Fuel Supply System - Repair BMW M3 E46

Scheme 125

Scheme 126

1. General: General function description for fuel systems. Refer to «16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS»(/bmw/m3/e46-1999-2006/remont/fuel-system/#fuel-supply-system-repair__16-00-general-function-description-for).
2. Parts Designation: PARTS DESIGNATION CHART 1. Fuel tank 14. Service vent line 2. Electric fuel supply pump 15. Expansion tank 3. Surge chamber 16. Roll-over valve 4. Suction jet pump 17. Distributor injection pump (M47) 5. Tank expansion line 17. High-pressure pump (M57) 6. Outlet protection valve 18. Inline pump (M57) 7. Filler pipe 19. Fuel filter 8. Tank cap 20. Fuel rail (M57) 9. Refueling vent line 21. Injection nozzle 10. Fuel return line 22. Bimetallic valve 11. Fuel feed line 23. Fuel cooler 12. H-piece 24. Pressure limiting valve (M57) 13. Service vent line
3. Function Description: Fuel system ( (Scheme 125)/ (Scheme 126) ): The saddle-shaped fuel tank contains the surge chamber with the electric fuel feed supply pump on its right side. The surge chamber ensures that the fuel supply pump is properly supplied in all vehicle operating states. The fuel is repumped from the right side of the fuel tank into the surge chamber via the suction jet pump integrated in the tank expansion line. The suction jet pump is operated via the fuel feed line. The outlet protection valve protects the fuel return line. The valve closes in the event of a pressure drop when the fuel return line is damaged or disconnected. This prevents fuel from escaping from the fuel tank in extreme vehicle positions (overturning, inclined position). Fuel Supply To Engine: M47 (Scheme 125) The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter to the distributor injection pump. The distributor injection pump supplies the relevant injection nozzle. The return fuel from the fuel injectors and the distributor injection pump is directed to the bimetallic valve, which divides the amount of return fuel as a function of the fuel temperature. At low fuel temperatures, the greater part of the fuel flows back into the fuel feed line ahead of the fuel filter. In this way, the fuel is heated up faster at low outside temperatures. At high fuel temperatures, the greater part of the fuel flows back into the fuel tank via the fuel cooler and the fuel return line. This prevents the fuel from being excessively heated at high outside temperatures. Large and heated amounts of return fuel occur under extreme operating conditions such as e.g. uphill driving or trailer towing. For this reason, part of the fuel is routed directly into the fuel feed line by the flow restrictor in the H-piece. This measure also counteracts any excessive heating of fuel in the fuel tank. M57 (Scheme 126) The fuel is routed from the electric fuel supply pump via the fuel feed line, the inline pump and the fuel filter to the high-pressure pump. The high-pressure pump supplies the injection nozzles with fuel via the fuel rail. The inline pump generates the necessary preliminary fuel pressure for the high-pressure pump. This preliminary pressure is maintained at a constant level by the pressure limiting valve in the engine circuit. The return fuel from the fuel injectors and the high-pressure pump is directed to the bimetallic valve, which divides the amount of return fuel as a function of the fuel temperature. At low fuel temperatures, the greater part of the fuel flows directly into the fuel feed ahead of the inline pump. In this way, the fuel is heated up faster at low outside temperatures. At high fuel temperatures, the greater part of the fuel flows back into the fuel tank via the fuel cooler and the fuel return line. This prevents the fuel from being excessively heated at high outside temperatures. Large and heated amounts of return fuel occur under extreme operating conditions such as e.g. uphill driving or trailer towing. For this reason, part of the fuel is routed directly into the fuel feed line by the flow restrictor in the H-piece. This measure also counteracts any excessive heating of fuel in the fuel tank. Venting system ( (Scheme 125)/ (Scheme 126) ). The fuel tank is vented during refueling via the refueling vent line in the filler necks. During driving, the fuel tank is vented via the service vent lines and the expansion tank. The condensed constituents of the fuel vapors pass from the expansion tank via the left service vent line back into the fuel tank. Determining fill level in fuel tank. The fuel level is measured by means of lever-type sensors on both sides of the fuel tank. The right lever-type sensor is integrated in the fuel supply unit. The left lever-type sensor is located in the left sensor unit. The combination of the determined ohm values from the right and left lever-type sensors produces the actual level in the fuel tank.
4. Service Data, Fuel System: Working pressure of fuel supply pump: 0.4 bar. Working pressure of suction jet pump: 1-1.3 bar.
5. Schematic Drawings Of Fuel Supply Systems: 5.1 Fuel supply system E46/M47. 5.2 Fuel supply system E46/M57.

