BMW Coupes and Sedans 1970-1988 Repair Guide

Assembly

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REMOVAL & INSTALLATION



1600, 2000 and 2002 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the fuel from the fuel tank.
  4.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Remove the fiber floor panel from the trunk, if equipped. Disconnect the positive lead and ground wire.
  2.  
  3. Disconnect the fuel feed hose from the immersion tube transmitter.
  4.  
  5. Label and disconnect all evaporative control vapor lines.
  6.  
  7. Disconnect the hose clamp from the bottom of the filler neck and push up on the rubber sleeve.
  8.  
  9. Remove the tank retaining bolts and carefully lift out the tank.
  10.  
  11. Reverse the above procedure to install.
  12.  

2002Tii Model
  1. Disconnect the negative battery cable.
  2.  
  3. Drain the fuel from the tank.
  4.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Remove the fiber floor panels from the trunk, if equipped. Disconnect the leads from the fuel gauge sending unit. Disconnect the fuel feed and return lines from the suction unit.
  2.  
  3. Label and disconnect all evaporative control vapor lines.
  4.  
  5. Disconnect the hose clamp from the filler neck.
  6.  
  7. Remove the tank retaining bolts, separate the filler neck sections and carefully lift out the tank.
  8.  
  9. Reverse the above procedure to install.
  10.  

2500, 2800, Bavaria, 3000 and 3.0 Models
  1. Drain the fuel and disconnect the negative battery terminal.
  2.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Remove the luggage compartment mat and the lining which rests against the right side quarter panel.
  2.  
  3. Remove the fuel hose from the tank sending unit. Pull the electrical connections off, noting that the ground wire (Brown) goes to the rounded connector, the Brown/Yellow wire to the G connector, and the Brown Black wire to the W connector.
  4.  
  5. Remove the filler cap and slip he rubber ring off the filler neck.
  6.  
  7. Detach the tank from the luggage compartment floor, tilt upwards at the front, and remove it.
  8.  

To install:
  1. Install in reverse order. Before putting the tank into position, check the foam gasket supporting the tank and replace it if necessary. Make sure to install the sealing ring onto the filler neck before the tank goes into final position.
  2.  

318i and 320i Models
  1. Disconnect the battery negative terminal and drain the fuel.
  2.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Remove the rear seat. Remove the black guard plate to gain access to fuel lines and the sending unit.
  2.  
  3. Unfasten the electrical connector and the suction and return lines at the sending unit. Disconnect the vent line at the tank.
  4.  
  5. Disconnect the filler neck at the lower end.
  6.  
  7. Remove the mounting screw and remove the guard from behind the connecting hose (which goes to the left side tank).
  8.  
  9. Disconnect the connecting hose. Then, remove the 2 mounting screws on the inboard side of the tank at the bottom, and lower the tank out of the car.
  10.  
  11. For the tank mounted on the left side, perform Steps 5 and 6 in a similar way, but before lifting the tank out of the car, disconnect the small vent line from the top of the tank. If this line should have to be replaced, limit the length of the replacement hose section to 23 inches (600mm).
  12.  
  13. Install the fuel tanks in reverse order.
  14.  

524td Model
  1. Open the tank cap, lift off the rubber cover and disconnect the 3 vent hoses. Drain the fuel.
  2.  


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile!

  1. Remove the trunk mat and unscrew the tank cover.
  2.  
  3. Disconnect the 2 electrical plugs and the 2 hoses.
  4.  
  5. Unscrew the bolts and disconnect the exhaust suspension parts on the rear axle carrier. Position the exhaust assembly out of the way and secure it with wire.
  6.  
  7. Unscrew the retaining strap mounting bolt, remove the liner and then remove the strap.
  8.  
  9. Unscrew the mounting bolt and remove the fuel tank.
  10.  
  11. Installation is in the reverse order of removal.
  12.  

5 Series Models
  1. Disconnect the battery ground cable. Siphon the fuel out of the tank.
  2.  
  3. Fold the floor mat out of the way for access. Remove the 3 screws and remove the round black cover which permit access to the sending unit
  4.  
  5. Disconnect the wires at the sending unit (Brown-ground, Brown/Yellow -G, Brown/Black-W). Detach the unclamped vent line.
  6.  
  7. Detach the feed and return lines at the filter and return pipe (both under the car).
  8.  
  9. Detach the front and rear mounting bushings of the rear-most muffler, and then remove the rear bracket from the body.
  10.  
  11. Loosen the tank mounting bolts at the front and right sides, remove the filler cap, and remove the tank.
  12.  
  13. Install in reverse order.
  14.  

6 Series Models
  1. Disconnect the negative battery cable, and siphon fuel from the tank. Lift the rear compartment rug out of the way. Remove the round access cover.
  2.  
  3. Disconnect the electrical plug and the 2 fuel lines from the top of the sending unit.
  4.  
  5. Remove the fuel tank filler cap and the rubber seal which surrounds the filler neck. Then, disconnect the 4 vent hoses.
  6.  
  7. Remove the bushings from the rear muffler at front and rear, and then remove the mounting bracket at the rear.
  8.  
  9. Bend the tabs down, remove the mounting bolts, and remove the heat shield. Remove the nut and bolt, and remove the stone guard.
  10.  
  11. Remove the 3 mounting bolts from the right side panel, and lower the tank, right side first, and then remove it, being careful to avoid pinching any of the hoses.
  12.  
  13. Install in reverse order, making sure the rubber bumpers against which the tank is held by the mounting straps are in good shape, or replace them, as necessary.
  14.  

7 Series Models
  1. Unscrew the filler cap and siphon out the tank.
  2.  
  3. Disconnect the negative battery cable. Fold the rug in the rear compartment out of the way, and remove the round access panel.
  4.  
  5. Disconnect inlet and outlet hoses at the sending unit.
  6.  
  7. Disconnect the sending unit electrical connector at the plug, located near the wiring harness in the trunk.
  8.  
  9. Remove the mounting bolts from the straps and lower the tank slightly and support it. Pull off the (4) vent hoses. Then, lower the tank out of the car.
  10.  
  11. Install in reverse order, making sure the rubber bumpers against which the tank is held by the mounting straps are in good shape, or replace them, as necessary.
  12.  

 
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