BMW X3 2005

Removal & Installation

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CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:

    Rear seat bench
     
    Underbody paneling
     
    Handbrake Bowden cables
     
    Complete driveshaft
     

  8.  
  9. Remove bolts (1) and remove cover (2) from right side of fuel tank.

    Click image to see an enlarged view

    Fig. Removing cover (2) and bolts (1) for fuel tank connection access

  10.  
  11. Disconnect plug (1) and service vent line (3) from fuel pump assembly along with hose (2).

    Click image to see an enlarged view

    Fig. Removing connections (1), (2), and (3) from the fuel pump assembly

  12.  
  13. Remove hose clamps and detach fuel filler hose from fuel tank.
  14.  
  15. Unclip fuel vent line from clips on fuel tank.
  16.  
  17. Disconnect fuel feed line and fuel return line at the fittings joining the fuel lines to the front of the vehicle.
  18.  
  19. Remove bolt and unclip lines from fuel line holder.
    NOTE
    Do not kink fuel lines when moving them aside. Seal the lines with special tools 13 5 281 and 13 5 282.

  20.  
  21. Support the fuel tank.
  22.  
  23. Remove bolts for fuel tank mounting strap on the left and right sides.
  24.  
  25. Lower fuel tank until line (1) is accessible.

    Click image to see an enlarged view

    Fig. Accessing fuel line (1) after lowering fuel tank

  26.  
  27. Unclip line (1) from the holders.
  28.  
  29. Move fuel tank downwards.
  30.  
  31. Feed out fuel line (2).
    NOTE
    Do not kink fuel line.

  32.  
  33. Remove fuel tank.
  34.  

To install:

  1. Raise fuel tank to a height that will allow the installation of the vehicle-s fuel line through the clips on the tank.
  2.  
  3. Clip the fuel lines to the tank.
  4.  
  5. Attach the fuel tank mounting straps around the fuel tank. Tighten the bolts in the straps to 14 ft. lbs. (19 Nm).
  6.  
  7. Install or connect the following:

    The fuel lines beneath the vehicle
     
    The fuel lines under the back seat area
     
    The fuel fill hose and fuel fill vent hose
     
    Clamps holding fuel supply and return lines
     
    Electrical connection at fuel pump assembly
     
    Driveshaft
     
    Handbrake Bowden cables
     
    Underbody paneling
     
    Rear seat bench
     

  8.  
  9. Fill tank with at least 5 gallons of fuel and test function of fuel pump.
  10.  
  11. Check for fuel leakage in fuel delivery system.
  12.  

 
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