Scheme 127

Scheme 128

Scheme 129

Scheme 130

1. General: General function description for fuel systems. Refer to «16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS»(/bmw/m3/e46-1999-2006/remont/fuel-system/#fuel-supply-system-repair__16-00-general-function-description-for).
2. Parts Designation: PARTS DESIGNATION CHART 1. Fuel tank (plastic) 18. Roll-over valve 2. Electric fuel supply pump 19. Float valve (USA only) 3. Surge chamber 20. Fuel filter 4. Pressure limiting valve 21. Pressure regulator 5. Outlet protection valve 22. 3/2-way valve (M52 USA, M73 only) 6. Suction jet pump 23. Fuel rail 7. Tank expansion line 24. Engine control unit 8. Non-return flap 25. Intake manifold 9. Filler pipe 26. Tank vent valve 10. Tank cap 27. Purge line 11. Pressure test line (USA only) 28. Vent line 11. Refueling vent line (worldwide) 29. Vacuum line (LDP USA only) 12. Fuel feed line 30. Evaporation line 13. Fuel return line 31. Carbon canister 14. Service vent line 32. Carbon canister (USA only) 15. Refueling vent line (USA only) 33. Leakage diagnosis pump (USA only) 15. Additional vent line (Japan) 34. Dust filter (USA only) 16. Service vent line 35. Tank leakage diagnostic module (USA only) 17. Expansion tank
3. Function Description ( (Scheme 127)/ (Scheme 128) / (Scheme 129) / (Scheme 130) ) Fuel System: The saddle-shaped fuel tank contains the surge chamber with the electric fuel feed supply pump on its right side. The surge chamber ensures that the fuel supply pump is properly supplied in all vehicle operating states. The fuel is repumped from the right side of the fuel tank into the surge chamber via the suction jet pump integrated in the tank expansion line. The suction jet pump is operated via the fuel feed line. The pressure limiting valve controls the pressure required to operate the suction jet pump. The outlet protection valve protects the fuel return line. The valve closes in the event of a pressure drop when the fuel return line is damaged or disconnected. This prevents fuel from escaping from the fuel tank in extreme vehicle positions (overturning, inclined position). The non-return flap prevents fuel from splashing back in the filler pipe after shutdown of the petrol/gas pump nozzle. Fuel Supply To Engine: M43TU/M52TU ( (Scheme 127), view A): The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter to the fuel rail. The fuel returns to the fuel tank via the pressure regulator secured to the fuel rail and the fuel return line. M52 USA (Scheme 129): The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter to the fuel rail. The fuel returns to the fuel tank via the 3/2-way valve (see view A), the pressure regulator and the fuel return line. This engine fuel circuit with return from the fuel rail is then switched for engine starting and a defined time < 1 minute. After this phase, the 3/2-way valve switches and interrupts the fuel return from the fuel rail. At the same time, the line branch directly at the fuel filter is activated by the 3/2-way valve to the pressure regulator (see view B). The fuel rail is now return-free. M54/M54 USA ( (Scheme 129), view and drawing 5.4): Pressure regulator and fuel filter are incorporated in a single unit. The fuel is routed from the electric fuel supply pump via the fuel feed line and the fuel filter/pressure regulator unit to the fuel rail. The fuel rail is return-free. The fuel flows directly from the fuel filter/pressure regulator unit back into the fuel tank. Venting System USA ( (Scheme 129)/ (Scheme 130) ) The fuel tank is vented during refueling via the refueling vent line. Because of its large cross-section, the refueling vent line directs the displaced volume (fuel vapors) at high speed through the expansion tank to the carbon canister. The activated carbon retains the fuel contained in the fuel vapors. The cleaned air is discharged to atmosphere via the evaporation line, the leakage diagnosis pump or the tank leakage diagnostic module and the dust filter. During driving, the system tank is vented in the same way via the refueling vent line and service vent lines. The condensed constituents of the fuel vapors pass from the expansion tank via the left service vent line back into the fuel tank. The float valve in the expansion tank is closed by the rising fuel if the tank is overfilled. This prevents overflowing of the expansion tank. The roll-over valve on the upper side of the expansion tank closes in the event of the vehicle overturning. This prevents the fuel from escaping into the carbon canister. The carbon canister is regenerated by purging with fresh air. The engine control unit opens the tank vent valve. Thus the vacuum pressure of the engine intake manifold is applied at the purge line. The carbon canister is purged in this way. The fresh air needed for this purpose is supplied via the leakage diagnosis pump or the tank leakage diagnostic module and the dust filter. The fuel constituents bound by the activated carbon are flushed out by the supplied air and directed via the purge line to the engine for combustion. This operation is only possible while the engine is running. Venting System Worldwide (Scheme 127) Refer to "Venting system USA" with following differences: During refueling, the fuel tank is vented via the refueling vent line, which directs the displaced volume into the filler neck. There is a second service vent line with a smaller cross-section in place of the refueling vent line (USA) with large cross-section. There is no float valve. The carbon canister has a smaller capacity. There is no leakage diagnosis pump/tank leakage diagnostic module or dust filter. For Japanese vehicles, the refueling vent line (USA) is replaced by an additional vent line with a float valve in the expansion tank, which is connected to the refueling vent line (worldwide). This modification is required on account of the more heavily gas-emitting fuel in Japan (see drawing 5.2). Leakage detection for tank venting system USA ( (Scheme 129)/ (Scheme 130) ) The leakage diagnosis pump or tank leakage diagnostic module serves to detect leakages for the tank venting system within the on-board diagnosis laid down by legislation. The tank venting system is pressurized and the pressure loss is detected in the event of a leak. With the leakage diagnosis pump, the pressure loss is measured by way of the repumping time. The pump is operated with vacuum pressure from the intake manifold via the vacuum line. The tank leakage diagnostic module detects the pressure loss by way of the power consumption of the integrated pump. The air required for this purpose is supplied via the dust filter. Both systems are activated by the engine control unit. The pressure test line establishes the connection between fuel tank and filler neck. This enables a leak to be detected in the filler pipe-tank cap area. Determining fill level in fuel tank The fuel level is measured by means of lever-type sensors on both sides of the fuel tank. The right lever-type sensor is integrated in the fuel supply unit. The left lever-type sensor is located in the left sensor unit. The combination of the determined ohm values from the right and left lever-type sensors produces the actual level in the fuel tank.
4. Service Data, Fuel System: Pressure regulator: 3.5 bar. Working pressure of suction jet pumps: 1-1.3 bar
5. Schematic Drawings Of Fuel Supply Systems: 5.1 Fuel supply system E46 with M43TU/M52TU/M54 5.2 Fuel supply system E46 with M43TU/M52/TU/M54 Japan. 5.3 Fuel supply system E46 with M52 USA. 5.4 Fuel supply system E46 with M54 USA.

