Fuel System Repair Information

2005 BMW Z4
2003-05 ENGINE Fuel System - Repair Information - Z4/E85
2003-05 ENGINE
Fuel System - Repair Information - Z4/E85
FUEL PICK-UP CLEANING

16 00 E85 FUEL SUPPLY SYSTEM (SPARK-IGNITION ENGINES)
1. General
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.
2. 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.
3. Parts designation
PARTS DESIGNATION
1. Fuel tank (plastic) 12. Non-return flap
2. Surge chamber 13. Fuel feed line
3. Electric fuel supply pump 14. Fuel rail
4. Suction jet pump 15. Carbon canister (AKF)
5. Fuel filter with pressure regulator 16. Purge air line
6. Fill level limiting valve (rollover valve) 17. Tank vent valve (TEV)
7. Overpressure safety valve 18. Intake manifold
8. Service vent valve (rollover valve) 19. Engine control unit (DME)
9. Vent line 20. Tank leakage diagnostic module (USA only)
10. Mushroom valve 21. Dust filter (USA only)
11. Fuel filler pipe A: Max. fuel tank fill height
4. Function description
Fuel system
The saddle-shaped fuel tank contains the surge chamber with integrated electric fuel supply pump and
level sensor on its right side.
The surge chamber ensures that the fuel supply pump is properly supplied in all vehicle operating states.
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2005 BMW Z4
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 fuel in the left tank half is repumped via a second suction jet pump from left to right.
Return line, pressure regulator and fuel filter are located in the tank.
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:
M54
The fuel is routed from the electric fuel supply pump via the fuel filter and the fuel feed line to the fuel
rail.
Pressure regulator and fuel filter are incorporated in a single unit in the tank. This removes the need for a
fuel return line.
The fuel passes through the pressure regulator into the left side of the 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.
Venting system USA
The fuel tank is vented during refueling via the vent line.
Because of its large cross-section, the vent line directs the displaced volume (fuel vapors) at high speed 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 leakage diagnostic 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 limiting valve in the tank is closed by the rising fuel if the tank is overfilled. The residual volume
thus created replaces the expansion tank. The ventilation function is maintained by a second float valve.
Both 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.

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2005 BMW Z4
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 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.
Leakage detection for tank venting system USA
The 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.
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.
The systems is activated by the engine control unit.
The mushroom valve establishes by way of the vent line the connection between the fuel tank and the
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.
5. Service data, fuel system
Pressure regulator: 3.5 bar.
Working pressure of suction jet pumps: 1 - 1.3 bar
6. Schematic drawings of fuel supply systems
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2005 BMW Z4
Fig. 1: Identifying Schematic Drawings 5.2 E85 Fuel Supply System USA
Courtesy of BMW OF NORTH AMERICA, INC.
16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS
Fuel supply systems, spark-ignition engines
Fuel system
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2005 BMW Z4
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.
16 00 005 DRAINING AND FILLING FUEL TANK
IMPORTANT: Observe relevant country safety legislation and regulations!

Ensure adequate ventilation in the place of work!
Connect the exhaust and extraction systems to the exhaust tailpipe.
Carefully withdraw extraction hose so as not to damage non-return flap.
The electric fuel pump must not operate without fuel!
After the repair work but before starting the engine for the first time, fill the fuel tank with min. 5 L of fuel
through the fuel filler pipe.
Drawing off fuel:
Start engine and allow to run. Electric fuel supply pump runs.
The fuel is thus repumped via 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. The residual amount on left and right can
continue to be drawn off after removal of the fuel filter.
Push extraction hose of suction extractor unit into fuel filler pipe. In so doing, turn slightly if necessary.
Insertion length:
Approx. 90 cm
Draw off fuel with suction extractor unit as far as possible.
Follow the fuel drawing-off procedure at the fuel gauge in the instrument cluster.
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2005 BMW Z4
Fig. 2: Pushing Extraction Hose Of Suction Extractor Unit Into Fuel Filler Pipe
Drawing off residual fuel quantity:
Catch dripping fuel in a suitable container.
Remove fuel filter. See 16 11 048 Removing And Installing/Replacing Fuel Filter With Pressure
Regulator .
Drawing off residual fuel amount on right side:
Draw off residual fuel amount in right tank half through service opening (A).
Drawing off residual fuel amount on left side:
Feed extraction hose through service opening in tank above saddle into left tank half (B). Residual fuel amount
can be drawn off.
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2005 BMW Z4
Fig. 3: Identifying Fuel Tank Points

