B160317

TIS Service Bulletin
SI B16 03 17
Fuel Supply Systems
Page 1 of 4
July 2018
Technical Service
E46 PZEV/SULEV (M56) FUEL TANKS: REPLACEMENT AND
PARTS RETURN PROCEDURE
New information provided by this revision is preceded by this symbol
.
This Service Information bulletin replaces SI B16 01 04 dated May 2015
What’s New:
• Emphasis of bulletin changed from tank disposal to tank recovery
• Fuel tank recovery procedure (added)
• Parts information section updated.
• Warranty Information section has been updated.
MODEL
E46 - 3 Series with the M56 Engine (Produced 2003 to 2006)
SITUATION
BMW of North America, LLC (“BMW NA”) will begin offering factory remanufactured fuel tank assemblies for
E46 (3 Series) PZEV/SULEV (Model vehicles with the M56 engine).
BMW NA will start to collect E46 PZEV/SULEV (M56) tanks that are in good shape and meet a weight
requirement that ensures proper drainage. All tanks deemed to be in good condition will be used to support the
remanufacturing process that has been established for these tanks.
IMPORTANT: Damage caused by improper removal of the tank that prevents the tank from being
remanufactured will cause the debit of the claim or core charge.
If you have recently performed such a repair and still have the tank or plan to replace a tank, please submit an
IDS ticket to the WPRC and inform your TSE
Specific instructions will then be provided as to what you need to do with the tank.
With the IDS ticket please indicate:

The VIN the tank is associated to.

The quantity of used E46 tanks you have on site for inspection & pickup.

Whether it is a warranty core return or customer pay core return.
NO FUEL TANKS SHOULD BE SHIPPED FROM YOUR CENTER TO THE WPRC!
Please hold the fuel tank on-site for inspection and supplemental draining by the TSE after following
the initial draining procedure (see attached).
https://www.bmwtis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/467... 8/1/2018
TIS Service Bulletin
Page 2 of 4
All tanks will need to be inspected and weighed (must be less than 40 lbs.) by your TSE in order to confirm they
have been effectively drained, once inspected and/or drained again the tanks can be prepared for local pickup
by a transport company (FedEx LTL Transport).
Please ensure that your workshop technicians and parts department personnel handle the removed fuel tank(s)
properly, to avoid unnecessary damage to the tank or the box that the tank was shipped in.
Please ensure that the fuel filler neck remains in place and do not drill any holes in the fuel tank to drain
the fuel!
Follow the attached instructions on how to use the special siphon hose to drain the tank while still in
the vehicle and again after removal.
PART RETENTION
E46 PZEV/SULEV (M56) fuel tank replacements that are reimbursed through a DCSnet claim submission are
the property of BMW NA.
Your center is responsible for the proper identification, storage and documentation of these parts (Part Number,
VIN, RO and claim number as applicable). They must be held in a secure retention area with no direct exposure
to the weather.
Since the box that the tank is shipped in will be used to return the tank, it must remain dry and
undamaged, otherwise dedicated local pickup cannot occur until a replacement box is obtained.
Upon notification of claim payment by BMW NA through DCSnet, a corresponding DCSnet generated Part
Return/Hold tag will be created. Please use the attached procedure to prepare the fuel tank for transport
inspection by the TSE.
Warning: Used fuel tanks are classified as dangerous goods (DG) by the Department of Transportation (DOT)
and require special preparation, packing and labeling for transport.



Your center is responsible for following all federal, state and local rules and regulations that apply
to the proper documentation and shipping of Hazardous Material.
As listed in the “Ship To” address section of the Part Return tag, the requested E46 PZEV/SULEV
(M56) fuel tanks must be held at your facility for transport inspection and local pickup.
Please DO NOT return these fuel tanks to “Lighting Resources.”
Your center can use the Labelmaster® Dangerous Goods Information System (DGIS) or the FedEx Ship
Manager for Hazardous Material for proper shipping procedures and guidelines once directed to do so.
Additional information for the DGIS can be found in SI B01 22 16.
PROCEDURE
Repair Preparation:
Important:
Please order an E46 SULEV (PZEV) Fuel Tank Return Kit (P/N 16 11 8 699 011) for each tank that will be used
to prepare the tank for storage and transport.

