Fuel Tank: Service and Repair

16 00 005 Draining And Filling Fuel Tank

Special tools required:







WARNING: High-voltage system - danger to life.







WARNING:
Compliance with the following points is mandatory before beginning work:
- Observe safety instructions for handling with hybrid vehicles







IMPORTANT:
Observe country-specific safety regulations.
Ensure adequate ventilation in the place of work.
Connect the exhaust and extraction systems to the exhaust tailpipe.
The electric fuel pump must not operate without fuel. After completing repairs but before starting the engine for the first time, fill the fuel tank with min. 5 l fuel through the fuel filler pipe.
Do not damage non-return flap when pulling out extraction hose.







IMPORTANT:
Fuel tank is under pressure.
Prior to starting any work on the fuel tank, the refuelling button (1) must be pressed.
Pressing the refuelling button (1) relieves pressure in the fuel tank.
The fuel filler flap can not be opened until the refuelling button (1) is pressed.







The fuel filler flap (1) must be opened after fuel tank pressure has been reduced.
Fuel tank flap (1) remains open during the entire duration of the repair.







Diesel vehicles:
Before starting the engine for the first time, if the tank has been run dry or drawn off, fill with diesel fuel and turn on ignition for approx. 1 minute. The fuel circuit is thus filled and vented, which results in the engine firing more quickly.







Drawing off fuel:
Start engine and allow to run.
The electric fuel pump runs.
In this way, the fuel is repumped through the suction jet pump from the left to the right side of the fuel tank.

NOTE: Fuel can be drawn out of left and right sides of tank through filler neck, leaving only a small residue. The residual quantity is drawn off through the service opening (on right/left).







Insert special tool 16 1 080 in the filler neck.
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles.

Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning Documentation, through special tool 16 1 080 into the fuel filler pipe, turning in the process if necessary.

Insertion length approx. 170 cm.

Draw off fuel with suction unit (refer to BMW Service Workshop Equipment) as far as possible.

Follow drawing off of fuel on fuel gauge in instrument cluster.

Drawing off residual fuel quantity:
Drawing off residual fuel amount is not included in the time value of this operation.







IMPORTANT:
Ensure car interior is adequately ventilated.
Catch dripping fuel in a suitable container.

Remove left sensor unit.
Remove right sensor unit.
Draw off residual fuel quantity through service openings.







Fuel filling:
Insert special tool 16 1 080 in the filler neck.

Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles.

Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning Documentation, approx. 40 cm into fuel filler pipe.

Fill fuel from suction extractor unit.







Extracting fuel after a defect in the suction jet pump or fuel pump:
Draw off right half of tank completely through fuel filler pipe.

Remove left sensor unit.

Insert extraction hose through service opening in tank, fuel (also residual quantity) can be drawn off.