16 00 General Function Description For Fuel Supply Systems

Fuel Supply Systems, Spark-Ignition Engines

Fuel system

The electric fuel pump in the fuel tank generates the pressure in the fuel system which is set by the pressure regulator to a specific level.

Tank venting system

The tank venting system is an enclosed system which is vented via a carbon canister. The carbon is incorporated in the carbon canister as granulate. The large surface of the carbon stores the fuel vapors which occur in the fuel tank. The carbon canister must be regenerated on a regular basis so as to be able to continue storing fuel vapors. Regeneration is performed by way of purging with fresh air via the intake manifold. This process is controlled by the engine control unit.

Fuel Supply Systems, Diesel Engines

Fuel system

The electric fuel pump in the fuel tank supplies the engine with fuel. Two types of high-pressure pump are used for cylinder injection.

1. The distributor injection pump supplies each cylinder directly with fuel via the corresponding injection nozzle.
2. The high-pressure pump for the common rail systems generates in the fuel rail the necessary pressure for all the injection nozzles.

In common rail systems, a further pump (inline pump, M57/gear pump, M67) is connected between the high-pressure pump and the electric fuel pump. This pump supports the fuel pump in the fuel tank in the event of a high fuel demand.

Tank venting system

Diesel fuel is non-volatile and therefore a carbon canister is not required. The fuel tank is vented directly to atmosphere.

16 00 005 Draining And Filling Fuel Tank

After completing repairs and before starting engine for first time, fill fuel tank through fuel filler pipe with min. 5 ltr. fuel.

M47, M57

Before starting the engine for the first time, if the tank has been run empty or drawn off, pour in diesel fuel and turn on ignition for approx. 1 minute. The fuel circuit is thus filled and vented, which results in the engine firing more quickly.

