16 00 100 Checking fuel tank and tank ventilation system for leaks
Necessary preliminary tasks
- Remove «COVER FOR CARBON CANISTER»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-removing-and-installingreplacing-cover)
The following procedure is only applicable to vehicles without the tank leak diagnosis module.
Comply with the following conditions in order to obtain plausible test results
- Content of fuel tank: Maximum 90 % Minimum 13 % (reserve telltale must not light up).
- Put vehicle into workshop for at least 2 hours such that the fuel temperature corresponds to the workshop temperature. (Ideal fuel temperature approx. 10...20°C)
Disconnect line to evaporation strainer (1) from carbon canister.
| IMPORTANT | Risk of breakage! |
Carefully remove evaporation strainer from carbon canister.
seal opening (2) for evaporation strainer on carbon canister with special tool 16 1 070 PLUG .
Scheme 155
Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Using thumbwheel (1), clamp special tool 16 1 174 to fuel filler neck.
Scheme 156
| IMPORTANT | Turn pressure regulator on special tool 16 1 171 counter-clockwise as far as the stop. |
Using compressed air line (1), connect special tool 16 1 171 to workshop compressed air system (8... 10 bar).
Connect pressure sensor (2) from Diagnosis and Information System with a measuring range of 0... 25 bar.
| IMPORTANT | Do not connect quick-release coupling (3) of special tool 16 1 171 as yet. |
Scheme 157
- Select "Measurement" function on Diagnosis and Information System (DIS).
- Using pressure regulator on special tool 16 1 171, increase pressure by 0.20 bar.
- Connect special tool 16 1 174 to quick-release coupling of special tool 16 1 171.
- Wait until the value at the Diagnosis and Information System has levelled out.
- Using pressure regulator on special tool 16 1 171, reset pressure in fuel tank to 0.20 bar above atmospheric.
| IMPORTANT | Do not under any circumstances increase pressure by more than 0.30 bar as this would result in damage to the fuel tank and venting system. |
Using special tool 13 3 010 TERMINAL , disconnect feed line from special tool 16 1 171 to fuel filler neck.
Allow a rest period of approx. 20 sec.
Read off and note down starting pressure value.
Wait approx. 120 sec.
Read off final pressure value and compare with starting pressure value.
Scheme 158
Measurement evaluation
- Pressure drop up to 0.01 bar: System OK
- Pressure drop over 0.02 bar: System leaking beyond permitted levels
If the system is leaking, a leak test must be carried out and the defective components replaced.
16 00 102 Checking fuel tank and tank venting system for leaks with tank leakage diagnosis module (DMTL)
Note. An OBD fault is indicated by the "Check Engine" indicator lamp in the instrument cluster lighting up. This may indicate a leak in the tank venting system. Information on this is provided by the fault memory of the DME control unit.
- Read out fault memory of DME control unit and carry out a diagnosis in accordance with faults stored.
- A leak test of the DMTL module is then carried out if: The components of the DMTL module are OK. A fault is stored in the DME fault memory (tank leak detected).
Adhere to following conditions in order to carry out a correct leak test
- Content of fuel tank < 90 %
- Reserve indicator lamp "off"
- Put vehicle into workshop for at least 2 hours such that the fuel temperature corresponds to the workshop temperature. (Ideal fuel temperature approx. 10...20°C)
- Never freshly refuel the vehicle. (Severe gas emissions from fresh fuel)
- Check that tank cap is correctly seated.
| WARNING | During the leak test, under no circumstances apply external pressurization through the fuel filler neck as this may cause incorrect readings. |
Clear DME fault memory.
In the Diagnosis and Information System (DIS), go to the "Function and component selection" page.
Work through tank leakage diagnosis module. Leakage test is carried out.
If fault is recorded again in DME fault memory (tank leak detected), CARRY OUT LEAK TEST .
16 00 510 Conducting leak test on fuel tank and tank venting system
| IMPORTANT | On vehicles with tank leak diagnosis modules (DMTL), do not work with external pressurization as the tank ventilation system will leak under this condition. On account of emerging fuel vapors, carry out all work in well ventilated rooms. Or use a suitable extractor system. Observe country-specific accident prevention and occupational safety regulations. |
Note. The following procedure is only applicable to vehicles with the tank leak diagnosis module (DMTL). For vehicles without tank leak diagnosis module: PRESSURIZE FUEL TANK AND TANK VENTING SYSTEM. During the leak test with a leak detector, be sure to follow the operating instructions of the equipment manufacturer.