Fuel filling:
Push extraction hose of suction extractor unit approx. 40 cm into fuel filler pipe.
Fill fuel from suction extractor unit.
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2005 BMW Z4
Fig. 4: Pushing Extraction Hose Of Suction Extractor Unit

Drawing off after fault in suction jet pump:
Draw off right tank half completely via fuel filler pipe.
Remove Fuel Filter .
Feed extraction hose through service opening in tank above saddle into left tank half (B). Fuel (also residual
amount) can be drawn off.
16 00 102 CHECKING FUEL TANK AND TANK VENTING SYSTEM FOR LEAKS WITH TANK
LEAKAGE DIAGNOSIS MODULE (DM-TL)
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
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2005 BMW Z4
unit.
{ Read out fault memory of DME control unit and carry out diagnosis in
accordance with faults stored.
{ A leak test of the DM-TL module is performed when:
z The components of the DM-TL module are O.K.
z 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"
{ Leave car in workshop for at least 2 hours so that fuel temperature comes into line with workshop
temperature (ideal fuel temperature approx. 10...20°C).
{ Do not under any circumstances fill up car with fresh fuel (strong exhalation of fresh fuel).
{ Check that tank cap is correctly seated.
WARNING: During the leak test, under no circumstance apply external pressurization
through the tank 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
screen.
By selecting:
{ Complete vehicle
{ Drive
{ Engine management
{ Tank system test
{ Tank leakage diagnostic module (DM-TL)
Adopt test module in test schedule.
Switch to the test schedule and implement the tank leakage diagnosis module. Leakage test is carried out.
Carry out leak detection if the fault is stored again in the DME fault memory (tank leak detected). See 16 00
510 Conducting Leak Test On Fuel Tank And Tank Ventilation System .
16 00 510 CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTILATION SYSTEM
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2005 BMW Z4
NOTE: The following procedure is only applicable to vehicles with the tank leak
diagnosis module (DM-TL).
IMPORTANT: On vehicles with tank leak diagnosis modules (DM-TL), do not work with
external pressurization as the tank venting 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
screen.
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.
Tank leak diagnosis pump pressurizes fuel tank and tank venting system.
Carry out leak test.
Terminate test module after completing leak test.
NOTE: Tank 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:
{ Tank cap leaking.

{ Tank vent line leaking (fuel tank-carbon canister).
{ Tank vent line leaking (engine compartment).
{ Sealing ring on fuel filter leaking.
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2005 BMW Z4
Fig. 5: Identifying Leak Detector

16 00 510 CONDUCTING LEAK TEST ON FUEL TANK AND TANK VENTILATION SYSTEM
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2005 BMW Z4
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:
{ Tank cap leaking.

{ Tank vent line leaking (fuel tank-carbon canister).
{ Tank vent line leaking (engine compartment).
{ Sealing ring on fuel filter leaking.
{ Carbon canister shut-off valve leaking.
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2005 BMW Z4
Fig. 6: Identifying Leak Tester

FUEL TANK WITH MOUNTING

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2005 BMW Z4
16 11 030 REMOVING AND INSTALLING FUEL TANK
Special tools required:
z 31 1 150
z 33 4 410
IMPORTANT: After installing fuel tank (before initial engine starting):
z Check resistance between metal filler bowl and wheel hub.
Measured value approx. 0.6 ohm.
z Fill fuel tank with min. 5 L fuel.
After installation:
Carry out wheel alignment check.
Necessary preliminary tasks:
Draw off fuel from fuel tank. See 16 00 005 Draining And Filling Fuel Tank .
Remove handbrake Bowden cables. See 34 41 120 REMOVING AND INSTALLING/REPLACING

BOWDEN CABLES .
Remove right wheel arch cover.
Remove right wheel arch lip.
Remove tank cap with cover.
Disconnect feed line (1) and connector (2) from fuel filter.
Unclip both lines from tank.
NOTE: To disconnect feed line, press ring (3) in direction of fuel filter and pull out feed
line.
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2005 BMW Z4
Fig. 7: Disconnecting Feed Line And Connector From Fuel Filter

