16 12 001 Removing and installing or replacing fuel gauge sensor (petrol/gasoline, left)

WARNING: This page does not describe the selected car, but rather 11 other vehicles, including the 2008 BMW 328xi, 2008 BMW 328i, 2008 BMW 323i, 2007 BMW 328xi, and 2007 BMW 328i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

16 1 020

IMPORTANT: Ensure adequate ventilation in the place of work!

Ensure absolute cleanliness when working on the open fuel tank.

Contaminants in the fuel tank can impair driving operation or may even result in vehicle breakdown!

Necessary preliminary tasks:

Release screws (1) and remove cover (2) from left side of fuel tank.

Fig 1: Identifying Fuel Tank Cover And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Disconnect plug connection (1).

Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.

IMPORTANT: Do not use any tools to release the fuel feed line.

After installing fuel feed line, carry out tensile test and leak test.

Fig 2: Identifying Fuel Sensor Plug Connection, Grey Ring And Fuel Feed Line

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw cap with special tool 16 1 020 and remove service cap.

Installation:

Procedure for tightening screw cap, see next work step.

Fig 3: Identifying Special Tool (16 1 020)

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Fit screw cap without using a tool and tighten hand-tight.

Then tighten screw cap with special tool 16 1 020 until notch (1) points to marking (2).

NOTE: Illustration shows the tank removed.

Fig 4: Identifying Screw Cap Notch And Marking

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Service cap can only be installed in one position.

When installing, make sure lug (1) of service cap engages in corresponding opening (2) on fuel tank.

Make sure that the lever sensor moves freely before fitting the service cap.

Clean sealing faces and install new seal.

Fig 5: Identifying Corresponding Fuel Lever Sensor Lug And Opening

Courtesy of BMW OF NORTH AMERICA, INC.

Attach an auxiliary lead (1) to hose pack (2) through service opening.

The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.

Installation:

Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not damaged.

Fig 6: Identifying Auxiliary Lead And Hose Pack

Courtesy of BMW OF NORTH AMERICA, INC.

Carefully lift sensor unit (1) out of tank.

In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.

NOTE: Illustration shows the tank removed.

Fig 7: Identifying Fuel Sensor Unit And Tab

Courtesy of BMW OF NORTH AMERICA, INC.

Remove sensor unit (1) and hose pack (2) with auxiliary cable to left.

Installation:

When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in through the tank.

NOTE: Illustration shows the tank removed.

Fig 8: Identifying Sensor Unit And Hose Pack

Courtesy of BMW OF NORTH AMERICA, INC.