BMW 16116752552 Plastic Fuel Tank

Drain fuel from the tank and disconnect the negative cable from the battery, ensuring to read the battery disconnection cautions beforehand. While working at the handbrake, use BMW special tool 34 1 030 to remove the lock nut and adjusting nut from the handbrake cables. Remove the rear seat to access the fuel pump and fuel level sender. On the right side of the fuel tank, disconnect the harness connector from the fuel pump and fuel level sender by sliding the lock to release it, then cut the hose clamp and disconnect the hose. Remove the hose clamp and release the fuel tank vent line from underneath the forward edge of the access opening. On the left side of the fuel tank, disconnect the harness connector from the fuel level sender by pinching the locking tabs to release it, then cut the hose clamp and disconnect the hose. Lift the car and support it safely, then remove the complete exhaust system and heat shield, followed by the rear drive shaft. Remove the fuel tank underbody protection on both the left and right sides, unclip the emergency brake cables from the guide tubes on the bottom of the fuel tank, and tie the cables out of the way. At the front edge of the fuel tank, remove the fuel filter by detaching the vacuum line, fuel lines, and fasteners to release it from the brackets. Using BMW special tool 16 1 050, remove the hose on the charcoal canister, then remove the right rear wheel well trim and detach the fuel filler hose from the filler pipe. Identify and label hoses for the fuel expansion tank, remove the clamp on the fuel tank side of each hose connection, and separate the hoses at the connection point. Support the fuel tank with a suitable jack, ensuring the retaining straps are not covered, then remove the fasteners from the right, left, and center fuel tank retaining straps, unhook the straps, and remove them while ensuring the fuel tank remains balanced on the jack. Carefully lower the fuel tank approximately 20 cm (8 in) and feed the expansion tank hoses through the opening in the right rear wheel well arch. Check for other hoses and electrical connectors, disconnect as necessary, and remove the fuel tank. For installation, reverse the removal process, using new seals, gaskets, O-rings, and hose clamps, inspecting hoses for any damage and replacing as needed, checking the heat shield and rubber buffers for corrosion or damage, and ensuring the filler neck grounding screw is reattached if removed. After completing repairs, fill the fuel tank with at least 5 liters (1.5 gallons) of fuel, as running the fuel pump without fuel will cause damage.

During the process of draining the fuel tank one should use a safe storage container as well as a fuel pumping equipment which has been certified. Switch the iron on and let the engine run for about 10 to 15 seconds to allow the fuel compensating siphon assembly to fill to facilitate drawing the contents of both lobes of the fuel tank through the fuel filler pipe. Remove the negative cable from the battery without fail while reading the battery disconnection cautions first. Twist the suction hose to withdraw fuel into the storage unit while the fuel tank filler cap is removed and the hose inserted into the filler neck to about 130 cm (51 inches). The fuel level reduction in both lobes should be checked; do this by removing the rear seat cushion to reveal both fuel tank sender harness connectors. Tester should use the multimeter to measure the resistance at both senders and expect the resistance to go down as the fuel level goes down. That if the siphoning mechanism was found to be faulty the left tank lobe having been separated should be drained by removing the sender cover and pumping the fuel directly out of the left lobe. When disconnecting the suction hose from the tank filler neck be cautious not to damage the filler neck baffle plate. Care should be taken to ensure there are at least 5 litres (1.5 US gallons) of fuel in the tank before starting the engine as operation of the fuel pump without fuel in the tank is detrimental to it.