Unfasten screws.
Installation:
Tightening torque, see 16 12 11AZ in FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .
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2005 BMW Z4
Fig. 8: Unfastening Screws

Unfasten nut.
Disconnect service vent lines from tank filler pipe.
Installation:
Installation:
Moisten connecting pieces and seals of vent lines with lowsurface-tension water or with a soapy solution.
Facilitates installation!
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2005 BMW Z4
Fig. 9: Disconnecting Service Vent Lines From Tank Filler Pipe

Disconnect cable for wear indicator and wheel speed sensor and detach from trailing arm.
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2005 BMW Z4
Fig. 10: Disconnecting Cable For Wear Indicator And Wheel Speed Sensor And Detaching From Trailing
Arm
Release both holders for brake line.
Detach brake line completely from right trailing arm.
Tightening torque, see 34 32 3AZ in BRAKES - TIGHTENING TORQUES .
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2005 BMW Z4
Fig. 11: Releasing Both Holders For Brake Line

Remove tension strut on final drive.
Support final drive with transmission lifter and special tool 33 4 410.
IMPORTANT: Make sure there is clearance between special tool 33 4 410 and dust sleeve (1).
Contact may be made with flange if dust sleeve (1) is damaged or bent.
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2005 BMW Z4
Fig. 12: Identifying Dust Sleeve

Consequence: noise!
If necessary, detach cable for ride level sensor from rear axle bracket.
Replace rear screws (1) on left and right with special tool 31 1 150.
NOTE: Screws of E38 front axle support (part number 9 900 223) can be used instead of
special tool 31 1 150.
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2005 BMW Z4
Fig. 13: Replacing Rear Screws On Left And Right With Special Tool 31 1 150
Lower rear axle bracket with special tool 33 4 410.
Clearance A=10 cm.
Installation:
Damaged threads in body-side sleeves can be repaired with Helicoil thread inserts. Install Helicoil thread inserts
flush with original thread.
Mark position of right bearing block to body with colored markings (1). This simplifies subsequent toe-in
adjustment.
Replace screw (2) with special tool 31 1 150.
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2005 BMW Z4
Fig. 14: Identifying Mark On Right Bearing Block To Body

NOTE: Screws of E38 front axle support (part number 9 900 223) can be used instead of
Release and lower bearing block.
Clearance A=9 cm.
Installation:
Damaged threads in body-side sleeves can be repaired with Helicoil thread inserts. Install Helicoil thread inserts
flush with original thread.
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2005 BMW Z4
Fig. 15: Identifying Clearance

Installation:
Pay attention to top vent line (1) when installing fuel tank.
Feed vent line (1) through opening (2) into wheel arch.
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2005 BMW Z4
Fig. 16: Feeding Vent Line Through Opening Into Wheel Arch
Support tank with lifter.
Unscrew left and right bolts (1).
Remove clamping band (2) on left and right.
Remove tank downwards with assistance of a 2nd person.
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2005 BMW Z4
Fig. 17: Identifying Bolts And Clamping Band

Installation:
When replacing fuel tank:
z Modify fuel pump. See 16 14 010 Removing and installing/replacing fuel pump .
z Modify fuel filter. See 16 11 048 Removing And Installing/Replacing Fuel Filter With Pressure
Regulator .
16 11 048 REMOVING AND INSTALLING/REPLACING FUEL FILTER WITH PRESSURE

REGULATOR
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2005 BMW Z4
z 16 1 020
z Draw off fuel from fuel tank. See 16 00 005 Draining and filling fuel tank .
z Remove exhaust system . See EXHAUST SYSTEM - REPAIR INSTRUCTIONS .
z Remove tunnel thermal insulation.
Disconnect feed line (1) and connector (2) from fuel filter.
NOTE: To disconnect feed line, press ring (3) in direction of fuel filter and pull out feed
line (1).
Fig. 18: Disconnecting Feed Line And Connector From Fuel Filter
Release screw cap with special tool 16 1 020.