Note. Select "Tank leak diagnosis module (DMTL)" on Diagnosis and Information System (DIS).
- The leak diagnosis pump pressurizes the fuel tank and tank ventilation system for 30 sec.
- If pressure is needed for longer than 30 sec., press "Activate" button again after 30 sec.
The leak test can be carried out with a leak detector.
Possible causes may be
- Tank cap leaking «(CHECK TANK CAP PRESSURE RELIEF VALVE)»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-11-130-checking-filler-cap) .
- Tank venting lines leaking (fuel tank - carbon canister - tank venting valve).
- Tank vent line leaking (engine compartment).
- Fuel level sensor flange on tank leaking.
Scheme 159
16 00 005 Draining and filling fuel tank
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! Avoid skin contact (wear gloves)! Connect the exhaust and extraction systems to the exhaust tailpipe. |
The electric fuel pump must not operate without fuel! After completing repairs but before starting the engine for the first time, fill the fuel tank with min. 5 l fuel through the fuel filler pipe.
Do not damage non-return flap when pulling out extraction hose.
Diesel vehicles
Note. Before starting the engine for the first time, if the tank has been run dry or drawn off, fill with 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.
Note. The electric fuel pump runs.
In this way, the fuel is repumped through the suction jet pump from the left to the right side of the fuel tank.
Fuel can be drawn out of left and right sides of tank through filler neck, leaving only a small residue. The residual quantity is drawn off through the service opening (on right/left).
Insert special tool 16 1 080 HOSE into filler neck.
Special tool 16 1 080 HOSE has two different diameters for gasoline and diesel vehicles!
Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning Documentation, through special tool 16 1 080 HOSE into the fuel filler pipe, turning in the process if necessary.
Insertion length approx. 120 cm.
| IMPORTANT | Comply with the following instruction if the extraction hose can only be inserted approx. 100 cm before meeting resistance. |
Scheme 160
Draw off fuel as much as possible with extractor unit, refer to BMW Service Workshop Equipment and Planning Documentation.
Follow drawing off of fuel on fuel gauge in instrument cluster.
Note. If the extraction hose meets resistance at an insertion length of approx. 100 cm, a second person must press gently against the rubber hose of the filler pipe.
Only for US cars with N51 engines (metal filler pipe)!
The extraction hose is correctly positioned in the tank at an insertion length of approx. 120 cm.
| IMPORTANT | Watch out for escaping fuel when withdrawing the extraction hose from the filler pipe. |
Scheme 161
Drawing off residual fuel quantity
Drawing off residual fuel amount is not included in the time value of this operation.
| IMPORTANT | Ensure car interior is adequately ventilated. Catch dripping fuel in a suitable container. |
Remove left sensor unit See 1612001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (GASOLINE, LEFT) or 1614016 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE REGULATOR .
Remove RIGHT SENSOR UNIT .
Draw off residual fuel quantity through service openings.
Note. Only for US cars with N51 engines!
Fuel filling
Insert special tool 16 1 080 HOSE into filler neck.
Special tool 16 1 080 HOSE has two different diameters for gasoline and diesel vehicles!
Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment and Planning Documentation, approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.
Drawing off after fault in suction jet pump
Draw off right half of tank completely through fuel filler pipe.
Remove cap from left service opening.
Insert extraction hose through service opening in tank, fuel (also residual quantity) can be drawn off.
Scheme 162
16 00... Fuel supply system (gasoline)
1. General
2. Part designation
Schematic drawings of fuel supply systems
Scheme 163
Fuel supply system (ECE/Japan)
Scheme 164
Fuel supply system (US version)
| 1. Fuel level sensor, left | 9. Purge air line to tank venting valve |
|---|---|
| 2. Suction jet pump, left | 10. Fuel line to engine |
| 3. Fuel level sensor, right | 11. Rollover valve |
| 4. Suction jet pump, right | 12. Service vent valve |
| 5. Surge chamber | 13. Filler vent valve |
| 6. Electric fuel pump | 14. Dust filter |
| 7. Fuel filter with pressure regulator | 15. To atmosphere |
| 8. Tank leak diagnosis module 8. Evaporator strainer |
FUEL SUPPLY SYSTEM REFERENCE CHART
3. Functional description (see also graphic)
Fuel system
The saddle-shaped fuel tank contains the surge chamber with integrated electric fuel pump on its right side.