The kits are not available through the RDC

All return kits must be ordered via the Virtual Warehouse

Orders can be placed using the Clear View site (https://clearview.excelda.com) or through your DMS

Refer to Aftersales Bulletin #: B-2-0317-0401 “BMW Aftersales Business Development & Marketing Clear
View Ordering Portal Update: Ordering and Drop Ship Now Available”
https://www.bmwtis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/467... 8/1/2018
TIS Service Bulletin

Page 3 of 4
All orders will be visible in your DMS/Atlas and you will be invoiced directly
Each kit contains the plugs, caps, labels, absorbing mat and wire ties needed to secure the fuel tank for
packaging and shipping using the original box. The kit does not contain duct tape.
The original box that contained the replacement fuel tank will be needed for the part return process.
Refer to the attached procedure to properly extract the fuel from the fuel tank and prepare it for temporary
storage and shipment using a dedicated local pick-up (FedEx LTL Service - FedEx BOL template is attached)
once approved by TSE.
IMPORTANT:
Extracting Fuel and Replacing Fuel Tank:
Note: Do not drill any holes in the fuel tank to drain the fuel. The fuel tank must be received intact
without any damage.
1. Before removing the fuel tank from the vehicle, extract as much fuel as possible using the
attached E46 SULEV Fuel Tank Recovery procedure.
The procedure steps MUST be followed as described in the attached document.
Note: Disregard any previous communication and information about removing the filler neck
“in-vehicle” by cutting or breaking it to expedite the tank’s removal.
2. Replace the fuel tank as per Repair Instruction 16 11 032 “Removing and installing/replacing fuel
tank (M56) and continue using the attached procedure.
PARTS INFORMATION
IMPORTANT! Do not damage the new fuel tank shipping box. The defective core fuel tank must be
returned in that box.
Part Number
Description
Quantity
16 11 8 699 011
E46 SULEV (PZEV) Fuel Tank Return Kit
1
16 11 6 763 569
Fuel tank, metal with filler pipe
1
or
Or
16 11 7 464 403
RMFD Fuel tank, metal with filler pipe
16 11 7 222 391
Fuel Filler Cap
1
NPN
Duct Tape (Local Source)
See below
WARRANTY INFORMATION
E46 (3 Series) SULEV/PZEV (M56) fuel tank replacements reimbursed by BMW NA through a claim
submission.
Please claim the following work time labor operation and FRU allowance for performing the additional work to
process the fuel tank for pickup.
https://www.bmwtis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/467... 8/1/2018
TIS Service Bulletin
Page 4 of 4
Defect Code:
Refer to KSD2
Claim with the defect code that applies to the
fuel tank replacement
Labor Operation:
Labor Allowance:
Description:
16 99 000
5 FRU
Work time for the additional work to process the
requested fuel tank to be held/stored until local
inspection and pickup can be arranged
Work time labor operation code 16 99 000 is not considered a Main labor operation. Also, since the “work time”
FRU allowance to be claimed is specified, a separate punch time is not required. However, it still requires an
explanation on the repair order and in the claim comments section.
And:
Sublet Materials – Duct Tape
Sublet Code 4
Up to $1.00
Sublet reimbursement, up to the amount listed
for (NPN) bulk quantity duct tape, which is
required to process the fuel tank for return
Posted: Monday, July 2, 2018
ATTACHMENTS
View PDF attachment B160317_Procedure.
[ Copyright ©2018 BMW of North America, Inc. ]
https://www.bmwtis.net/tiscode/cgi-bin/bulletin.aspx?sie_path=/tsb/bulletins/htm_store/467... 8/1/2018
SI B16 03 17 Procedure
June 2018
E46 SULEV Fuel Tank Recovery Procedure
IMPORTANT!
Read this instruction before removing the fuel tank from the vehicle.
These detailed steps must be performed correctly so that the fuel extraction is safe and efficient.
Additional items needed for this procedure:
Angle finder or similar angle measuring device.
Always wear the proper protective clothing as per
local and state laws.
1
SI B16 03 17 Procedure
June 2018
Procedure:
Part 1: Draining Tank in and out of vehicle.
Before removing the fuel tank from the vehicle
extract as much fuel as possible using the steps
described in this procedure. Use special tool 83
30 2 458 587 in conjunction with a properly
maintained fuel caddy (fuel extraction storage
unit). For more details on tool 83 30 2 458 587
refer to SI B04 12 17. Connect the siphon kit to
the fuel caddy, refer to SI B04 12 17.
Fuel Siphon Kit P/N 83 30 2 458 587 Contents:
1 – Siphon tube with cap
2 – Vapor recovery hose
3 – Ground cable
4 – Siphon hose sleeve
5 – Teflon tape
6 – Universal adaptors
7 – Replacement O-rings for the hose tip
1. Adjust the siphon hose plastic sliding stop and
mark the hose with an ink marker at 65 inches
(165cm) from the stainless steel tip of the
siphon hose.
2
SI B16 03 17 Procedure
June 2018
2. Insert the siphon hose sleeve (1) into the filler
