I bought the Radium Walbro Fuel Pump Kit earlier this year and did a DIY for the install on our E46 M3. The product quality is great and I personally have not experienced any issues however there have been 4 reported cases from purchasers that their fuel pump is dying on them leaving them stranded. I’ve been in contact with Radium over the past few days:
7/27/2018: There have been multiple reports from E46 M3 owners that the Radium Engineering Walbro 255 LPH kit (20-0082) wiring melts on the basket side of the fuel pump assembly causing the car to stall and become immobile. I reached out to Radium via email on 7/9/2018 and their response was the following:
We have never seen an issue like this before. A problem like this could occur from improper installation. For example: improper crimping, improper insulation on wiring, pump malfunction that did not trigger fuse to blow.
This kit has been installed on thousands of vehicles for years without an issue. What would you like us to verify?
7/30/2018: They responded back and took time to explain the issue, but they’re still not admitting fault and have no interest in resolving the issue for customers including me. The issue is that the locking terminals need to be bent back in order for the connectors to lock in place. This was not in the original directions. The only thing they tried to do was send me an updated PDF direction sheet that they had just edited (I checked the meta data on the PDF and the document was saved 7 minutes prior to sending me the email) to trick me into thinking those directions were there the whole time. So if they had to update the direction, they clearly know there was something missing.
When my friend told me about his Radium fuel pump kit dying on him I thought it was a one-off. Then I saw another report from a different user on the E46 M3 Facebook groups with the identical issue. From that thread, 2 other people have reported the same exact issue. The obvious issue is that the fuel pumps are dying on them, but what’s happening is that the wire terminal on the basket side of the fuel pump is jumping causing intermittent connections when loose resulting in a melted wire. The original directions from Radium did not specify how to secure the connection, but simply stated to peel back the locking terminals and slide the connection in – then finally sealing it with the heat shrink wrap. What they failed to observe is that their spade connector is not a snug enough fit to just heat shrink wrap.
I’ve been in contact with Radium for the past few days to find a solution for this matter and the immediate response I got from them was rather unwelcoming and just felt like they were shooing me away. It was not after a few back and forth emails that they finally decided to investigate the issue. Although they did some investigation, they still are not finding a solution for their current customers. I am very upset at their customer service which sucks because they make such nice products. For those that have purchased the fuel pump kit from Radium I’d advise you to ask for a new connector kit so you can re-secure the spade connections.
We found that if there is too much force applied to the BMW terminal locking tabs when removing them from the fuel pump, they will need to be bent back into place in order to lock in place…The instructions were revised only to help customers from accidentally overstressing the BMW terminals. This is fairly common knowledge when working with any locking pins including spade terminals. They are designed to deflect back into position.
So in conclusion, you’re not going to receive support from Radium about this matter. For all customers after 7/28/18 you’ll be fine since you have the new directions, but for the others that did not use the new directions, your fuel pump may leave you stranded in the middle of the road.