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

WARNING: This page is about a different car, the 2011 BMW M3, 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
Remove GUIDE TUBE FOR HANDBRAKE CABLES
Remove right WHEEL ARCH TRIM
Remove REAR LEFT AND RIGHT UNDERBODY PANELLING
Remove left and right UNDERBODY COVER

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

Fig 1: Identifying Fuel Tank Cover And Screws

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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

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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 (USA National Version)

Courtesy of BMW OF NORTH AMERICA, INC.

ECE national-market 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.

Installation:

Tightening torque 16 12 1AZ .

Fig 5: Identifying Hose Clamp

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

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

Fig 6: Identifying Quick Release Fastener, Vent Line And Holder

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Heavily support the fuel tank.

Fig 7: Identifying Fuel Tank With Support

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Unfasten nut.

Installation:

Replace self-locking nut.

Tightening torque 16 11 1AZ .

Fig 8: Replacing Self Locking Nut

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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 .

Fig 9: Removing Screws And Tightening Straps

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Installation

Note rubber mount with spacer bush.

Wide collar on spacer bush points to screw head.

Fig 10: Identifying Rubber Mount With Spacer Bush

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

Modify vent line (1)
Modify right sensor unit See 1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP or 1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP (GASOLINE) (2)
Modify left sensor unit See 1612001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (GASOLINE, LEFT) or 1614016 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE REGULATOR (3)

Fig 11: Identifying Vent Line And Sensor Units

Courtesy of BMW OF NORTH AMERICA, INC.