16 00 100 Checking fuel tank and tank ventilation system for leaks
Necessary preliminary tasks
- Remove cover for carbon canister
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).
- 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).
Disconnect line to evaporation strainer (1) from carbon canister.
| IMPORTANT | Risk of breakage! Carefully remove evaporation strainer from carbon canister. |
Using special tool 16 1 070, seal opening (2) for evaporation strainer on carbon canister.
Scheme 135
Remove fuel filler cap and connect special tool 16 1 174 to fuel filler neck.
Clamp special tool 16 1 174 on fuel filler neck with adjusting wheel (1).
Scheme 136
| IMPORTANT | Turn pressure regulator on special tool 16 1 171 counterclockwise up to stop. |
Connect special tool 16 1 171 using compressed air line (1) to garage 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 yet connect fast-release coupling (3) of special tool 16 1 171. |
Scheme 137
- 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 fast-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 gauge pressure in fuel tank to 0.20 bar.
| 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 , disconnect delivery 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 138
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 00 510 Conducting leak test on fuel tank and tank venting system
Pressurize fuel tank and tank venting system.
Note. When leak-testing with a leak tester device, follow the operation instructions of the device manufacturer.
| IMPORTANT | Emerging fuel vapors! These tasks should only be performed in well ventilated rooms or with a suitable extractor facility provided. Observe country-specific accident prevention and occupational safety regulations. |
The leak test can be carried out with a leak detector.
Possible causes may be
- «FUEL FILLER CAP LEAKING»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-11-130-checking-filler-cap)
- Tank vent line leaking (fuel tank - carbon canister).
- Tank vent line leaking (engine compartment).
- Locking ring on fuel filter leaking
- Carbon canister - shut-off valve leaking
Scheme 139
16 00 005 Draining and filling fuel tank
| IMPORTANT | Observe country-specific safety regulations. Ensure adequate ventilation in the place of work! 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. |
Drawing off fuel
Start engine and allow to run.
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.
Note. Fuel can be drawn out of left and right sides of tank through filler neck, leaving only a small residue. The residual amount is drawn off via the service opening.
Insert special tool 16 1 080 into fuel filler neck.
Special tool 16 1 080 has two different diameters for petrol/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 into the fuel filler pipe, turning in the process if necessary.
Insertion length approx. 118 cm.
Draw off fuel with suction unit (refer to BMW Service Workshop Equipment) as far as possible.
Follow drawing off of fuel on fuel gauge in instrument cluster.
Scheme 140
Drawing off residual fuel amount
Drawing off residual fuel amount is not included in the time value of this operation.
Remove FUEL FILTER .
Drawing off residual fuel amount, right side
Draw off residual fuel amount in right tank half through service opening (A).
Drawing off residual fuel amount, left side
Feed extraction hose through service opening above saddle into left tank half (B).
Residual fuel amount can be drawn off.
Scheme 141
Extracting fuel after a defect in the suction jet pump or fuel pump
Draw off right half of tank completely through fuel filler pipe.
Remove FUEL FILTER .
Insert extraction hose through service opening in tank, fuel (also residual quantity) can be drawn off.
Fuel filling
Insert special tool 16 1 080 into fuel filler neck.
Special tool 16 1 080 has two different diameters for petrol/gasoline and diesel vehicles!
Slide extraction hose of extractor unit, refer to BMW Service Workshop Equipment, approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.
16 00 510 Leak test on fuel tank and tank ventilation system (DMTL)
| 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 the escaping fuel vapors, these tasks should only be carried out in well ventilated rooms or with a suitable extractor facility provided. Observe country-specific accident prevention and occupational safety regulations. |
In the Diagnosis and Information System (DIS), go to the "Function and component selection" page.
By selecting
- Service functions
- Drive
- Digital Motor Electronics
- Activation DMTL pump
Adopt test module in test schedule.
Switch to the test schedule and implement the "Activation DMTL pump" test module.
Leak diagnosis pump pressurizes fuel tank and tank ventilation system.
Carry out leak test.
Terminate test module after completing leak test.
Note. Leak diagnosis pump is automatically shut down after approx. 15 minutes due to risk of overheating. Allow pump to cool down for at least 15 minutes. Then continue procedure.
