Fuel Tank: Service and Repair

16 11 030 Removing and installing fuel tank (50-litre tank)







Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.







IMPORTANT:
Avoid skin contact (wear gloves).
Ensure adequate ventilation in the workbay.
After installation of fuel tank/prior to first engine start-up:
- Check electrical resistance between metal filler bowl and wheel hub.
- Measured value: Approx. 0.65 Ohms
- Fill fuel tank with at least 5 liters of fuel







Necessary preliminary tasks:
- Draw off fuel from fuel tank
- Remove wheel arch panel at rear left and right.
- Remove underbody panelling on left and right (R57)
- Remove exhaust system
- Remove heat shield.







Detach retaining clip (1) in direction of arrow.
Disengage parking brake Bowden cable (2) from operating lever (3) at brake caliper.
Feed out parking brake Bowden cable (2) downwards.







Release bolts (2) from rear axle support.

Installation note:
Tightening torque 34 41 2AZ. 00 00 Excerpt From Company Standard BMW GS 90003-2

Disengage parking brake Bowden cables from brackets (1) and feed out through rear axle support.

NOTE: Parking brake Bowden cables remain suspended on handbrake lever.







Unlock quick-release fasteners (1) on carbon canister and detach.

Installation note:
Make sure quick-release fasteners engage correctly.







Release hose clamp (1) and disengage filler vent line from holder (2).

Installation note:
Replace hose clamp.







Pull off hose clamp (1) and remove filler hose from fuel tank.

Installation note:
Tightening torque 16 11 4AZ. 00 00 Excerpt From Company Standard BMW GS 90003-2







Unlock and disconnect quick-release fastener (1) of fuel delivery line.

Installation note:
Make sure that snap fastener is correctly engaged.







IMPORTANT: Secure fuel tank over a wide area with a suitable workshop jack and secure against falling down.







Remove expander rivets (1).
Release screws (2) and lower fuel tank a little.

Installation note:
Tightening torque 16 11 3AZ. 00 00 Excerpt From Company Standard BMW GS 90003-2

Disconnect plug connection from sensor unit on left.

IMPORTANT: Tank ventilation lines on left must be carefully passed through the openings in the body.

Lower fuel tank.







Replacement:
- Modify filling level sensor on left and right
- Modify fuel delivery line between delivery unit and separation point
Unfasten hose clip (1) and remove hose.

Installation note:
Replace hose clamp.

Disconnect quick-release fasteners (2), release tank ventilation lines (3) from holder and modify.

Installation note:
Make sure lines and wiring harness are not trapped or crushed during installation.