Sylvie Willis
Removing the fuel tank from a BMW E30 is a complex process that requires careful attention to detail. It is important to ensure that the car is safely jacked up on stands and supported securely. The process involves draining the fuel tank, removing the rear seat and carpet to access the fuel pipes and electrical connections, undoing fuel lines and hoses, and carefully detaching various components such as the exhaust, heat shield, and prop shaft. It is crucial to take precise notes and photographs to ensure that everything is reinstalled correctly. This process can be challenging and time-consuming, but with patience and careful attention, it is possible to successfully remove and replace the fuel tank in a BMW E30.
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What You'll Learn
Drain the fuel tank
To drain the fuel tank of a BMW E30, you will need to locate the drain plug on the driver's side. An Allen key, either 5 or 6mm, will be needed to remove it. If you are worried about damaging your Allen key, you can use a pair of vice or mole grips, or self-locking pliers to turn it.
Once the drain plug has been removed, the remaining fuel can be drained out. You will then need to remove the rear seat and lift the carpet to reveal one or two access panels. These need to be unscrewed. Underneath, you will find fuel pipes and electrical connections. Undo the wiring plugs and separate the fuel lines, marking them if that helps with reassembly.
Now, you need to remove the fuel filter from its jubilee clip to access the bolt that holds the filter hanger bracket. Undo this bolt, and then undo the bolt/nut on the other side of the tank.
At this point, you can remove the fuel pump and housing, along with the fuel level sender. Transfer the plastic fuel lines to the new tank, being careful not to damage the copper pipe.
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Remove the rear seat and carpet
To remove the rear seat and carpet of a BMW E30, follow these steps:
First, remove the rear seat. The process may vary slightly depending on the model year and configuration of your E30, but the basic steps are as follows:
- Locate the mounting arm and bolt: The mounting arm and bolt hold the seat back in place. It may be covered by a vinyl body panel, so look carefully. For some E30s, the bolts may be towards the centre-line of the vehicle.
- Release the seat back: Simply pull the seat cushion upwards on both sides to release the hooks. Be careful with the mounting arms as they can scratch the car's interior or your skin.
- Remove the side bolsters: There should be a small 10mm bolt at the bottom that you can remove, allowing you to lift and unhook the bolster from the top.
- Fold and lift the seat: Fold one seat back forward approximately 45 degrees or more. Lift it up and out of the slot at the outer hinge, pull it forward, and slide it off the centre joint. Repeat this process for the other side.
With the rear seat removed, you can now access the carpet. Here are the steps to remove the carpet:
- Lift the carpet: Simply lift the carpet to reveal one or two access panels.
- Unscrew the access panels: Beneath these panels, you will find fuel pipes and electrical connections. Be careful not to damage any of the components.
- Disconnect the wiring: Undo the wiring plugs and separate the fuel lines. Mark the fuel lines if it helps with reassembly.
- Remove the carpet: With the access panels removed, you can now lift and remove the carpet. Be careful not to damage any underlying components, such as the heater core or fuel tank.
Remember to take your time and be careful during the removal process to avoid any damage to your vehicle's interior.
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Disconnect fuel pipes and electrical connections
Disconnecting the fuel pipes and electrical connections is a crucial step in removing the fuel tank from a BMW E30. Here is a detailed guide on how to do this safely and effectively:
First, lift or remove the rear seat of the car and lift the carpet to access the fuel pipes and electrical connections. You will find one or two access panels, which you should unscrew. Underneath, you will see the fuel pipes and electrical connections. It is important to be careful during this step to avoid any damage to the components.
Next, you will need to disconnect the wiring plugs. There may be one plug in each hole, and they are typically for the fuel pump and the fuel senders. Use a small flat-head screwdriver to carefully split the clips that hold the fuel lines in place. It is recommended to replace these with new jubilee clips to make reassembly easier. Mark the fuel lines if it helps with identification when reconnecting them.
Now, separate the fuel lines and undo the hoses beside the fuel filter. Again, marking the hoses can be helpful for reassembly. Remove the fuel filter from its jubilee clip to access the bolt holding the filter hanger bracket. Undo this bolt, as well as the bolt/nut on the other side of the tank.
At this point, you have successfully disconnected the fuel pipes and electrical connections. You can now continue with the next steps to remove the fuel tank. Remember to take pictures and notes during the process to make reassembly easier and to ensure that everything is put back in its original place.
Safety is a top priority when working on any fuel system, so ensure you are working in a well-ventilated area, and avoid any open flames or sparks that could cause an explosion.
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Remove the fuel pump
To remove the fuel pump from a BMW E30, first remove the rear seat base and the carpet to reveal one or two access panels. Beneath these, you will find fuel pipes and electrical connections. Undo the wiring plugs and separate the fuel lines.
Now, remove the fuel filter from its jubilee clip to access the bolt that holds the filter hanger bracket. Undo this bolt, then undo the bolt/nut on the other side of the tank.
On top of the fuel pump housing, remove four 8mm bolts, then remove the fuel pump and housing. Transfer the plastic fuel lines to the new tank, being careful not to damage the copper pipe.
Get the tank back up into position and support it. Connect the fuel lines on top of the tank to those still in the car. Refit the wiring plugs to the fuel pump and sender units.
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Swap everything over
To swap everything over, start by removing the fuel filter, which is connected to a bracket on the rear driver's side. Next, carefully wiggle out the old fuel tank, which may require some force and patience, especially if it gets caught on hoses. Once the fuel tank is out, you can begin the process of swapping everything over to the new tank.
On top of the fuel pump housing, remove the four 8mm bolts and then remove the fuel pump and housing. Transfer the fuel pump to the new tank, along with the fuel level sender. Ensure that you add new O-rings and clamps to avoid future headaches.
Now, transfer the plastic fuel lines to the new tank, being cautious not to damage the copper pipe. If the clips on the original tank are worn out or need replacing, you can use plastic tie wraps to secure the plastic lines, but be careful not to overtighten them.
Get the new tank back into position and connect the fuel lines on top of the tank to those still attached to the car. Jubilee clips are recommended for a faster and easier connection. Finally, refit the wiring plugs to the fuel pump and sender units.
Once everything is swapped over, it's important to put everything back in its original place. Taking pictures during the disassembly process can be helpful to remember the exact positions of each component.
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Frequently asked questions
First, drain the fuel tank. It should have a drain plug on the passenger side rear. Once the tank is drained, remove the bolts connecting to the cat (4 x 12mm bolts) and the bolts holding the straps in the rear of the muffler (2 x 12mm bolts).
Start by removing the heat shield above the exhaust (4 x 10mm bolts). Then, remove the exhaust bolts from the headers (6 x 14mm bolts). Once the exhaust is out, remove the heat shield (6 x 13mm bolts).
Remove the four 13mm bolts from the cross member, and then remove the two bolts from the drive shaft support bearing (2 x 13mm bolts). If you have metal strips (air deflector plates) just in front of the tank, remove these as well.
Remove the four 8mm bolts on top of the fuel pump housing. Then, remove the fuel pump and housing and swap them over to the new tank, along with the fuel level sender. Make sure to add new O-rings and clamps to avoid headaches during reassembly.