The leak test can be carried out with a leak detector. Follow manufacturer's operating instructions in doing so.
Possible causes of leaks are
- «FUEL FILLER CAP LEAKING»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-11-130-checking-filler-cap)
- Tank vent line leaking (fuel tank - carbon canister).
- Tank vent line leaking (engine compartment).
- Locking ring on fuel filter leaking
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 via compressed air line (1) to workshop/garage compressed air system (8...10 bar).
Connect pressure sensor (2) from Diagnosis and Information System.
Connect special tool 16 1 172 to quick-connect coupling (3).
Install tank cap on special tool 16 1 172.
Scheme 142
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).
Increase pressure by 0.2 bar with pressure regulator on special tool 16 1 171.
Using special tool 13 3 010 , clamp off supply line from special tool 16 1 171.
Read off and note down pressure.
Wait 60 seconds.
Read off pressure again and compare with starting pressure value.
Measurement evaluation
| Pressure drop > 0.012 bar | Test equipment leaking. Check connection points for leaks. |
PRESSURE MEASUREMENT CHART
Check filler cap pressure relief!
Select "Measurement/Pressure" function on Diagnosis and Information System (DIS).
Increase pressure by 0.3 bar with pressure regulator on special tool 16 1 171.
Using special tool 13 3 010 , clamp off supply line from special tool 16 1 171.
Read off and note down pressure.
Wait 60 seconds.
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 filler cap. |
PRESSURE MEASUREMENT CHART
16 11 030 Removing and installing fuel tank
| IMPORTANT | After installing fuel tank (before initial engine starting): Check ground connection at fuel filler neck to body for continuity. If necessary, clean contact surface between body and fuel filler pipe screw connection. Fill fuel tank with min. 5 l fuel. |
After installation
Carry out wheel alignment check.
Necessary preliminary tasks
- Draw off «FUEL FROM FUEL TANK»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-00-005-draining-and-filling)
- Remove «FUEL FILLER CAP WITH COVER HOUSING»(/bmw/z4/e89-2009-2013/remont/exterior-body-panels/#body-repair__41-63-002-replacing-cover-bowl)
- Remove «REAR AXLE»(/bmw/z4/e89-2009-2013/remont/axle-shafts/#rear-axle-repair__33-31-000-removing-and-installing)
- Remove tunnel thermal insulation
Detach cable ties (1) on rotary catch.
Disconnect plug (2) from fuel filter.
Press lock (3) towards fuel filter and detach feed line (4).
Scheme 143
Release screws (1).
Installation
Tightening torque 16 11 1AZ .
Scheme 144
Slacken nut (1).
Installation
Tightening torque 16 11 3AZ .
Detach grounding strap (2) from stud.
Disconnect service vent lines (3) and unclip from holder.
Scheme 145
Unclip line (1) from fuel tank (2).
Scheme 146
Disconnect plug connection (1) and unclip line (2).
Scheme 147
Detach fuel feed line from holder (1).
Heavily support the fuel tank.
Unscrew nuts (3).
Installation
Tightening torque 16 11 2AZ .
Swing clamping bands (2) downwards and disengage.
Lower fuel tank downwards.
Scheme 148
Installation
Before engaging clamping bands (1), make sure rubber damper (2) is correctly seated.
Scheme 149
Installation
Pay attention to top vent line (1) when installing fuel tank.
Feed vent line (1) through opening (2) into wheel arch.
Scheme 150
When replacing fuel tank
- Modify «FUEL PUMP»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-14-015-removing-and-installingreplacing) .
- Modify «FUEL FILTER»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-11-048-removing-and-installingreplacing) .
16 11 048 Removing and installing/replacing fuel filter with pressure regulator
Recycling
Fuel escapes when fuel lines are detached. Have a 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 and protective goggles). Ensure absolute cleanliness when working on the open fuel system. Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown! |
Necessary preliminary tasks
- Draw off «FUEL FROM FUEL TANK»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-00-005-draining-and-filling) .
- Remove «EXHAUST SYSTEM (N52K)»(/bmw/z4/e89-2009-2013/remont/exhaust/#exhaust-system-repair-n52__18-00-020-removing-and-installing) or «1800 EXHAUST SYSTEM (N54)»(/bmw/z4/e89-2009-2013/remont/exhaust/#exhaust-system-repair-n54) .
