16 11 030 Removing and installing/replacing fuel tank

WARNING: This page is about a different car, the 2003 BMW Z8, 2002 BMW Z8, 2001 BMW Z8, and 2000 BMW Z8. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: The electric fuel pump must not be operated without fuel! After repairs, first fill the replaced or reused fuel tank with min. 5 liters of fuel through the fuel filler pipe. The engine can then be started.

Draw off fuel from fuel tank. Refer to 16 00 005 Draining and filling fuel tank .

Remove partition wall. Refer to 16 11 ... Removing and installing/replacing partition wall, retaining bracket and wheel arch trim .

Unfasten plug connection (1) and disconnect.

Fig 1: Identifying Plug ,Quick-Release Couplings And Hose Clamp

G03206547

Courtesy of BMW OF NORTH AMERICA, INC.

Release quick-release couplings (2) and detach.

Installation:

Check locking of both quick-release couplings by pulling, do not actuate release elements in the process.

Unfasten hose clip (3) and remove hose.

Installation:

Replace hose clamp (3) on vent hose.

Tightening torque 16 12 8AZ. Refer to FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .

CAUTION: Do not release hose clamp on fuel tank side. Arrow marking on filler neck hose must always point to fuel tank partition.

Release hose clamps (1).

Fig 2: Releasing Hose Clamps

G03206548

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Replace hose clamps (1).

Vent hose:

Tightening torque 16 12 8AZ. Refer to FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .

Filler pipe:

Tightening torque 16 12 9AZ. Refer to FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .

Press filler neck hose away and detach vent hose.

NOTE: Release screws (2) first on right and then on left on fuel tank.
Release screws (1) and remove carbon canister underguard.

Fig 3: Removing Carbon Canister Underguard

G03206549

Courtesy of BMW OF NORTH AMERICA, INC.

Release quick-release coupling (1) and detach.

Fig 4: Releasing Quick-Release Coupling

G03206550

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Check locking of quick-release coupling by pulling, do not actuate release element in the process.

CAUTION: Do not damage rubber seal.

NOTE: Tape off edges of elongated hole with adhesive tape to protect hoses.

Push hose (1) through and remove from below.

Fig 5: Identifying Hose

G03206551

Courtesy of BMW OF NORTH AMERICA, INC.

CAUTION: Do not damage hoses.

Slide seal (1) over connections (2) and remove.

Fig 6: Sliding Seal Over Connections

G03206552

Courtesy of BMW OF NORTH AMERICA, INC.

Press hoses through elongated hole (3).

CAUTION: Do not damage fuel tank or acoustic cover.

Remove fuel tank with acoustic cover (1).

Fig 7: Removing Fuel Tank With Acoustic Cover

G03206553

Courtesy of BMW OF NORTH AMERICA, INC.

Small openings (1) delivery and return hoses

Large opening (2) tank venting

Fig 8: Identifying Rubber Seal Openings

G03206554

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Install rubber seal correctly.