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SI B01 03 14
Warranties
March 2014
Warranties
SUBJECT
E46 SULEV (PZEV) Fuel Tanks: New Warranty Parts Return Procedure
MODEL
E46 (3 Series with the M56 engine)
SITUATION
BMW of North America, LLC (“BMW NA”) will begin offering factory remanufactured fuel tank assemblies for
E46 3 Series SULEV (Super Ultra Low Emission Vehicle)/PZEV (Partial Zero Emission Vehicle) model vehicles
with the M56 engine.
Starting in March 2014, the initial phase of the remanufacturing process will begin. When this fuel tank is replaced
and a corresponding claim is submitted for reimbursement, BMW NA will request to have the fuel tank returned
to the Warranty Parts Return Center (WPRC) after claim payment.
Please ensure that your workshop technicians and Parts department personnel handle the removed fuel
tank(s) properly to avoid unnecessary damage.
The E46 SULEV (PZEV) Fuel Tank Disposal Procedure outlined in SI B16 01 04 applies only to non-claim
related tank replacements. BMW NA will not request that these tanks be returned to the WPRC
IMPORTANT INFORMATION
A “used” fuel tank is eligible for classification as “UN3363, Dangerous Goods in Apparatus, 9.” The following
requirements apply when shipping:

There are limitations on the amount of liquid which can remain in the tank: It MUST be less than 0.5 liters
of fuel.

The tank must be placed in strong outer packaging; this topic is addressed in the procedure section.

This package is a hazardous material shipment; you are required to mark the package accordingly, as noted
in the procedure section.

As the shipper, your center is responsible for proper packaging and documentation completion.

The shipping document requires the UN number, proper shipping name and hazard class (UN3363,
Dangerous goods in apparatus, 9), the number of packages and total quantity, along with a shipper’s
certification and a signature.

The person preparing and packaging the fuel tank(s) for shipping must have received the hazardous material
training per 49CFR 172.702 and the IATA regulations. Those training records must be on file at your center.
The U.S. Department of Transportation (“DOT”) will impose substantial fines and/or penalties on the
shipper if the packaging, labeling, or documentation is not properly prepared and the customer’s (center)
copy of the hazmat shipping paperwork is not kept on file for a minimum of two (2) years.
PROCEDURE
Your center will receive a “fuel tank return” preparation kit in the box containing the replacement fuel tank.
The kit contains the plugs, caps, labels, absorbing mat and other materials, except for the duct tape, that you will
need to secure the fuel tank for packaging and shipping.
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The original box that contained the replacement fuel tank will also be needed for the part return process.
Note: It is important to extract as much fuel as possible.
To process the fuel tank for packaging and shipping, the following procedure steps MUST be followed as
described below:
1. Before removing the fuel tank from the vehicle, extract as much fuel as possible using the procedure
described in Repair Instruction 16 11 005, “Draining and filling fuel tank.”
2. Remove the fuel tank as per Repair Instruction 16 11 030, “Removing and installing fuel tank (M56).”
3. Do not drill any holes into the fuel tank to drain the fuel. The fuel tank must be received 100% intact
without any damage.
After the fuel tank has been removed from the vehicle and is placed on the ground, slightly tilt the fuel tank
so that all of the fuel moves to the part of the tank that is closest to the filler neck.
Extract the remaining fuel as described in Repair Instruction 16 11 005, “Draining and filling fuel tank.”
4. The “fuel tank return”
preparation kit includes various
plugs, caps and bags for
securing the fuel tank.
5. Reinstall the vehicle’s existing
fuel tank filler cap on the
removed fuel tank for return
shipment.
A new fuel tank filler cap will
need to be installed on the
replacement tank.
Bill out this item separately.
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6. Reconnect the fuel vent hose to
the filler neck connection.
7. Cover the connection with duct
tape, as shown. (Duct tape is
locally sourced.)
8. Insert the red rubber plug from
the kit to close the fuel line.
9. Use additional duct tape to
secure the red rubber plug to the
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fuel line.
10. Install the supplied plastic bag
over the end and use a single
wire tie to secure the bag.
11. From the kit, apply the Teflon
tape to the large metal threaded
plug.
12. Insert the threaded plug into the
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fuel tank and torque it to 15 Nm.
13. Place the fuel tank on top of the
plastic as shown.
14. Wrap the fuel tank in the large
plastic bag from the kit as shown
Insert the sheet of “absorbing
mat,” also from the kit, inside
the bag with the fuel tank.
Use the supplied wire tie to
secure and seal the open end of
the plastic bag.
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Reusing the Fuel Tank’s Corrugated Box

To return the removed and “shipping prepared” fuel tank, reuse the corrugated box that contained the
replacement fuel tank.

Pre-tag the corrugated box to identify this item, and secure it in your center’s parts retention area.

Secure the corrugated box with tape and straps as shown.
DCSnet Part Tag and Packing Slip

Print and attach the corresponding DCSnet Part Return Tag to the fuel tank.

Assign the fuel tank part tag to a DCSnet packing slip by itself, and attach it outside the corrugated box.
Assign the fuel tank part tag to a DCSnet packing slip by itself, and attach it outside the corrugated box.
Fuel Tank’s Corrugated Box Labeling

As shown, from the kit, attach the “UN3363, Dangerous Goods in Apparatus” label in the upper left
corner on the outside of the box. On the same side of the box as the “UN3363” label, attach the Class 9 label
in the center.

Return the fuel tank to the WPRC through your normal part warranty return freight procedure.
PARTS INFORMATION
Part Number
Description
Quantity
16 11 6 763 569
Fuel tank, metal with filler pipe
1
16 11 7 222 391
Filler cap
1
WARRANTY INFORMATION
When an E46 3 Series SULEV (PZEV) Fuel Tank replacement is to be reimbursed by BMW NA through a claim
submission, please claim the following labor operation and FRU allowance for performing the additional work to
process the fuel tank for return to the WPRC.
Defect Code:
Refer to KSD2
Claim with the defect code that
applies to the fuel tank replacement
Labor Operation:
Labor Allowance:
Description:
Work time to process the requested
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16 99 000
3 FRU
fuel tank for return to the WPRC as
outlined above
This work time labor is for an “associated” repair procedure.
Even though work time labor operation code 16 99 000 ends in “000,” it 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.
Sublet Materials – Duct Tape
Sublet Code 4
$1.00
Sublet reimbursement up to the amount
listed, charged to sublet code 4, for the
length of locally sourced duct tape
(Bulk quantity) required to process the
fuel tank for return.
[ Copyright ©2014 BMW of North America, Inc. ]
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