The surge chamber ensures that the fuel pump is properly supplied in all vehicle operating states.
The fuel is pumped from the right side of the fuel tank into the surge chamber via the suction jet pump integrated in the surge chamber.
The suction jet pump in the left fuel tank half pumps the fuel through the tank expansion line to the right side of the fuel tank.
The suction jet pump is operated via the fuel feed line.
Return line, pressure regulator and fuel filter are located in the tank.
Fuel supply to engine
The fuel is routed from the electric fuel pump via the fuel feed line and the fuel filter/pressure regulator unit to the fuel rail.
Pressure regulator and fuel filter are incorporated in a single unit in the tank. There is thus no need for a fuel return line.
The fuel passes through the pressure regulator into the left side of the fuel tank and thereby drives a suction jet pump. This pump repumps the fuel from the left side of the tank to the right side.
The fuel rail is return-free.
Tank safety valve (US version)
The fuel tank is vented during refuelling via the refuelling vent line.
Because of its large cross-section, the refuelling vent line directs the displaced volume (fuel vapors) at high speed through the expansion volume 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 tank leak diagnosis module and the dust filter.
During driving, the system tank is vented in the same way via the vent line.
The condensed constituents of the fuel vapors remain in the tank because the tank has an integrated compensating volume.
The refuelling shutoff valve in the fuel tank is closed by the rising fuel if the fuel tank is overfilled. The ventilation function is maintained by a second float valve.
Al three valves are designed as rollover valves. This prevents fuel from escaping from the fuel tank in extreme vehicle positions (overturning, inclined position).
The carbon canister is regenerated by purging with fresh air.
The DME control unit opens the tank vent valve. Thus the vacuum pressure of the engine intake manifold is applied at the purge air line. The carbon canister is purged in this way. The fresh air needed for this purpose is supplied via the tank leak diagnosis 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.
Tank safety valve (worldwide)
Refer to Tank venting system (US version) with following differences
- Carbon canister has a smaller capacity.
- No tank leak diagnosis module or dust filter.
Leak diagnosis for tank safety valve (US version)
The tank leak diagnosis module (see drawing 5.2) serves to diagnose 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.
The tank leak diagnosis module is activated by the DME control unit and 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.
The pressure test line establishes the connection between fuel tank and fuel filler neck. This enables a leak to be detected in the fuel filler pipe - fuel tank cap area.
Determining fill level in fuel tank
The fuel level is measured by means of lever sensors on both sides of the fuel tank. The combination of the determined ohm values from the right and left lever-type sensors produces the actual level in the fuel tank.
4. Operating data, fuel system
16 00 Functional description for general fuel supply systems
Gasoline engine fuel supply systems
Fuel system
The fuel pump in the fuel tank generates pressure in the fuel system, which is set by the electronic pressure control valve to a certain level.
Tank-venting system
The tank safety valve is a closed system that is bled via a carbon canister. The carbon in the canister is stored as granules. The large surface of the granules traps the fuel vapor, that occurs in the fuel tank. The carbon canister needs to be refreshed regularly in order to be able to continue to store fuel vapor. This is done by flushing it with fresh air from the intake pipe. This process is controlled by the engine control unit.
Diesel engine fuel supply system
Fuel system
The fuel pump in the fuel tank supplies the engine with fuel. Two types of high pressure pump are used for direct injection.
- The distributor-type injection pump. This supplies each cylinder directly with fuel via individual injector nozzles.
- The high pressure pump for the common rail systems. This generates the required pressure in the injector pipe for all injector nozzles. With common rail systems another pump (inline pump, M57/geared pump, M67) is connected between the high pressure pump and the fuel pump. This pump aids the fuel pump in the fuel tank during times of high fuel requirement.
Tank-venting system
Diesel fuel is slow-evaporating, therefore no carbon canister is required. The fuel tank is bled directly into the atmosphere.
