Fuel Cap Area Drain Kit for E39 BMW 5 Series (1996-2003)

The E39 5 Series lacks a water drainage point in the fuel cap area, which is a well known design flaw and can often lead to rust buildup in this area, even for cars in relatively dry climates. Water is able to easily pool underneath the fuel cap and sit for extended periods of time after rain or washing the vehicle, leading to corrosion, particularly at the seam of the fuel cap area tub where it meets the body.

D3D has first hand experience with issue and after researching solutions on the market, we found there weren't any... so we made our own! Our Fuel Cap Area Drain Kit is a complete package we've designed in-house to rectify this previously unaddressed issue. It includes all the parts you need to easily fit an effective drainage system to the fuel cap area, and only requires basic equipment for installation. It’s great either as a preventative measure, or as a final step after treating existing corrosion. The Inlet Fitting is designed to be resistant to clogs, with a notched profile that bottlenecks the system against debris - this ensures the narrowest point of the tubing is the entry point.

For international buyers, we have also made the files available for you to 3D print the required parts and put the kit together yourself if desired. You can purchase the files here.

Installation takes less than 2 hours, including time for touch-up paint to dry. All fittings and tubing are made here in Australia.

In this kit:

• 50cm of 7mm OD Drainage Hose (more than enough)
• 1x Inlet Fitting
• 1x Body Grommet
• 1x Rubber Grommet
• 1x Alcohol Wipe

Equipment required for installation:

• 10mm and 11mm drill bit (we also recommend a smaller drill bit for a pilot hole)
• 8mm and 10mm sockets
• RTV / silicone sealant
• Small needlenose pliers
• Vehicle jack
• Trim Clip Removal Tool

Recommended additional items:

• Touch-up paint
• Scissors / flush cutters
• Small metal file
• Axle stand to support vehicle jack

Please note: Because the Inlet Fitting protrudes slightly from the surface of the metal, it is unable to drain 100% of the water in the fuel cap area. However, it will drain the vast majority of water if installed correctly and keep the seam of the fuel cap area dry, which is the most common point of rust formation. This draining also makes evaporation much faster after wet weather, significantly reducing the amount of time the metal is exposed to moisture.