Drawing Off Fuel

Start engine and allow to run. Electric fuel delivery pump runs. This pumps the fuel through the suction jet pump and the tank expansion line from the left to the right side of the fuel tank.

Note. Fuel can be drawn off from the left and right tank halves through the fuel filler pipe down to a small residual amount. This residual amount is drawn off after removal of the sensors for the fuel gauge (right/left).

Slide extraction hose of extractor unit into filler pipe, turning hose slightly if necessary.

Insertion Length

130 cm.

Draw off fuel with extractor unit, as far as possible.

Follow the fuel drawing-off procedure at the fuel gauge in the instrument cluster.

Scheme 131

Drawing Off Residual Fuel Quantity

Remove sensor for fuel gauge (left). Refer to 16 12 001 REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (LEFT) (COMPLETE UNIT) .

Draw off residual fuel quantity through installation openings.

Fuel Filling

Slide extraction hose of extractor unit approx. 40 cm into filler pipe.

Fill fuel from extractor unit.

Scheme 132

Drawing Off After Fault In Suction Jet Pump

Draw off right half of tank completely through filler pipe.

Remove sensor for fuel gauge (left). Refer to 16 12 001 REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (LEFT) (COMPLETE UNIT) .

Insert extraction hose through sensor opening in tank, fuel (also residual quantity) can be drawn off.

Scheme 133

16 00 100 Checking Fuel Tank And Tank Ventilation System For Leaks

Note. For Special Tool identification, see FUEL SUPPLY SYSTEM - SPECIAL TOOLS - 3-SERIES (E46/S54) .

Special Tools Required

1. 13 3 010
2. 16 1 157
3. 16 1 171
4. 16 1 174

Note. The following procedure is only applicable to vehicles without the tank leak diagnosis module (DM-TL). Vehicles With Carbon Canister Only . A leak test must be carried out if a leak is suspected in the tank ventilation system. Vehicles With Leak Diagnosis Pumps (LDP) . If a leak in the tank ventilation system is indicated by the "Check engine" indicator lamp in the instrument cluster lighting up, a leak test must be carried out. Read out the fault memory of the DME control unit and carry out a diagnosis. If the sensors are OK, then begin the leak test.

The following conditions must be observed to obtain plausible measuring results

1. Contents of fuel tank 50 % +/- 25 %
2. Park the car in the workshop at least 2 hours before the test so that the fuel temperature is approximately that of the workshop temperature (Ideal fuel temperature approx. 10-20° C).
3. Never refuel the vehicle directly prior to the leak test due to the strong emission of gas by the fresh fuel.

Release screws (1/3), remove panel (2).

Remove expansion rivet (4), remove panel (5).

Scheme 134

Applicable To Vehicles With Leak Diagnosis Pumps (LDP) Only.

Unlock line (3) and detach from dust filter.

Seal dust filter with special tool 16 1 157.

Scheme 135

Applicable To Vehicles Only Equipped With A Carbon Canister Only.

Release lock of line (1), detach line from carbon canister (5).

Seal opening on carbon canister with special tool 16 1 157.

Scheme 136

Remove tank cap and connect special tool 16 1 174 to tank filler neck.

Using adjusting wheel (1), clamp special tool 16 1 174 firmly to tank filler neck.

Scheme 137

Connect special tool 16 1 171 using compressed air line (1) to garage compressed air system (8-10 bar).

Connect pressure sensor (2) of Diagnosis and Information System with measuring range of 0-3.5 bar.

Scheme 138

Select "Measurement" function on Diagnosis and Information System (DIS).

Set measuring range in accordance with pressure sensor to 0-3.5 bar.

Using pressure regulator on special tool 16 1 171, increase pressure by 0.050 bar.

Connect special tool 16 1 174 to fast-release coupling of special tool 16 1 171.

Using pressure regulator on special tool 16 1 171, reset gauge pressure in fuel tank to 0.050 bar.

Using special tool 13 3 010, disconnect supply line from special tool 16 1 171 to tank filler neck.

Allow a rest period of approx. 20 secs.

Read off and note down starting pressure value, then wait 60 secs.

Read off final pressure value and compare with starting pressure value.

Measurement Evaluation

MEASUREMENT EVALUATION

16 11 130 Checking Filler Cap Pressure Relief Valve

Note. For Special Tool identification, see FUEL SUPPLY SYSTEM - SPECIAL TOOLS - 3-SERIES (E46/S54) .