neck.
3. Connect one of the three grounds clips (1) to
the brass connection where the siphon hose (2)
meets the gas caddy hose (3).
4. Connect one of the two remaining ground clips
(1) to the gas caddy pump housing.
3
SI B16 03 17 Procedure
June 2018
5. With the ball tip attached to the hose, insert the
siphon hose. There is no need to change tips.
Lubricate the lower 30 inches of the siphon
hose with WD-40 or similar before inserting.
When the hose stops, continue to apply
pressure while rotating the hose 90 degrees
clockwise and counterclockwise in each
direction. See arrows.
The siphon hose tip will continue traveling
through the lower filler neck flap and into the
fuel tank.
6. The filler neck diameter is very narrow and will
cause the hose to spring backwards when
inserted.
Push the hose in about 2-3 inches too far and
pull back out gently until the previously marked
area on the siphon hose lines up with the edge
of the siphon hose sleeve (1).
The siphon hose must be inserted to the
specified length to achieve proper siphoning
results.
7. Adjust the siphon hose sliding stop (1) so that it
contacts the siphon hose sleeve.
4
SI B16 03 17 Procedure
June 2018
8. Install the cap (1) onto the filler neck.
Install the third ground clip to the brass lug
found on the side of the cap (2).
Begin extracting fuel.
When the available fuel is siphoned from the
fuel tank, remove the siphon tube and reinstall
the fuel filler cap.
Proceed to the next step.
9. Remove the fuel tank as per Repair Instruction
16 11 030 “Removing and installing fuel tank
(M56).
The fuel tank MUST be removed from the
vehicle with it level to the ground as shown in
the illustration. Do not turn or twist the tank in
any other direction when removing it.
Use the special tools or similar tools to keep
the fuel tank level with the ground.
Use a suitable jack with the basic carrier for
special tool 00 2 040.
Assemble the basic carrier with special tools
16 1 180.
Keeping the tank level with the ground will
allow the fuel to be siphoned more efficiently
for shipping.
Do not drill any holes in the fuel tank or cut
the fuel filler neck to drain the fuel. The fuel
tank assembly must be returned 100 percent
intact without any damage.
5
SI B16 03 17 Procedure
June 2018
10. Using two people, remove the fuel tank from
the basic carrier or suitable lifting device.
Place the fuel tank flat on the ground as shown
in the illustration
Always keep the fuel tank level with the ground
when moving it.
Do not dent or scratch the fuel tank when
performing these instructions.
Place the fuel tank on a smooth surface so
that the bottom of the fuel tank is not
damaged.
Place a large piece of scrap cardboard
under the fuel tank to avoid damage when
performing these instructions.
11. Tank overview.
Left (1)
Right (2)
Front (3)
Back (4)
Filler Neck (5)
Arrow = Direction of vehicle travel
Supplemental Draining After Removal of Tank:
12. The residual fuel will need to be siphoned from
the fuel tank again after it is removed.
Please perform the supplemental draining
process in a well-ventilated area.
Adjust the siphon hose plastic sliding stop and
mark the hose with an ink marker at 65 inches
(165Cm) from the stainless steel tip of the
siphon hose.
6
SI B16 03 17 Procedure
June 2018
13. Insert the siphon hose sleeve (1) into filler neck
(2).
14. Connect one of the three grounds clips (1) to
the brass connection where the siphon hose (2)
meets the gas caddy hose (3).
15. Connect one of the two remaining ground clips
(1) to the gas caddy pump housing.
7
SI B16 03 17 Procedure
June 2018
16. Insert the siphon hose.
Lubricate the lower 30 inches of the siphon
hose with WD-40 or similar before inserting.
When the hose stops continue to apply
pressure while turning hose 90 degrees
clockwise and counterclockwise in each
direction. See arrows.
The siphon hose tip will continue traveling
through the lower filler neck flap and into the
fuel tank.
17. The filler neck diameter is very narrow and will
cause the hose to spring backwards when
inserted.
Push the hose in about 2-3 inches too far and
pull back out gently until the previously marked
area on the siphon hose lines up with the edge
of the siphon hose sleeve (1).
The siphon hose must be inserted to the
specified length to achieve proper siphoning
results.
18. Adjust the siphon hose sliding stop (1) so that it
contacts the siphon hose sleeve.
8
SI B16 03 17 Procedure
June 2018
19. Install the cap (1) onto the filler neck (2).
20. Install the third ground clip (1) onto the brass
lug found on the side of the cap (2).
21. The fuel tank is lying flat on the floor with the
siphon tube inserted and ready to extract fuel.
Activate Siphon – Extract Fuel
9
SI B16 03 17 Procedure
June 2018
22. Lift the fuel tank from the left side and hold it
upright with the filler neck on the ground
position for 30 seconds while activating the
siphon pump to extract all fuel accumulated at
