BMW Cars 1999-06

Removal & Installation

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CAUTION
Gasoline is extremely flammable and the vapors can be explosive. Work in a well ventilated area away from any sources of ignition. Keep a fire extinguisher of the type for liquid fueled fires within reach during the handling of gasoline. Personal injury or death can result from mishandling gasoline.

E30 Models



  1. Turn the ignition switch to the OFF position. Remove the fuel from the tank by draining or siphoning.
  2.  
  3. Remove the rear seat bottom cushion and pull back the plastic sheet.
  4.  
  5. Remove the covers on both sides to expose the fuel pickups and level senders. Mark and disconnect the hoses and electrical plugs.
  6.  
  7. Remove the fuel level senders from both sides of the tank as equipped. Siphon out any remaining fuel from the tank from the openings.
  8.  
  9. Remove the rear muffler, heat shield and the connecting pipe. Remove the driveshaft.
  10.  
  11. Disconnect the fuel pipes and hoses from the tank. Remove the stone guards on both sides.
  12.  
  13. Support the fuel tank. Remove the fastening hardware and tilt the tank down to remove.
  14.  

To install:

  1. Tilt the tank into place and torque the nuts to 18-20 ft. lbs. (25-28 Nm). Torque the bolts to 16-17 ft. lbs. (22-24 Nm).
  2.  
  3. Install the stone guards and connect the hoses and pipes to the tank. Install the driveshaft. Install the connecting pipe and torque to 17-19 ft. lbs. (23-27 Nm).
  4.  
  5. Install the heat shield and torque to 6.0-6.5 ft. lbs. (8-9 Nm). Install the rear muffler.
  6.  
  7. Install the fuel level senders in the tank. Connect the electrical plugs and the hoses.
  8.  
  9. Install the covers and the plastic sheet. Install the rear seat cushion. Torque the drain plug to 16-18 ft. lbs. (21-25 Nm). Fill the tank with gasoline before operating the fuel pumps.
  10.  

E36 Models



  1. Turn the ignition switch to the OFF position. Remove the fuel from the tank by draining or siphoning.
  2.  
  3. Remove the rear seat bottom cushion and pull back the plastic sheet.
  4.  
  5. Remove the covers on both sides to expose the fuel pickups and level senders. Mark and disconnect the hoses and electrical plugs.
  6.  
  7. From under the vehicle, use fuel line block-off clamps on the fuel feed and return lines. This will prevent fuel from running out of the lines once disconnected. Loosen the hose clamps at the connections and disconnect the lines.
  8.  
  9. Remove the 6 screws holding the heat shield. Remove from the vehicle. Remove the driveshaft.
  10.  
  11. Disconnect the parking brake cables from the parking brake lever. Push the cables out from the clamps and pull out of the holder.
  12.  
  13. Disconnect the filler hose from the fuel tank. Support the fuel tank from below. Remove the mounting bolts and lower the tank.
  14.  
  15. Disconnect the tank vent line at the tank. Unclip the lines and remove the fuel tank.
  16.  



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Fig. Fuel tank mounting points-E36 3 Series



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Fig. Disconnect the vent line and unclip from the tank-E36 3 Series



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Fig. Disconnect the vent pipes 2 and 3-E36 3 Series

To install:

  1. Place the tank into position and connect the vent line. Replace the vent lines into position. Install the tank mounting bolts and torque to 16-17 ft. lbs. (22-24 Nm).
  2.  
  3. Connect the filler hose. Install the parking brake cables by passing through the holders and into the clamps. Connect at the parking brake lever.
  4.  
  5. Install the driveshaft and the heat shield. Connect the fuel feed and return lines. Remove the block-off clamps. Connect the fuel lines and the electrical connectors at the fuel pickups and level senders.
  6.  
  7. Install the rear seat cushion. Fill the tank with gasoline before operating the fuel pumps.
  8.  

 
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