBLEM ON ~2001 BMW 3-SERIES COUPES AND IT APPEARS THAT IT IS FAILING WELDS. *TR

THE WELDS ON THE FRONT (PASSENGER SIDE) FUEL TANK SUPPORT STRAP FITTING (WELDED TO THE UNDER SIDE OF THE BODY) BROKE AWAY ALLOWING THE SUPPORT STRAP TO FALL, CONTACT, BEND BACKWARD AND SCRAPE ALONG THE ROAD SURFACE CAUSING SPARKS. THE TANK WAS FULL OF FUEL, AND THE WEIGHT OF THE TANK CAUSED IT TO SAG DOWNWARD TOWARD THE ROAD SURFACE. FORTUNATELY IT DID NOT BREAK OR CONTACT THE ROAD SURFACE BEFORE I WAS ABLE TO PULL OVER AND SEEK ASSISTANCE. THIS IS A DANGEROUS DESIGN/MANUFACTURING FLAW THAT COULD CAUSE SERIOUS INJURY IF NOT CORRECTED. I AM REPORTING IT BECAUSE AFTER THIS EVENT I LEARNED THAT THERE HAVE BEEN NUMEROUS REPORTS OF THIS FAILURE IN THIS MODEL BMW. *TR

DROVE THROUGH A PARKING LOT EARLIER TODAY WHEN I HEARD SOMETHING THAT SOUNDED LIKE SCRAPING METAL COMING FROM THE REAR OF MY CAR. PULLED OVER AND FOUND THE PASSENGER SIDE GAS TANK STRAP HANGING DOWN TOUCHING THE GROUND. *TR

1) CAR WOULD NOT START, FUSE BLOWN ON FUEL PUMP. (NO. 1 ORIGINAL) TOWED TO MECHANIC. 2) MECHANIC REPLACES FUEL PUMP. (NO.2) 3) RETURN CAR TO DRIVEWAY WHERE IT SITS OVER NIGHT. CAR WON'T START. TOWED IT TO MECHANIC. REPLACED FUEL PUMP, AND HE ALLOWS IT TO SIT IN HIS GARAGE OVER NIGHT. (NO.3) 4) CAR WON'T START. HE THOROUGHLY CHECKS THE CAR FOR PROBLEMS, REPLACES THE FUEL PUMP, EMPTYING FUEL TANK, REPLACING WITH NEW GASOLINE. (NO.4) MECHANIC CUT OPENED THE ORIGINAL FUEL PUMP AND FOUND THAT THE IMPELLER HAD SWOLLEN. THIS SUGGESTED TO HIM THAT THE HIGH ETHANOL CONTENT FUEL WAS SWELLING THE IMPELLER. HE TRIED USING BOTH BMW PARTS AND AFTER MARKET PARTS. THIS ISN'T NOT AN ISSUE WITH THE AGE OF THE CAR. HE SAVED THE FUEL PUMP AND A GASOLINE SAMPLE. *TR

FUEL TANK SENDING UNIT BEHIND DRIVER'S SEAT LEAKING FUEL IN A STREAM ONLY WHEN TANK IS FULL. WHEN VIEWED FROM THE TOP, THERE IS AN ENCLOSED PLASTIC COLUMN, APPROXIMATELY 3/4 OF AN INCH IN DIAMETER THAT IS LEAKING AT A "SEAM" THROUGH PINHOLES. *TR

TL* THE CONTACT OWNS A 2001 BMW 325I. THE CONTACT WAS DRIVING 35 MPH WHEN THE VEHICLE HESITATED AND BEGAN TO LOSE POWER. THE CONTACT PULLED OVER AND SHUT THE VEHICLE OFF YET IT WOULD NOT RESTART. THE VEHICLE WAS THEN TOWED TO THE DEALER WHERE THE DEALER DIAGNOSED THE FAILURE AT THE FUEL PUMP. THE FUEL PUMP WAS REPLACED. THE MANUFACTURER WAS CONTACTED AND ADVISED THAT THE VEHICLE WAS NOT UNDER RECALL. THE FAILURE AND THE CURRENT MILEAGE WAS 100,000. UPDATED 04/13/11*LJ UPDATED 06/01/11*LJ UPDATED 01/04/2012 *LN *TR