Regan Brown
Replacing the fuel door assembly on an E70 X5 30d is a complex task that requires a range of tools and a good understanding of the vehicle's mechanics. The process involves removing the old fuel filter, which is held in place by two brackets with 10mm bolts, and then removing the inlet/pre-heater assembly from the filter using a flat-head screwdriver. The new filter can then be installed, along with a new rubber hose and hose clamp. Finally, the brackets and bolts can be reinstalled.
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What You'll Learn
Removing the fuel filter brackets
To remove the fuel filter brackets, you will need to locate the fuel filter. It is held in place by two brackets with 2 x 10mm bolts. Remove these bolts and then remove the brackets completely. The fuel filter should now be free to move around slightly. It will only be held on by the pipe on one end and the inlet/fuel heater assembly on the rear of the filter.
To remove the inlet/pre-heater assembly from the filter, there will be a metal retaining clip. Use a flat-head screwdriver to pry it off by pulling it down. Grab the filter with one hand and the assembly with the other. Now the brackets have been removed.
Reinstall the rubber hose on the outlet side of the filter and use a new hose clamp. Once everything is connected, reinstall the brackets that hold the filter, as well as the 2 x 10mm bolts.
To replace the fuel door assembly, you will need to drill the holes and then drill a slot shape where the indentions were to break the tabs holding the fuel door. You can use a slotted screwdriver to break the tabs, but be careful not to bend the sheet metal in the area.
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Removing the inlet/pre heater assembly
To remove the inlet/pre heater assembly from the filter, you will need to use a flat-head screwdriver to pry off the metal retaining clip. Pull the clip down and then grab the filter with one hand and the assembly with the other. The fuel filter should now be free to move around slightly.
When you buy a new filter, you may not be given a new rubber o'ring. If this is the case, simply remove the o'ring from the old filter and install it on the new one. Push the inlet/preheater assembly onto the filter and then reinstall the retaining metal clip by pushing it into the slot. Re-position the filter but don't install the brackets yet. Reinstall the rubber hose on the outlet side of the filter and use a new hose clamp. Now everything is connected, reinstall the brackets that hold the filter as well as the 2 x 10mm bolts.
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Reinstalling the inlet/preheater assembly
To reinstall the inlet/preheater assembly, you will need to push the assembly onto the filter. Then, reinstall the retaining metal clip by pushing it into the slot. Re-position the filter but don't install the brackets yet. Reinstall the rubber hose on the outlet side of the filter and use a new hose clamp. Now that everything is connected, reinstall the brackets that hold the filter as well as the 2 x 10mm bolts.
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Drilling the holes
To replace the E70 fuel door assembly, you will need to drill the holes. Get your drill or dremel ready and use a 3/16 drill bit. Drill the holes and then drill a slot shape where the indentions were to break the tabs holding the fuel door. Drill slots in all five holes and then stick a slotted screwdriver into the holes and break the tabs. Be very careful when doing this as you can bend the sheet metal in the area if you apply too much force. Once you have broken the tabs, you should be able to take the fuel door assembly out by pulling it to the right side and sliding/pulling it out. The assembly is partially rubber where the fuel neck sticks out so you should be able to just pull it over your fuel neck and off.
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Sliding the new fuel door assembly in
To slide the new fuel door assembly in, you will need to slide it in the same way that you took the old one out. Slide the new assembly in from the right side, sliding/pulling it in. The assembly is partially rubber where the fuel neck sticks out, so you should be able to just pull it over your fuel neck and push it on. Remember to put foam in your new assembly if it is salvageable, or cut your own from some spare foam. You can also use a drill to drill holes and then drill a slot shape where the indentions were to break the tabs holding the fuel door. Be careful not to bend the sheet metal in the area if you use this method.
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Frequently asked questions
You should be able to take the fuel door assembly out by pulling it to the right side and sliding/pulling it out. The assembly is partially rubber where the fuel neck sticks out so you should be able to just pull it over your fuel neck and off.
You will need a drill or dremel with a 3/16 drill bit.
Slide the new fuel door assembly in like the old one came out, and slide the rubber part over your fuel neck and push it on.
You can put foam in your new assembly if it's salvageable, or cut your own off some spare foam. However, it is not essential, as you can leave it out.