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2005 BMW Z4
Installation:
Always replace rubber seal.
Fig. 19: Releasing Screw Cap With Special Tool 16 1 020

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.
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2005 BMW Z4
Fig. 20: Identifying Notch And Marking On Fuel Tank

Installation:
The fuel filter can only be installed in one position.
When installing, make sure lug (1) of fuel filter engages in corresponding opening on fuel tank.
Always replace seal (2).
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2005 BMW Z4
Fig. 21: Identifying Lug Of Fuel Filter And Seal

Pull off plug (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.
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2005 BMW Z4
Fig. 22: Disconnecting Lines And From Fuel Filter

16 11 130 CHECKING FILLER CAP PRESSURE RELIEF VALVE
z 13 3 010
z 16 1 171
z 16 1 172
z 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 workshop/garage compressed air system (8...10
bar).
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2005 BMW Z4
Connect pressure sensor (2) of Diagnosis and Information System with a measuring range of 0...3.5 bar.
Fig. 23: Connecting Special Tool 16 1 171 Via Compressed Air Line
Select special tool 16 1 172 or 16 1 173 matching vehicle's filler cap and attach to quick-release coupling of
Install filler cap on selected special tool.
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2005 BMW Z4
Fig. 24: Identifying Special Tool 16 1 172 Or 16 1 173 Matching Vehicle's Filler Cap
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).
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 fuel filler neck.
Wait 60 secs.
Read off final pressure value and compare with starting pressure value.
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2005 BMW Z4
Measurement evaluation:
MEASUREMENT EVALUATION
Pressure drop > 0.012 bar Testing equipment leaking. Check connection points for leaks.
Check filler cap pressure relief!
Follow same test procedure as for "Checking testing equipment for leaks". See 16 00 510 Conducting Leak
Test On Fuel Tank And Tank Ventilation System .
Increase pressure by 0.3 bar with pressure regulator on special tool 16 1 171.
Measurement evaluation:
MEASUREMENT EVALUATION
Pressure drop > 0.012 bar Filler cap pressure relief valve faulty. Replace filler cap I.
FUEL TRANSFER SENSOR

16 12 000 REMOVING AND INSTALLING/REPLACING THE SENSOR FOR THE FUEL LEVEL
GAUGE (RIGHT)
NOTE: In the E85 only the right sensor for fuel level indication can be replaced. If the
left sensor is faulty, the fuel tank must be replaced.
Sensors for fuel level indication, electric fuel pump and right suction jet pump together form a single unit and
can only be replaced as such.
z Draw off fuel from fuel tank. See 16 00 005 Draining and filling fuel tank .
z Remove fuel filter. See 16 11 048 Removing and installing/replacing fuel filter with pressure
regulator
Remove electric fuel pump. See 16 14 010 Removing and installing/replacing fuel pump .
16 12 010 REMOVING AND INSTALLING/REPLACING CARBON CANISTER WITH DM-TL
DM-TL = diagnosis module-tank leakage
1. Remove rear right wheel arch cover.
Unfasten plug connection (1).

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2005 BMW Z4
Unlock lines (2) to 4 and detach.
2. Scavenging air line.

3. Vent line to tank.
4. Evaporation line.
Fig. 25: Identifying Scavenging Air Line & Vent Line To Tank And Evaporation Line
Release screws and remove carbon canister with DM-TL towards bottoms.
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2005 BMW Z4
Fig. 26: Removing Carbon Canister With DM-TL Towards Bottom

FUEL VENTILATION
16 13 015 REMOVING AND INSTALLING/REPLACING TANK LEAK DIAGNOSTIC MODULE
(DM-TL)
z Remove rear right wheel. See 36 10 300 REMOVING OR INSTALLING FRONT OR REAR
WHEEL .
z Remove rear right wheel arch cover.
Unfasten line (1) and detach.
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2005 BMW Z4
Remove hose (2).
Fig. 27: Removing Hose

Release screws (1).
Release lugs (2).
Detach DM-TL from carbon canister.
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2005 BMW Z4
Fig. 28: Releasing Lugs