Special Tools Required

1. 13 3 010
2. 16 1 171
3. 16 1 172
4. 16 1 173

Set pressure regulator on special tool 16 1 171 fully in "-" direction.

Connect special tool 16 1 171 via compressed air line (1) to garage compressed air system (8-10 bar).

Connect pressure sensor (2) of Diagnosis and Information System with a measuring range of 0-3.5 bar.

Scheme 139

Select special tool 16 1 172 or 16 1 173 matching vehicle's filler cap and attach to quick release coupling of special tool 16 1 171.

Install filler cap on selected special tool (3).

Scheme 140

Note. Only the absolute pressure is indicated in the display of the Diagnosis and Information System (DIS). The current ambient air pressure is already displayed without additional pressurization.

Check Testing Equipment For Leaks!

Select "Measurement" function on Diagnosis and Information System (DIS).

Set measuring range according to pressure sensor to 0-3.5 bar.

Increase pressure by 0.2 bar with pressure regulator on special tool 16 1 171.

Using special tool 13 3 010, disconnect delivery line from special tool 16 1 171 to tank filler neck.

Wait 60 secs.

Read off final pressure value and compare with starting pressure value.

Measurement Evaluation

MEASUREMENT EVALUATION

Check Filler Cap Pressure Relief!

Follow same test procedure as for "Checking testing equipment for leaks".

Increase pressure by 0.3 bar with pressure regulator on special tool 16 1 171.

Measurement Evaluation

MEASUREMENT EVALUATION

16 11 030 Removing And Installing Fuel Tank

Draw off fuel from fuel tank. Refer to 16 00 005 DRAINING AND FILLING FUEL TANK .

Detach handbrake cables from handbrake lever.

Remove propeller shaft. Refer to 26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT or 26 11 000 REMOVING AND INSTALLING PROPELLER SHAFT (CARDAN UNIVERSAL JOINT) COMPLETELY .

Remove tension strut on left and right (E46 convertible only).

Remove tank trim on left.

Scheme 141

Remove lip (2) on left, pay attention to guide (1) during installation.

Scheme 142

Remove tank trim on right.

Scheme 143

Remove lip (2) on right, pay attention to guide (1) during installation.

Scheme 144

Pull handbrake Bowden cables (1) out of guide tubes.

Scheme 145

Release hose clips (1) and detach fuel lines.

1. (2) Feed line.
2. (3) Return line.

Installation

1. Replace hose clips.

Scheme 146

Release hose clamp (1) and detach fuel filler pipe-fuel tank connecting hose from fuel tank.

Installation

Replace hose clips.

Scheme 147

Support fuel tank over a wide area with a lifter. Release hexagon nut (1).

Scheme 148

Right

Release screw (1), remove tightening strap (2).

Scheme 149

Left

Replace screw (1), remove tightening strap (2).

Scheme 150

Lower fuel tank and disconnect plug connections.

Release hose clamp (1), disconnect vent line. Remove fuel tank towards bottom.

Scheme 151

Note. M3 Only!

Before installing a new fuel tank, it is absolutely essential to fit the swirl pot attachment on the swirl pot.

16 11 060 Removing And Installing/Replacing Fuel Filler Pipe

Draw off fuel down to below level of filler opening in tank. Refer to 16 00 005 DRAINING AND FILLING FUEL TANK .

Remove rear right wheel. Refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .

Remove rear right wheel arch trim.

Release hose clip (1), release plastic nut (2). Withdraw fuel filler pipe from connecting hose.

Scheme 152

Release plastic nuts (1/2).

Withdraw fuel filler pipe (3) from rubber sleeve (4).

Installation

1. When installing fuel filler pipe, make sure rubber sleeve (4) is correctly seated.

Scheme 153

For model 46/5 only

Release plastic nuts (1/2).

Withdraw fuel filler pipe (3) from rubber sleeve (4).

Installation

1. When installing fuel filler pipe, make sure rubber sleeve (4) is correctly seated.

Scheme 154

16 11 120 Removing And Installing/Replacing Expansion Tank For Tank Ventilation

Remove rear right wheel

refer to 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL .

Remove rear right wheel arch trim.

Unfasten plastic nut (1).

Unfasten hose clip (2) and remove hose.

Tilt expansion tank (3) forwards at bottom.

Scheme 155

Release hose clip (1) and disconnect hose (2).

