Removal & Installation (5-Series)

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Fill fuel tank with at least 1.2 gallons (5 L) of fuel. Draw fuel out of fuel tank. With Special Tool (34 1 030), unfasten lock nuts. Twist lock nuts and adjustment nuts completely out of handbrake cables and pull Bowden cables downward out of their guide tubes. Remove right rear wheel. Remove right rear wheel arch trim. Unfasten hose clip and remove hose from tank. See Fig 1. Remove propeller shaft completely. Remove heat shield from tank. See Fig 2. Remove handbrake Bowden cables from guide tubes.
Unfasten screw and remove cover from rear axle bearing. See Fig 3. Unfasten hose clips, mark fuel lines and remove hoses. Open hose clip with pliers and remove hose (park heating only). See Fig 4. On all models, unfasten screws and remove clamping straps. See Fig 5.
Support fuel tank. Unfasten bolts for left and right tank mounting, then lower tank until hose connections and plug connections are accessible. See Fig 6. On left half of tank, disconnect connector from fuel level sensor, unfasten hose clips and remove tank vent lines. See Fig 7.
On right half of tank, disconnect connector on fuel delivery unit. Unfasten hose clip and remove tank vent line. See Fig 8. Lower fuel tank and remove downwards. To install, reverse removal procedure. Note location of rubber mount and washers on left and right tank. After the installation of the fuel tank and prior to first engine start-up, check the electrical resistance between ground lug (tank filling pipe) and wheel hub. Measured value should be approximately.6 ohms.

Fig 1: Removing Hose Clip & Hose From Tank (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 2: Removing Heat Shield (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 3: Removing Cover From Rear Axle Bearing (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 4: Removing Return Hose, Inlet Hose & Park Heating Hose (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 5: Removing Clamping Strap (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 6: Removing Tank Mounting Bolts (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 7: Disconnecting Left Tank Fuel Level Sensor (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.

Fig 8: Disconnecting Right Tank Fuel Level Sensor (5-Series)
Courtesy of BMW OF NORTH AMERICA, INC.