16 11 130 Checking filler cap pressure relief valve
Set pressure regulator on special tool 16 1 171 fully in "-" direction.
Connect special tool 16 1 171 using compressed air line (1) to workshop compressed air system (8... 10 bar).
Connect pressure sensor (2) from Diagnosis and Information System.
Connect special tool 16 1 172 to quick-release coupling of special tool 16 1 171.
Install fuel filler cap on special tool 16 1 172 (3).
Scheme 165
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/Pressure" function on Diagnosis and Information System (DIS).
Using pressure regulator on special tool 16 1 171, increase pressure by 0.2 bar.
Using special tool 13 3 010 TERMINAL clamp off feed line from special tool 16 1 171.
Read off and note down pressure.
Wait 60 secs.
Read off pressure again and compare with starting pressure value.
Measurement evaluation
| Pressure drop > 0.012 bar | Testing equipment leaking. Check connection points for leaks. |
PRESSURE MEASUREMENT EVALUATION CHART
Check fuel filler cap pressure relief valve!
Select "Measurement/Pressure" function on Diagnosis and Information System (DIS).
Using pressure regulator on special tool 16 1 171, increase pressure by 0.3 bar.
Using special tool 13 3 010 TERMINAL clamp off feed line from special tool 16 1 171.
Read off and note down pressure.
Wait 60 secs.
Read off pressure value again and compare with starting pressure value.
Measurement evaluation
| Pressure drop > 0.012 bar | Filler cap pressure relief valve faulty. Replace fuel tank cap. |
PRESSURE MEASUREMENT EVALUATION CHART
16 11 060 Removing and installing or replacing fuel filler pipe
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! Avoid skin contact (wear gloves)! After installation of fuel tank/prior to first engine start-up |
- Fill fuel tank with at least 5 liters of fuel.
- Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove «REAR RIGHT WHEEL ARCH TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-041-removing-and-installingreplacing)
- Lower «REAR AXLE»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#rear-axle-repair-e90__33-31-503-loweringraising-rear-axle)
Unhook retaining strap (1) from tank flap.
Open cap and set to one side.
Scheme 166
| IMPORTANT | There may still be residual amounts of fuel in the tank. Catch and dispose of escaping fuel. |
Unfasten hose clip (1).
Detach fuel filler hose from fuel filler pipe.
Installation
Replace hose clip.
Tightening torque 16 12 1AZ .
Scheme 167
Unlock quick-release fastener (1) and detach vent hose (2).
Unscrew nut (3).
Scheme 168
Unscrew nuts (1).
Installation
Tightening torque 16 12 2AZ .
Withdraw fuel filler pipe (2) completely out of rubber gaiter at wheel arch and feed out.
Installation
Make sure rubber cup fits correctly.
Scheme 169
Installation
Clean contact surface on body and earth cable on fuel filler pipe.
Ground connection must be guaranteed.
16 11 030 Removing and installing or replacing fuel tank (gasoline)
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! Avoid skin contact (wear gloves)! After installation of fuel tank/prior to first engine start-up |
- Fill fuel tank with at least 5 liters of fuel.
- Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
- Check «TRANSFER FUNCTION OF SUCTION JET PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-checking-repumping-function-of) .
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove «REAR SEAT BENCH»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-005-removing-and-installingreplacing)
- Remove «GUIDE TUBE FOR HANDBRAKE CABLES»(/bmw/m3/e90-2007-2013/remont/mechanical-hydraulic/#brakes-repair-e90__34-41-140-removing-and-installing)
- Remove right «WHEEL ARCH TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-041-removing-and-installingreplacing)
- Remove «REAR LEFT AND RIGHT UNDERBODY PANELLING»(/bmw/m3/e90-2007-2013/remont/axle-shafts/#rear-axle-repair-e90__51-75-001-removing-and-installingreplacing)
- Remove left and right «UNDERBODY COVER»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-removing-and-installingreplacing-left)
Release screws (1) and remove cover (2) from left and right sides of fuel tank.
Scheme 170
Left sensor unit
Disconnect plug connection (1).
Press grey ring (2) towards sensor unit and pull out fuel feed line (3).
Scheme 171
USA national version
Disconnect plug connection (1).