Release hose clip (3) and disconnect hose (4).

Remove expansion tank (5).

Scheme 156

Note. For Special Tool identification, see FUEL SUPPLY SYSTEM - SPECIAL TOOLS - 3-SERIES (E46/S54) .

Special Tools Required

1. 13 3 010
2. 16 1 171
3. 16 1 172
4. 16 1 173

Set pressure regulator on special tool 16 1 171 fully in "-" direction.

Connect special tool 16 1 171 via compressed air line (1) to garage compressed air system (8-10 bar).

Connect pressure sensor (2) of Diagnosis and Information System with a measuring range of 0-3.5 bar.

Scheme 157

Select special tool 16 1 172 or 16 1 173 matching vehicle's filler cap and attach to quick release coupling of special tool 16 1 171.

Install filler cap on selected special tool (3).

Scheme 158

Note. Only the absolute pressure is indicated in the display of the Diagnosis and Information System (DIS). The current ambient air pressure is already displayed without additional pressurization.

Check Testing Equipment For Leaks!

Select "Measurement" function on Diagnosis and Information System (DIS).

Set measuring range according to pressure sensor to 0-3.5 bar.

Increase pressure by 0.2 bar with pressure regulator on special tool 16 1 171.

Using special tool 13 3 010, disconnect delivery line from special tool 16 1 171 to tank filler neck.

Wait 60 secs.

Read off final pressure value and compare with starting pressure value.

Measurement Evaluation

MEASUREMENT EVALUATION

Check Filler Cap Pressure Relief!

Follow same test procedure as for "Checking testing equipment for leaks".

Increase pressure by 0.3 bar with pressure regulator on special tool 16 1 171.

Measurement Evaluation

MEASUREMENT EVALUATION

16 12 000 Removing And Installing/Replacing Fuel Level Sensor (Right) (Complete Unit)

Sucking the fuel out of the fuel tank, refer to DRAINING AND FILLING FUEL TANK

Remove rear bench seat. See 52 24 005 REMOVING AND INSTALLING / REPLACING REAR SEAT (NORMAL)

Fold floor trim panel (1) forwards.

Cut insulating mat at perforation and fold back, releasing rubber grommet in process.

Scheme 159

Release hexagon nuts (1) and remove cover (2).

Installation

1. Check seal for cover (2), replace if necessary.

Scheme 160

Unfasten plug connection (1) and disconnect.

Release hose clip (2) and disconnect hose (3).

Scheme 161

Unfasten rotary connection with special tool 16 1 020.

Installation

1. Replace rubber seal; in so doing, always insert rubber seal in tank.
2. Tighten down rotary connection to correct torque.
3. Tightening torque, refer to 16 14 2AZ in «FUEL SUPPLY SYSTEM - TIGHTENING TORQUES»(ref-201364) .

Scheme 162

Installation

1. When installing the fuel level sensor, ensure the lug (1) locates in the recess (2) on the tank.
2. When tightening to torque, notch (3) on screw cap can be heard and felt to engage in the toothed segment (4) on the tank.

Scheme 163

16 12 001 Removing And Installing/Replacing Fuel Level Sensor (Left) (Complete Unit)

Sucking the fuel out of the fuel tank, refer to DRAINING AND FILLING FUEL TANK .

Remove rear bench seat. See 52 24 005 REMOVING AND INSTALLING / REPLACING REAR SEAT (NORMAL)

Fold floor trim panel (1) forwards.

Cut insulating mat (2) at perforation and fold back, releasing rubber grommet in process.

Scheme 164

Release hexagon nuts (1) and remove cover (2).

Installation

1. Check seal for cover (2), replace if necessary.

Scheme 165

Release hose clip (1) and disconnect hose (2).

Unfasten plug connection (3) and disconnect.

Scheme 166

Unfasten rotary connection with special tool 16 1 020.

Installation

1. Replace rubber seal; in so doing, always insert rubber seal "1 in tank.
2. Tighten down rotary connection to correct torque.

Tightening torque, refer to 16 14 2AZ in FUEL SYSTEM - TIGHTENING TORQUES .

Scheme 167

Installation

1. When installing the fuel level sensor, ensure the lug (1) locates in the recess (2) on the tank.
2. When tightening to torque, notch (3) on screw cap can be heard and felt to engage in the toothed segment (4) on the tank.

Scheme 168

Carefully withdraw fuel level sensor.