- Remove tunnel thermal insulation.
Detach cable ties (1) on rotary catch.
Disconnect plug (2) from fuel filter.
Press lock (3) towards fuel filter and detach feed line (4).
Release screw cap with special tool 16 1 020.
Installation
Tightening torque 16 14 2AZ.
Scheme 151
Installation
After tightening to specified torque, make sure the notch (2) on the rotary catch is located between the two markings (1) on the fuel tank.
Scheme 152
Installation
The fuel filter can only be installed in one position.
When installing, make sure lug (1) of fuel filter engages in corresponding opening (2) on fuel tank.
Always replace seal (3).
Scheme 153
Unfasten plug connection (1).
Disconnect lines (2) and (3) from fuel filter.
Note. Lines (2) and (3) must not be switched round as they have different diameters. Fuel filter and pressure regulator together form a single unit and can only be replaced as such.
Scheme 154
16 12 010 Removing and installing or replacing carbon canister
Necessary preliminary tasks
- Remove cover for carbon canister
Unlock quick-release fasteners (1) and disconnect vent lines.
Release screws (2) and swing out carbon canister (3).
Installation
Tightening torque 16 13 1AZ .
Scheme 155
16 12 010 Removing and installing/replacing carbon canister (US version)
Necessary preliminary tasks
- Remove cover for carbon canister
Disconnect plug connection (1).
Unlock quick-release fasteners (2) and disconnect vent lines.
Scheme 156
Release screws (1) and swing out carbon canister (2).
Installation
Tightening torque 16 13 1AZ .
The following components must be modified when the carbon canister is replaced
- «DIAGNOSIS MODULE»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-13-015-removing-and-installingreplacing)
Scheme 157
16 12 000 Removing and installing/replacing sensor for fuel gauge
Necessary preliminary tasks
- Remove «FUEL PUMP WITH FUEL LEVEL SENSOR»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-14-015-removing-and-installingreplacing)
Press plug connection (1) in direction of fuel pump.
Unlock lug (2) with a screwdriver and detach plug connection (1).
Installation
Check locking of plug connection by pulling.
Scheme 158
Release lugs (1) in direction of arrow.
Lift out tank fill level sensor (2).
Scheme 159
16 13 015 Removing and installing/replacing tank leak diagnosis module (petrol/gasoline cars with US DMTL version)
Necessary preliminary tasks
- Remove «CARBON CANISTER»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-12-010-removing-and-installingreplacing)
Release screws (1).
Disconnect tank leak diagnosis module (2) from carbon canister in direction of arrow.
Installation
Replace sealing ring.
Scheme 160
16 14 500 Removing and installing or replacing control unit for electric fuel pump
| IMPORTANT | Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DAMAGE (ESD protection). |
Necessary preliminary tasks
- Remove right luggage compartment «WHEEL ARCH TRIM»(ref-381258-S02492626752010122800000)
Disconnect plug connection (1).
Unscrew nuts (2).
Installation
Tightening torque 16 14 1AZ .
Remove control unit (3).
Scheme 161
Replacement
- Carry out programming/coding
16 14 060 Removing and installing/replacing dust filter for tank leakage diagnosis module
Necessary preliminary tasks
- Remove cover for carbon canister
Unlock quick-connect coupling (1) and detach vent lines.
Scheme 162
Unlock quick-connect coupling (1) and detach vent lines (2) from dust filter.
Scheme 163
Release screws (1).
Slide dust filter (2) in direction of arrow from holder.
Scheme 164
16 14 015 Removing and installing/replacing fuel pump with fuel level sensor
Necessary preliminary tasks
- Remove «FUEL FILTER»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-supply-system-repair__16-11-048-removing-and-installingreplacing) .
Disconnect fuel line (1).
Scheme 165
Disconnect plug.
To do so, bend lug (1) on both sides outwards and pull plug apart.
Scheme 166
Disconnect line (2) from fuel pump.
Unlock fuel pump by pressing lug (1).
Release fuel pump upwards from catch.
Remove fuel pump with sensor through service aperture.
Installation
When installed, fuel pump must clearly be heard to snap into place.
Do not bend sensor arm during installation.
Line (2) must not be kinked!