Unlock and detach vent lines (2).
If necessary, remove fuel line for independent heating.
Scheme 172
ECE national-market version
Right sensor unit
Disconnect plug connection (1).
Unlock quick-release fastener and detach vent line (2).
Installation
Make sure quick-release fasteners engage correctly.
Scheme 173
| IMPORTANT | There may still be residual amounts of fuel in the tank. Catch and dispose of escaping fuel. |
Release hose clamp (1) and detach fuel filler hose from fuel filler pipe.
If necessary, draw off residual amount of fuel via filler hose.
Installation
Tightening torque 16 12 1AZ .
Unlock quick-release fastener (1) and detach vent line (2).
Detach vent line (2) from holder (3).
Scheme 174
Heavily support the fuel tank.
Scheme 175
Unfasten nut.
Installation
Replace self-locking nut.
Tightening torque 16 11 1AZ .
Scheme 176
Release screws for tightening straps on left and right and remove tightening straps.
Carefully lower fuel tank.
| IMPORTANT | Carefully feed the vent line through the body when lowering the fuel tank. |
Installation
Tightening torque 16 11 2AZ .
Scheme 177
Installation
Note rubber mount with spacer bush.
Wide collar on spacer bush points to screw head.
Scheme 178
The following components must be modified when the fuel tank is replaced
- Modify vent line (1)
- Modify right sensor unit See «1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing) or «1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP (GASOLINE)»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing) (2)
- Modify left sensor unit See «1612001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (GASOLINE, LEFT)»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-001-removing-and-installing) or «1614016 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE REGULATOR»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-016-removing-and-installingreplacing) (3)
Scheme 179
16 11 350 Replacing tensioning straps for fuel tank
Necessary preliminary tasks
- Partially detach «REAR UNDERBODY PANELLING»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-47-removing-and-installingreplacing-left)
| IMPORTANT | Secure fuel tank against slipping and falling out. |
Heavily support the fuel tank.
Release screws (1) and remove clamping band.
Installation
Tightening torque 16 11 2AZ .
Scheme 180
16 11 071 Replacing rubber sleeve between fuel filler pipe and fuel tank
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! Avoid skin contact (wear gloves)! Before starting the engine for the first time |
- Fill fuel tank with at least 5 liters of fuel.
- Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection.
Necessary preliminary tasks
- Draw off «FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
| IMPORTANT | There may still be residual amounts of fuel in the tank. Catch and dispose of escaping fuel. If necessary, draw off residual amount of fuel via filler hose. |
Loosen hose clamps (1).
Detach rubber sleeve first from fuel filler pipe and then from fuel tank.
Installation
Tightening torque 16 11 3AZ .
Scheme 181
16 12... Checking repumping function of suction-jet pump with BMW diagnosis system
| IMPORTANT | Ensure adequate ventilation in the place of work! Ensure absolute cleanliness when working on the open fuel tank. Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown! Catch escaping fuel in a suitable container. |
Necessary preliminary tasks
- Fill level must be < or = 28 l If necessary, «DRAW OFF F FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Pour two to three liters of fuel into left tank chamber via the flange opening
- Connect diagnosis system Path: Brief test KOMBI Instrument cluster Diagnosis connect unit functions Diagnosis requests Tank sensor 1 tank sensor 2
Note. Tank sensor 1 = right tank sensor Tank sensor 2 = left tank sensor
Start engine.
Compare display for left and right tank chambers.
Repumping function OK
If fill level of tank sensor 2 (left chamber) is falling (approx. one liter per minute).
Repumping function not OK
If fill level of tank sensor 2 (left chamber) is stable or rising.
16 14 016 Removing and installing/replacing fuel filter with pressure regulator
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! |
Avoid skin contact (wear gloves)!
Ensure absolute cleanliness when working on the open fuel tank.
Before starting the engine for the first time
- Fill fuel tank with at least 5 liters of fuel.
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove rear seat bench See «5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-005-removing-and-installingreplacing) or «5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-24-005-removing-and-installing)
- Remove right sensor unit See «1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing) or «1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP (GASOLINE)»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing)
After completing work
- «CHECK REPUMPING FUNCTION OF SUCTION-JET PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-checking-repumping-function-of)
Release screws (1) and remove cover (2) from left side of fuel tank.
