5 Series E39 530d (M57) SAL
VS-22/Uhse
Baugruppe/Group: 16
16 01 06 (250)
weltweit
all countries
Datum/Date:
03/2006
Inadvertent refuelling with petrol
All diesel vehicles
Situation:
The vehicle is inadvertently refuelled with petrol.
Petrol has no lubricating function. For this reason, operating the Common Rail system with
petrol will cause considerable damage to the fuel system.
Affected
vehicles:
All diesel vehicles with Common Rail system
Procedure:
If the vehicle is inadvertently refuelled with petrol, proceed as follows, depending on which
of the four possible situations is prevalent:
Case 1: Vehicle has not been started
Drain the fuel tank completely and check the fuel baffle in the fuel tank for magnetic swarf
(use a magnet). If magnetic swarf (not brass swarf or similar!) is present in the tank,
proceed as described in Case 2. If there is no magnetic swarf in the tank, fill the inlet side
of the tank with 5 litres of diesel fuel. Then reinstall the fuel level sensor. Open the tank
return line at the fuel level sensor and connect an extension to a separate collector on the
return line. Rinse the fuel system thoroughly with diesel fuel by switching the ignition on for
approx. 1 minute (this actuates the fuel pumps for approx. 1 minute). In this time, at least
2 litres of fuel should flow into the collector (the pre-supply pumps can be repeatedly
actuated via terminal 15). Now reconnect the return line to the fuel level sensor. Then
replace the fuel filter and refuel the vehicle. If the ignition is not switched on after incorrectly
refuelling the vehicle, it is sufficient to completely drain the tank (provided there is no
magnetic swarf!).
Case 2: Vehicle has been started and driven (e.g. after refuelling at the filling station)
Empty the fuel tank completely and check the fuel baffle in the fuel tank for magnetic swarf
(use a magnet). If no magnetic swarf can be detected in the system, drain and rinse the fuel
system as described in Case 1. In this case, not only the fuel filter but also the high-
pressure pump must be replaced. Then refuel the vehicle. If magnetic swarf is present in
the fuel system, proceed as described in Case 3.
Case 3: Vehicle has been driven, magnetic swarf in system
The complete fuel system, including the tank must be replaced. Only the rigid feed and
return lines remain in the vehicle (rinse in the opposite direction to the regular fuel flow).
Check the tapered connection on the high-pressure pump for friction welding. If an incipient
welding can be detected, check the engine's valve timing. Finally, refuel the vehicle. Should
the damage be greater that anticipated, proceed as described in case 4.
Case 4: Vehicle has been driven, high-pressure pump seized, camshaft broken, timing
chain(s) broken.
Note:
In conjunction with Case 4, please refer also to the separately issued PuMA
measures (e.g. "M57/M67... - Engine stops, magnetic swarf in system")!
Check the tapered connection on the high-pressure pump for friction welding. If traces can
be seen on the tapered connection, the lower chain and the chain wheel on the high-
pressure pump must be replaced. If the camshafts cannot be turned, damage analysis on
the engine mechanics must be performed at the cylinder head (lower chain broken, broken
SI Inadvertent refuelling with petrol All diesel vehicles
BMW AG - TIS
20.02.2013 08:59
Issue status (12/2007) Valid only until next DVD is issued
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