Hi there - I had an issue with my 1990 325i where it was running fine when cold, but would then start to misfire and lose power when the engine got up to temperature. From a bit of googling this seemed to indicate that the fuel pump was faulty. The external one was changed a couple of years ago so I swapped the one in the tank.
I disconnected the battery removed the fuel sender, followed by the pump, and reinstalled both. The car would crank but not start. I disconnected the sender and the car started fine. I then test drove it 30 miles and it ran better than it has ever run and the running issues it was suffering before have gone away.
I then reconnected the sender and it failed to start again, so I disconnected the battery and tried again. Car fired up, Next morning no start. Again disconnected the sender and it fired up straight away. I've tried this over the last couple of days - sometimes it starts without issue, other times it won't but if I disconnect and reconnect the battery or disconnect the sender it'll fire up. The fuel level is showing fine in the gauge cluster.
Is there something the sender is doing to stop the car from firing up, and is it common that it might have got damaged during removal?
Fuel Sender
Moderator: martauto