FUEL PUMP
16 14 010 REMOVING AND INSTALLING/REPLACING FUEL PUMP
NOTE: Fuel pump, right suction jet pump and right sensors for fuel level indication
together form a single unit and can only be replaced as such.
z Remove fuel filter. See 16 11 048 Removing And Installing/Replacing Fuel Filter With Pressure
Regulator .
Disconnect plug.
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2005 BMW Z4
To do so, bend lug (1) on both sides outwards and pull plug apart.
Fig. 29: Pulling Plug Apart

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. See 16 14 010 Removing And Installing/Replacing
Fuel Pump .
Installation:
When installed, fuel pump must clearly be heard to snap into place.
Do not bend sensor arm during installation.
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2005 BMW Z4
Line (2) must not be kinked!
Fig. 30: Unlocking Fuel Pump By Pressing Lug

16 14 030 REPLACING SUCTION JET PUMP (RIGHT)
NOTE: In the E85 only the right suction jet pump can be replaced. If the left suction jet
pump is faulty, the fuel tank must be replaced.
Sensors for fuel level indication, electric fuel pump and right suction jet pump together form a single unit and
can only be replaced as such.
z Draw off fuel from fuel tank. See 16 00 005 Draining And Filling Fuel Tank .
z Remove fuel filter. See 16 11 048 Removing And Installing/Replacing Fuel Filter With Pressure
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2005 BMW Z4
Regulator .
Remove electric fuel pump. See 16 14 010 Removing And Installing/Replacing Fuel Pump .
16 14 060 REMOVING AND INSTALLING/REPLACING DUST FILTER FOR TANK LEAKAGE

DIAGNOSIS MODULE (DM-TL)
z Remove rear right wheel arch cover .

z Remove carbon canister. See 16 12 010 Removing And Installing/Replacing Carbon Canister With
DM-TL .
Detach line (2) from carbon canister.
Unfasten screws.
Remove dust filter (1) with line (2).
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2005 BMW Z4
Fig. 31: Removing Dust Filter With Line

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2005 BMW Z4

2003-05 ENGINE Fuel System - Repair Information - Z4/E85

Fuel System - Repair Information - Z4/E85

FUEL PICK-UP CLEANING

2. Tank venting system

Fuel supply to engine:

The fuel rail is return-free.

Venting system USA

The carbon canister is regenerated by purging with fresh air.

This operation is only possible while the engine is running.

Leakage detection for tank venting system USA

The systems is activated by the engine control unit.

Determining fill level in fuel tank

5. Service data, fuel system

Pressure regulator: 3.5 bar.

Working pressure of suction jet pumps: 1 - 1.3 bar

6. Schematic drawings of fuel supply systems

16 00 GENERAL FUNCTION DESCRIPTION FOR FUEL SUPPLY SYSTEMS

Fuel supply systems, spark-ignition engines

Tank venting system

16 00 005 DRAINING AND FILLING FUEL TANK

IMPORTANT: Observe relevant country safety legislation and regulations!

The electric fuel pump must not operate without fuel!

Drawing off fuel:

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

Drawing off residual fuel quantity:

Catch dripping fuel in a suitable container.

Drawing off residual fuel amount on right side:

Drawing off residual fuel amount on left side:

Fig. 3: Identifying Fuel Tank Points

Fill fuel from suction extractor unit.

Fig. 4: Pushing Extraction Hose Of Suction Extractor Unit

Drawing off after fault in suction jet pump:

Remove Fuel Filter .

z 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 %

Clear DME fault memory.

Adopt test module in test schedule.

Adopt test module in test schedule.

Carry out leak test.

Terminate test module after completing leak test.

Possible causes of leaks are:

{ Tank cap leaking.

Fig. 5: Identifying Leak Detector

Pressurize fuel tank and tank venting system.

IMPORTANT: Emerging fuel vapors!

The leak test can be carried out with a leak detector.

Possible causes may be:

{ Tank cap leaking.

Fig. 6: Identifying Leak Tester

FUEL TANK WITH MOUNTING

16 11 030 REMOVING AND INSTALLING FUEL TANK

Special tools required:

IMPORTANT: After installing fuel tank (before initial engine starting):

z Check resistance between metal filler bowl and wheel hub.

Measured value approx. 0.6 ohm.

z Fill fuel tank with min. 5 L fuel.

Carry out wheel alignment check.

Necessary preliminary tasks: