BMW e60 5 series stalling after fuel pump replacement
Vehicle originally presented with strong fuel odor in passenger compartment, no Driveability concerns and no DTCs in PCM. Our shop replaced both the fuel pump and level sensor units due to cracking and fuel leaking. We test drove the vehicle for about 5 miles with no problems. The customer picked up the vehicle and later came back on a tow truck with a stalling concern. Vehicle now has a code for the fuel pump 2AAE. Removed both assembly's again for inspection expecting to find something disconnected, everything looked good but the fuel pump side(passenger side) of the fuel tank was completely empty and the level sensor side(drivers side) was half full. Voltage signal from the fuel pump control module located in the trunk is good. I am leaning towards a defective fuel pump assembly especially since there was no driveability concerns before the pump replacement.
Sounds like a possible issue with the suction jet system. The pump side of the saddle tank should never empty before the non pump side. I believe the suction jet return line should be routed into the fuel pump cup.
I agree with William, the suction jet pump isn't working. Either a problem with your installation or the suction jet pump is faulty. It's more common that something went wrong with the install. Hoses routed wrong or connected wrong or a leak at one of the connections.
Where did the part come from? Dealer?
Bosch pump from parts distributor