Disconnect plug connection (1).
Press grey ring (1) towards sensor unit and detach fuel feed line (3).
| IMPORTANT | Do not use any tools to release the quick-release fasteners. |
Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.
Installation
Tightening torque 16 14 1AZ .
Scheme 182
| IMPORTANT | After tightening to specified torque, notch (1) on screw cap (2) must be in area (A)! |
Note. Illustration shows the tank removed.
Scheme 183
Installation
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Make sure that the lever sensor moves freely before fitting the service cap.
Clean sealing faces and install new seal.
Scheme 184
Attach an auxiliary lead (1) to hose pack (2) through service opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.
Scheme 185
Carefully lift sensor unit (1) out of tank.
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.
Scheme 186
Remove fuel filter (1) and hose pack (2) with auxiliary cable to left.
Installation
When replacing the fuel filter, modify the end of the auxiliary lead to the new hose pack and carefully pull in through the tank.
Note. Illustration shows the tank removed.
Scheme 187
16 12 010 Removing and installing or replacing carbon canister
Necessary preliminary tasks
- Remove «COVER FOR CARBON CANISTER»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-removing-and-installingreplacing-cover)
Unlock quick-release fasteners (1) and disconnect vent lines.
Release screws (2) and remove carbon canister (3).
Installation
Tightening torque 16 13 1AZ .
Scheme 188
16 12 001 Removing and installing or replacing fuel gauge sensor (gasoline, left)
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! |
Avoid skin contact (wear gloves)!
Before starting the engine for the first time
- Fill fuel tank with at least 5 liters of fuel.
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove rear seat bench See «5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-005-removing-and-installingreplacing) or «5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-24-005-removing-and-installing)
- Remove «RIGHT SENSOR UNIT»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing)
Release screws (1) and remove cover (2) from left side of fuel tank.
Disconnect plug connection (1).
Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.
| IMPORTANT | Do not use any tools to release the fuel feed line. After installing fuel feed line, carry out tensile test and leak test. |
Scheme 189
Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.
Installation
Procedure for tightening screw cap, see next work step.
| IMPORTANT | Fit screw cap without using a tool and tighten hand-tight. |
Then tighten screw cap with special tool 16 8 020 LIFTING GEAR until notch (1) points to marking (2).
Note. Illustration shows the tank removed.
Scheme 190
Installation
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Make sure that the lever sensor moves freely before fitting the service cap.
Clean sealing faces and install new seal.
Attach an auxiliary lead (1) to hose pack (2) through service opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.
Installation
Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not damaged.
Carefully lift sensor unit (1) out of tank.
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.
Note. Illustration shows the tank removed.
Remove sensor unit (1) and hose pack (2) with auxiliary cable to left.
Installation
When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in through the tank.
Note. Illustration shows the tank removed.
16 12 000 Removing and installing or replacing fuel gauge sensor (gasoline, right)
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! Avoid skin contact (wear gloves)! Before starting the engine for the first time |
- Fill fuel tank with at least 5 liters of fuel.
- Check «TRANSFER FUNCTION OF SUCTION JET PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-checking-repumping-function-of)
Necessary preliminary tasks
- Remove «FUEL PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing)
Carefully unlock tabs (1) and pull off fuel level sensor upwards in direction of arrow.
Disengage line (2) from holders.
Unlock plug connection (3) and detach from service cap.
Installation
Fuel level sensor and connector must audibly snap into place!
Scheme 191
| IMPORTANT | Risk of damage: Carefully feed cable out of cable guide. Do not kink cable. |
16 12 010 Removing and installing/replacing carbon canister (DMTL)
Necessary preliminary tasks
- Remove «COVER FOR CARBON CANISTER»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-removing-and-installingreplacing-cover)
Disconnect plug connection (1).
Unlock quick-release fasteners (2) and disconnect vent lines.
Release screws (3) and remove carbon canister (4).
Installation
Tightening torque 16 13 1AZ .
Scheme 192
Installation
Lug (1) must be correctly seated in guide (2).
Scheme 193
16 13 015 Removing and installing/replacing tank leak diagnosis module (gasoline cars with US DMTL version)
Necessary preliminary tasks
- Remove «CARBON CANISTER»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-010-removing-and-installingreplacing)
Release screws (1).