Scheme 169

Depress detent (1) and remove tank expansion line.

Scheme 170

Installation

1. Ensure that non-return valve (1) is fitted in tank expansion line.

Scheme 171

Note. If the air valve does not function, the fuel delivery unit (right) must be removed, refer to REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (RIGHT) (COMPLETE UNIT) . After removal of fuel level sensor (left), check whether tank expansion lead (1) has engaged in surge tank (2).

Scheme 172

16 12 010 Removing And Installing/Replacing Carbon Canister (M3 With DM-TL)

DM-TL = Diagnosis Module, Tank Leakage .

Release screws (1) from rear.

Scheme 173

Release screws (1) from front. Remove panel (2).

Scheme 174

Unfasten lines (1)-(3) and detach.

1. Line to expansion tank.
2. Scavenging air line.
3. Intake line for dust filter.

Unlock plug (4) and detach.

Release screws (6) and remove carbon canister (7) with DM-TL (5) towards bottom.

Scheme 175

Installation

Press rubber-encased lugs (1) on carbon canister (2) into mountings (3).

Scheme 176

16 12 010 Removing And Installing/Replacing Carbon Canister (M3)

Release screws (1) from rear.

Scheme 177

Release screws (1) from front. Remove panel (2).

Scheme 178

Unfasten lines (1)- (3) and detach.

Release screws (4) and remove carbon canister (5) towards bottom.

Scheme 179

Installation

Press rubber-encased lugs (1) on carbon canister (2) into mountings (3).

Scheme 180

16 13 015 Removing And Installing/Replacing Tank Leakage Diagnosis Module (M3 With DM-TL)

DM-TL = Diagnosis Module, Tank Leakage.

Release screws (1) from rear.

Scheme 181

Release screws (1) from front. Remove panel (2).

Scheme 182

Unlock plug (4) and detach.

Release screws (6) and lower carbon canister (7) with DM-TL (5).

Scheme 183

Installation

Press rubber-encased lugs (1) on carbon canister (2) into mountings (3).

Scheme 184

Unfasten line (1) and detach.

Unfasten screws (2).

Detach DM-TL (3) from carbon canister (4).

Scheme 185

Refer to 16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (M3 WITH DM-TL) .

Refer to 16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (M3) .

Refer to 16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAKAGE DIAGNOSIS MODULE (M3 WITH DM-TL) .

Refer to 16 12 000 REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (RIGHT) (COMPLETE UNIT)

Refer to 16 12 001 REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (LEFT) (COMPLETE UNIT) .

16 14 010 Removing And Installing/Replacing Fuel Pump (Complete Sensor Unit)

Note. This operation is identical to REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (RIGHT) (COMPLETE UNIT)

16 14 530 Replacing Sucking Jet Pump

Suck the fuel out of the fuel tank, refer to DRAINING AND FILLING FUEL TANK .

Remove fuel level sensor (right), refer to REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (RIGHT) (COMPLETE UNIT) .

Remove fuel level sensor (left), refer to REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (LEFT) (COMPLETE UNIT) .

Left Side

Pull tank expansion line (1) on fuel baffle (2) out of locking fixture.

Installation

1. Ensure that tank expansion line is perfectly connected in fuel baffle.

Scheme 186

Right Side

Remove tank expansion line from fuel tank.

Installation

1. Tank expansion line must not be bent when it is being removed.

Scheme 187

Installation

1. Ensure that non-return valve (1) is fitted in tank expansion line.

Scheme 188

See also:
• FUEL SUPPLY SYSTEM - SPECIAL TOOLS - 3-SERIES (E46/S54)
• 26 11 000 REMOVING AND INSTALLING COMPLETE PROPELLER SHAFT
• 36 10 300 REMOVING OR INSTALLING FRONT OR REAR WHEEL
• 52 24 005 REMOVING AND INSTALLING / REPLACING REAR SEAT (NORMAL)
• 16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS
• 16 12 000 REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (RIGHT) (COMPLETE UNIT)
• 16 12 001 REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (LEFT) (COMPLETE UNIT)
• 16 00 005 DRAINING AND FILLING FUEL TANK
• REMOVING AND INSTALLING/REPLACING FUEL LEVEL SENSOR (RIGHT) (COMPLETE UNIT)
• 16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER (M3 WITH DM-TL)
• 16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAKAGE DIAGNOSIS MODULE (M3 WITH DM-TL)