16 12 000 Removing and installing or replacing fuel gauge sensor (petrol/gasoline, right)

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2013 BMW 128i, 2012 BMW 128i, 2011 BMW 128i, 2010 BMW 128i, and 2009 BMW 128i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

16 1 020

See FUEL SUPPLY SYSTEM - SPECIAL TOOLS (N51, N52K) .

Recycling

Fuel escapes when fuel lines are detached. Have a suitable collecting container ready.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

IMPORTANT: Ensure adequate ventilation in the place of work!
Avoid skin contact (wear gloves)!
Before starting the engine for the first time:

Fill fuel tank with at least 5 liters of fuel.

Necessary preliminary tasks:

Draw off Draw off fuel from fuel tank
Remove rear seat bench . See SEATS - REPAIR (CONVERTIBLE) or SEATS - REPAIR (COUPE) .

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

Fig 1: Identifying Fuel Tank, Cover And Screws

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USA national version:

Disconnect plug connection (1).

Unlock and detach vent lines (2).

If necessary, remove fuel line for independent heating.

Fig 2: Identifying Plug Connection And Vent Lines

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ECE national version:

Disconnect plug connection (1).

Unlock and detach vent line (2).

If necessary, remove fuel line for independent heating.

Fig 3: Identifying Plug Connection And Vent Line

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

Installation:

Procedure for tightening screw cap, see next work step.

Fig 4: Identifying Special Tool (16 1 020)

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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 5: Identifying Marking Points Of Notch

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Carefully raise service cap (1).

Unlock and detach vent line (2).

Installation:

Clean sealing faces and install new seal (3).

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

Locating rods (4) must fit correctly in the hole of the delivery unit.

Fig 6: Identifying Vent Line And Service Cap

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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.

Fig 7: Identifying Fuel Tank And Lug

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Unclip black return lines (1) from bracket.

Unlock and disconnect quick-release fastener (2) of fuel line.

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

Draw off remaining fuel from surge chamber.

Carefully lift fuel pump with fuel level sensor (3) out of fuel tank.

If necessary, turn fuel pump 90° counterclockwise and tilt towards lever sensor.

Fig 8: Identifying Black Return Lines And Quick-Release Fastener

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Removing fuel level sensor:

Carefully unlock tabs (1) and pull off fuel level sensor upwards in direction of arrow.

Disengage line (2) from holders.

Unlock plug connection (3) and detach from service cap.

Installation:

Fuel level sensor and cable connector must audibly snap into place!

IMPORTANT: Risk of damage:
Carefully feed cable out of cable guide.
Do not kink cable.

Fig 9: Identifying Plug Connection And Holders

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