Disconnect tank leak diagnosis module (2) from carbon canister in direction of arrow.
Installation
Tightening torque 16 13 2AZ .
Replace sealing ring.
Scheme 194
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! |
Avoid skin contact (wear gloves)!
Ensure absolute cleanliness when working on the open fuel tank.
Before starting the engine for the first time
- Fill fuel tank with at least 5 liters of fuel.
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove rear seat bench See «5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-005-removing-and-installingreplacing) or «5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-24-005-removing-and-installing)
- Remove right sensor unit See «1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing) or «1614010 REMOVING AND INSTALLING OR REPLACING FUEL PUMP (GASOLINE)»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-14-010-removing-and-installing)
After completing work
- «CHECK REPUMPING FUNCTION OF SUCTION-JET PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-checking-repumping-function-of)
Release screws (1) and remove cover (2) from left side of fuel tank.
Disconnect plug connection (1).
Press grey ring (1) towards sensor unit and detach fuel feed line (3).
| IMPORTANT | Do not use any tools to release the quick-release fasteners. |
Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.
Installation
Tightening torque 16 14 1AZ .
| IMPORTANT | After tightening to specified torque, notch (1) on screw cap (2) must be in area (A)! |
Note. Illustration shows the tank removed.
Installation
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Make sure that the lever sensor moves freely before fitting the service cap.
Clean sealing faces and install new seal.
Attach an auxiliary lead (1) to hose pack (2) through service opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.
Carefully lift sensor unit (1) out of tank.
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.
Remove fuel filter (1) and hose pack (2) with auxiliary cable to left.
Installation
When replacing the fuel filter, modify the end of the auxiliary lead to the new hose pack and carefully pull in through the tank.
Note. Illustration shows the tank removed.
16 14 500 Removing and installing or replacing control unit for electric fuel pump
| IMPORTANT | Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION) . |
Necessary preliminary tasks
- E81, E82, E87, E91, E92 and E84: Remove «BACKREST SIDE SECTION»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-008-removing-and-installingreplacing) for right rear seat
- E90
Remove BACKREST
Disconnect plug connection (1).
Release nuts (2) and remove control unit (3).
Installation
Tightening torque 16 14 2AZ .
Scheme 195
Replacement
16 14 010 Removing and installing or replacing fuel pump
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! Avoid skin contact (wear gloves)! |
Before starting the engine for the first time
- Fill fuel tank with at least 5 liters of fuel
- Check «TRANSFER FUNCTION OF SUCTION JET PUMP»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-12-checking-repumping-function-of)
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove rear seat bench See «5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-005-removing-and-installingreplacing) or «5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-24-005-removing-and-installing)
Release screws (1) and remove cover (2) from right side of fuel tank.
USA national version
Disconnect plug connection (1).
Unlock and detach vent lines (2).
If necessary, remove fuel line for independent heating.
ECE national version
Disconnect plug connection (1).
Unlock and detach vent line (2).
If necessary, remove fuel line for independent heating.
Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.
Installation
Procedure for tightening screw cap, see next work step.
| IMPORTANT | Fit screw cap without using a tool and tighten hand-tight. |
Then tighten screw cap with special tool 16 8 020 LIFTING GEAR until notch (1) points to marking (2).
Note. Illustration shows the tank removed.
Carefully raise service cap (1).
Unlock and detach vent line (2).
Installation
Clean sealing faces and install new seal (3).
Make sure that the lever sensor moves freely before fitting the service cap.
Locating rods (4) must fit correctly in the hole of the delivery unit.
Scheme 196
Installation
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Disconnect plug connection (1).
Installation
Connect cable with cable tie (2).
Ensure correct routing of cables.
Scheme 197
Unlock quick-connect coupling (1) of fuel feed line and pull off hose pack (2) in upward direction.
Unlock catch (4) and detach corrugated tube (3) towards top.
| IMPORTANT | Do not use any tools to release the fuel feed line. |
Draw off remaining fuel from surge chamber.
Carefully remove fuel pump with level sensor from fuel tank. If necessary, turn fuel pump 90° counterclockwise and tilt towards lever sensor.
