16 11 030 Removing and installing or replacing fuel tank (petrol/gasoline)

WARNING: This page is about a different car, the 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

Recycling

Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

IMPORTANT: Ensure adequate ventilation in the place of work!
Avoid skin contact (wear gloves)!
After installation of fuel tank/prior to first engine start-up:

Fill fuel tank with at least 5 liters of fuel.
Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
Check transfer function of suction jet pump .

Necessary preliminary tasks:

Draw off fuel from fuel tank
Remove rear seat bench . See 52 24 000 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR SEAT (CONV) or 52 24 005 REMOVING AND INSTALLING OR REPLACING REAR SEAT .
Remove guide tube for handbrake cables . See 34 41 140 REMOVING AND INSTALLING OR REPLACING GUIDE TUBE FOR HANDBRAKE CABLES .
Remove right wheel arch trim . See 51 71 041 REMOVING AND INSTALLING/REPLACING REAR LEFT OR RIGHT WHEEL ARCH COVER .
Remove rear left and right underbody panelling . See 51 47 ... REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY PANELLING .
Remove left and right underbody cover. See 51 75 001 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT UNDERBODY COVER .

Release screws (1) and remove cover (2) from left and right sides of fuel tank.

Fig 1: Identifying Cover Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Left sensor unit:

Disconnect plug connection (1).

Press grey ring (2) towards sensor unit and pull out fuel feed line (3).

Fig 2: Disconnecting Plug Connection

Courtesy of BMW OF NORTH AMERICA, INC.

USA national version:

Disconnect plug connection (1).

Unlock and detach vent lines (2).

If necessary, remove fuel line for independent heating.

Fig 3: Identifying Plug Connection And Vent Lines

Courtesy of BMW OF NORTH AMERICA, INC.

ECE national version:

Right sensor unit:

Disconnect plug connection (1).

Unlock quick-release fastener and detach vent line (2).

Installation:

Make sure quick-release fasteners engage correctly.

Fig 4: Identifying Plug Connection And Vent Line

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: There may still be residual amounts of fuel in the tank.
Catch and dispose of escaping fuel.

Release hose clamp (1) and detach fuel filler hose from fuel filler pipe.

If necessary, draw off residual amount of fuel via filler hose.

Fig 5: Identifying Hose Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Tightening torque 16 12 1AZ . See 16 12 FUEL DELIVERY .

Unlock quick-release fastener (1) and detach vent line (2).

Detach vent line (2) from holder (3).

Fig 6: Identifying Quick-Release Fastener And Vent Line

Courtesy of BMW OF NORTH AMERICA, INC.

Heavily support the fuel tank.

Fig 7: Supporting Fuel Tank

Courtesy of BMW OF NORTH AMERICA, INC.

Unfasten nut.

Installation:

Replace self-locking nut.

Tightening torque, 16 11 1AZ . See 16 11 FUEL TANK AND MOUNTING PARTS .

Fig 8: Locating Self-Locking Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws for tightening straps on left and right and remove tightening straps.

Carefully lower fuel tank.

IMPORTANT: Carefully feed the vent line through the body when lowering the fuel tank.

Installation:

Tightening torque 16 11 2AZ . See 16 11 FUEL TANK AND MOUNTING PARTS .

Fig 9: Locating Fuel Tank Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Note rubber mount with spacer bush.

Wide collar on spacer bush points to screw head.

Fig 10: Locating Rubber Mount With Spacer Bush

Courtesy of BMW OF NORTH AMERICA, INC.

The following components must be modified when the fuel tank is replaced:

Modify vent line (1)
Modify right sensor unit (2)
Modify left sensor unit and 16 14 016 Removing and installing / replacing fuel filter with pressure regulator .

Fig 11: Identifying Right And Left Sensor Unit With Vent Line
Courtesy of BMW OF NORTH AMERICA, INC.