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).

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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”

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

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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.

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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. ]

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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.