the bottom of the tank. See arrow.
After 30 seconds, lower the fuel tank to the
floor.
Activate Siphon – Extract Fuel
23. Slightly tilt the fuel tank so that all of the fuel
moves to the portion of the fuel tank that is
closest to the filler neck. Do this by lifting the
left side of the fuel tank to 70 degrees.
Lean the fuel tank against the wall or a work
bench as shown in the illustration.
Use an angle finder to precisely measure the
angle of the fuel tank.
Activate Siphon – Extract Fuel
Siphon as much fuel from the fuel tank as
possible, by rotating the tank through various
angles while siphon pump is active.
If using a powered fuel extraction pump, let the
pump run for approximately 30 seconds after
the pump stops siphoning the fuel and before
lowering the fuel tank again.
If using a manual fuel extraction pump,
continue cranking for approximately 30
seconds after the pump stops siphoning the
fuel and before lowering the fuel tank again.
10
SI B16 03 17 Procedure
June 2018
24. Lower the fuel tank and keep it level with the
floor.
Remove the siphon hose.
25. The tank will need to be stored for the TSE to
conduct a final inspection and a weight check.
An additional draining process may be needed
to ensure that the maximum amount of fuel has
been extracted.
The final weight of the tank without filler cap
and plugs must be 40 pounds or less, before it
can be shipped.
Please proceed with part 2 to prepare the tank
for temporary storage and onsite inspection by
TSE.
11
SI B16 03 17 Procedure
June 2018
Part 2: Preparing and Packing The Fuel Tank to Hold for
Onsite Review by TSE.
1. The fuel tank return preparation kit includes
various plugs, caps, wire ties and bags for
securing and packaging the fuel tank
2. For the initial draining procedure, and to store
the tank in the original box, use only the
following items:
1 - Extra Large 3 Mil Clear Bag (48x35x72)
1 - Liquid Absorbent Pad
1 - Mini Re-closable Bag
1 - Cable Tie
1 - Red Silicone Stoppers
12
SI B16 03 17 Procedure
June 2018
3. The additional un-used items from the kit
should be retained in the original bag for the kit
and placed into the box with the tank.
1 - Adhesive Envelop for Shipping Documents
1 - UN3336 Label
2 - Mini Re-closable Bags
1 - DOT Label
3 - Cable Ties
1 - M24 Hex Socket Pipe Plug
1 - Red Silicone Stopper
1 - Bag containing kit contents
4. Reuse the original fuel filler cap to return the
defective fuel tank.
13
SI B16 03 17 Procedure
June 2018
5. Install one of the red tapered plugs (Red
Silicone Stopper) included in the kit onto the
short hose (fuel supply line).
6. The new fuel tank will be equipped with a black
protective cap on the short hose (fuel supply
line).
Reuse the black cap and install it on the used
fuel tanks short hose, placing it over the red
tapered plug.
7. Using one of the small bags and a cable tie
included in the kit, wrap and tie the bag so it is
covering the entire length of the black
protective cap.
14
SI B16 03 17 Procedure
June 2018
8. The new fuel tank will be equipped with a black
protective cap on the long hose that connects
to the fuel filler neck.
Reuse the black cap and install it on the used
fuel tank’s long line.
9. Remove the protective cap from the filler neck
on the new fuel tank and install it onto the used
fuel tank, in the same location.
10. Remove the electrical connector protective cap
from the new fuel tank and install it onto the
used fuel tank electrical connector.
15
SI B16 03 17 Procedure
June 2018
11. Prepare the large shipping bag included in the
kit.
12. Place the used fuel tank inside the shipping
bag.
Place the white absorbent pad included in the
kit under the center of the fuel tank.
13. Leave the shipping bag open do not seal the
bag at this time.
Place the used fuel tank, diagonally, into the
corrugated box that the new tank was received
in.
Please do not use the bag to lower the tank
into the box, as it will tear.
Ensure that the filler neck is not bent
sharply. Potential damage to the filler neck
must be avoided in order to remanufacture the
tank.
Keep the unused labels, bags and ties in the
bag and place it into the box. They will be
needed once the tank is approved for
transport.
14. DCSnet Part Tag
16
SI B16 03 17 Procedure
June 2018
a. DO NOT SHIP/RETURN THIS OR ANY
USED TANK TO THE WPRC OR RDC.
Create/submit an IDS ticket to the WPRC
indicating the VIN and that a tank is
available for pickup.
•
Inform your TSE.
•
Further instructions for next steps will be
provided once the TSE has confirmed
the weight and inspected the tank.
b. Print and attach the corresponding DCSnet
Part Return Tag or Core Return Tag to the
fuel tank.
c. Pre-tag the corrugated box to identify this
item and secure it in your center’s parts
retention area.
All tanks should be retained whether in
warranty or out of warranty.
Any damage attributed to removal, where
the tank cannot be remanufactured, will be
subject to a claim or core charge
adjustment.
17