Removing and installing fuel tank (gasoline US 53L) (Cooper)

Preliminary work needed:

Extract FUEL from fuel tank.
Remove UNDERBODY PLANKING on left and right.
Remove EXHAUST SYSTEM .
Remove heat shield.
Remove rear left WHEEL ARCH TRIM .
Remove REAR SEAT .

Removal:

Turn the sealing cap of floor panel (2) on plastic tabs (1) in the arrow direction.

Remove floor panel sealing cap (2).

If unscrewing is not possible, destroy the floor panel sealing cap (2) and replace it.

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Disconnect plug connection (1).

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Attention!

To unlock/lock or disconnect/connect the fuel line with a quick connector, no tool must be used.

To unlock snap fastener (1) on the fuel line, follow the instructions given below.

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Press in locks (1) and (2) in the arrow direction.

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Disconnect fuel lines (1) and (2) in the arrow direction.

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Press the snap fastener towards the delivery unit. Then press locks (1) and (2) in the arrow direction and detach the snap fastener in the arrow direction.

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Unlock and disconnect snap fasteners (1).

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Unhook tank vent line from holders (1).

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Release hose clamp (1) and detach fuel filler hose (2) from fuel tank.

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Unlock and disconnect snap fastener (1).

Detach fuel filler neck vent pipe from holders (2).

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Attention!

Support fuel tank over a wide area with a suitable workshop jack and secure against falling down!

Release screw and nut (1) and remove luggage strap.

Release nuts (2) and lower fuel tank.

Attention!

While the fuel tank is being lowered, the fuel filler neck vent pipe must be led from the wheel well through the body aperture!

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Preparation for the installation:

Remount CARBON CANISTER .
Remount the DELIVERY UNIT .

Installation:

Attention!

While the fuel tank is being raised, the fuel filler neck vent pipe must be led into the wheel well through the body aperture!

Raise fuel tank and position and screw in nuts (2).

Tightening torque 16 11 2AZ .

Fit luggage strap and position and tighten screw and nut (1).

Tightening torque 16 11 4AZ .

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Position snap fastener (1) and lock.

Hook the fuel filler neck vent pipe into holders (2).

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Mount fuel filler hose (2) to fuel tank.

Parts: Hose clamp

Tighten hose clamp (1).

Tightening torque 16 11 3AZ .

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Hook the tank vent line into holders (1).

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Position snap fasteners (1) and lock.

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Attention!

To unlock/lock or disconnect/connect the fuel line with a quick connector, no tool must be used.

Procedure for installing a new fuel line:

When installing a new fuel line, ensure that lock (1) protrudes.

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Insert fuel line (2) into fuel line (1).

Slide fuel line (2) into fuel line (1) by clicking the first lock (white).

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Lock the red lock (1) in the arrow direction.

Lock (1) can be locked only if the fuel lines are connected correctly.

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Check to ensure that snap fastener (1) locks in place correctly.

The snap fastener must engage audibly and perceptibly.

A traction check is not permitted!

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Procedure for installing a previous fuel line:

When installing a fuel line that has already been installed, the red lock (1) is already pressed down.

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Slide fuel line (2) into fuel line (1) in the arrow direction until the two locks lock audibly.

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Check to ensure that snap fastener (1) locks in place correctly.

The snap fastener must engage audibly and perceptibly.

A traction check is not permitted!

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Locking tabs (1) and (2) must be locked in place.

Position the snap fastener in the arrow direction and lock it in place.

Attention!

Check the locking mechanisms of the snap fastener for damages and replace if necessary!

Check to ensure that the snap fastener locks in place correctly.

The snap fastener must engage audibly and perceptibly.

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A traction check is not permitted!

Connect plug connection (1).

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Always replace floor panel sealing cap.

Reusing it poses a risk of leakage.

Coat gasket in area (1) using Carbaflo KSP 105 lubricant (see applicable BMW Electronic Parts Catalog).

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Mount floor panel sealing cap (1).

Lock the sealing cap of floor panel (1) in place on plastic tabs (2) up to the stop in the arrow direction.

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Required follow-up work:

Install UNDERBODY PLANKING on left and right.
Install EXHAUST SYSTEM .
Fit heat shield.
Fit rear left WHEEL ARCH PANEL .
Install REAR SEAT .

Attention!

After installation of fuel tank/prior to first engine start-up:

Check BATTERY GROUND LEAD at fuel filler neck to body for passage. If necessary, clean contact surface between body and fuel filler pipe screw connection.
Fill fuel tank with at least 5 liters of fuel.