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Old 09-26-2017, 04:17 PM
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Join Date: Aug 2017
Location: Florida
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Zack is on a distinguished road
Borked my fuel service cap! ('05 X3 2.5i)

Hey everyone,

I am embarrassed that my first post here is a call for help after getting frustrated and losing my temper a bit while working... but, here we are...

I borked the right (passenger side) fuel tank service cap on my 2005 X3 2.5i (6sp MT, 156k mi). "Borked", as in the urban dictionary definition -- meaning to break something so badly and so stupidly, the word "broke" doesn't quite cut it.

Image of borked cap: https://imgur.com/a/Ab0D4

In attempting to loosen the metal retaining ring, which was apparently frozen to the white plastic service cap from accumulation of grime and time, the entire assembly (retaining ring + service cap) rotated. In doing so, all of the connections to the service cap from inside the fuel tank (wiring and breather/fuel hoses) snapped. BORKED.

Do any of you fine folks have experience/insight on how to go about fixing this? Seeing if I might be able to replace things piecemeal, I tried to trace the hoses and wires inside the tank (which is essentially empty) back to where they originated from, but the clearances are too small relative to my arms/hands to successfully get back that far, and the saddle shape of the tank makes me concerned for trying to route the wiring that runs from the left (driver's side) fuel level sender to the harness on the right side. Am I missing something obvious (hopefully)??

Thanks for any insight, y'all!

Last edited by Zack; 09-26-2017 at 05:01 PM. Reason: Title clarification
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fuel cap, fuel filter, fuel line, pump, wiring

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