Scheme 198
16 14 010 Removing and installing or replacing fuel pump (gasoline)
Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.
Catch and dispose of escaping fuel.
Observe country-specific waste-disposal regulations.
| IMPORTANT | Ensure adequate ventilation in the place of work! |
Avoid skin contact (wear gloves)!
Before starting the engine for the first time
- Fill fuel tank with at least 5 liters of fuel.
Necessary preliminary tasks
- «DRAW OFF FUEL FROM FUEL TANK»(/bmw/m3/e90-2007-2013/remont/fuel-system/#fuel-supply-system-repair-e90__16-00-005-draining-and-filling)
- Remove rear seat bench See «5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING)»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-26-005-removing-and-installingreplacing) or «5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT»(/bmw/m3/e90-2007-2013/remont/seats/#seats-repair-e90__52-24-005-removing-and-installing)
Release screws (1) and remove cover (2) from right side of fuel tank.
USA national version
Disconnect plug connection (1).
Unlock and detach vent lines (2).
If necessary, remove fuel line for independent heating.
ECE national-market version
Disconnect plug connection (1).
Unlock and detach vent line (2).
If necessary, remove fuel line for independent heating.
Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.
Installation
Procedure for tightening screw cap, see next work step.
| IMPORTANT | Fit screw cap without using a tool and tighten hand-tight. |
Then tighten screw cap with special tool 16 8 020 LIFTING GEAR until notch (1) points to marking (2).
Note. Illustration shows the tank removed.
Carefully raise service cap (1).
Unlock and detach vent line (2).
Installation
Clean sealing faces and install new seal (3).
Make sure that the lever sensor moves freely before fitting the service cap.
Locating rods (4) must fit correctly in the hole of the delivery unit.
Installation
Service cap can only be installed in one position.
When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.
Disconnect plug connection (1).
Installation
Connect cable with cable tie (2).
Ensure correct routing of cables.
Unclip black return lines (1) from bracket.
Unlock and disconnect quick-release fastener (2) of fuel line.
| IMPORTANT | Do not use any tools to release the fuel feed line. |
Draw off remaining fuel from surge chamber.
Carefully lift fuel pump with fuel level sensor (3) out of fuel tank. If necessary, turn fuel pump 90° counter-clockwise and tilt towards lever sensor.
Scheme 199
16 14 060 Removing and installing/replacing dust filter for tank leak diagnosis module (DMTL)
Necessary preliminary tasks
- Remove «REAR RIGHT WHEEL ARCH TRIM»(/bmw/m3/e90-2007-2013/remont/door-locks-anti-theft-systems/#body-equipment-repair-e90__51-71-041-removing-and-installingreplacing)
Build date up to 09/08
Unlock and disconnect quick-connect coupling (1).
Release screws (2) and remove dust filter (3).
Installation
Tightening torque: 16 13 3AZ .
Scheme 200
Build date after 09/08
Press lugs (1) apart in direction of arrow.
Pull out filter cartridge (2) downwards.
Scheme 201
See also:
• COVER FOR CARBON CANISTER
• 16 1 070 PLUG
• 13 3 010 TERMINAL
• FUEL PUMP OPERATING PRESSURE
• REAR RIGHT WHEEL ARCH TRIM
• REAR AXLE
• 16 12 1AZ
• REAR SEAT BENCH
• GUIDE TUBE FOR HANDBRAKE CABLES
• REAR LEFT AND RIGHT UNDERBODY PANELLING
• UNDERBODY COVER
• 5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT
• PROTECTION AGAINST ELECTROSTATIC DISCHARGE (ESD PROTECTION)
• BACKREST SIDE SECTION
• BACKREST
• CARRY OUT LEAK TEST
• PRESSURIZE FUEL TANK AND TANK VENTING SYSTEM.
• (CHECK TANK CAP PRESSURE RELIEF VALVE)
• 1612001 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (GASOLINE, LEFT)
• 1614016 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE REGULATOR
• RIGHT SENSOR UNIT
• GENERAL FUNCTION DESCRIPTION OF FUEL SYSTEM
• DRAW OFF FUEL FROM FUEL TANK
• TRANSFER FUNCTION OF SUCTION JET PUMP
• CARBON CANISTER