16 12 000 Removing And Installing / Replacing Fuel Gauge Sensor (Right)

WARNING: This page is about a different car, the 2008 BMW Alpina and 2007 BMW Alpina. 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:

Draw off fuel from fuel tank . See 16 00 005 DRAINING AND FILLING FUEL TANK .
Remove rear seat . See 52 24 005 REMOVING AND INSTALLING/REPLACING REAR SEAT (NORMAL) .

Fold floor trim panel (1) (carpet) forwards.

Detach insulating mat (2) at perforation and fold back towards rear. Pop out rubber plugs here.

Fold back rubber mat.

Fig 1: Detaching Insulating Mat At Perforation

G04740470

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Do not damage gasket.

Release screws (1) and fold back metal cover.

Fig 2: Releasing Screws And Folding Metal Cover

G04740471

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Fuel hoses are pressurized.

Unfasten plug connection (1) and disconnect.

Unfasten hoses and detach carefully.

Do not damage connecting piece when doing so.

Fig 3: Identifying Plug Connection

G04774095

Courtesy of BMW OF NORTH AMERICA, INC.

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

Installation:

Replace seal.

Tightening torque. See FUEL SYSTEM - TIGHTENING TORQUES .

Fig 4: Identifying Special Tool (16 1 020)

G04725775

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Risk of breakage!
Carefully raise service cap. In so doing, do not pull excessively on connecting piece of fuel feed.

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.

During torque tightening, notch (3) on screw cap can be clearly heard and felt to engage toothed segment (4) on fuel tank.

Replace seal.

Fig 5: Identifying Lug, Notch On Screw Cap And Toothed Segment

G04740474

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Do not bend sensor.

Disconnect plug connection (2).

Disengage fuel level sensor (1) and carefully feed out of tank opening.

Fig 6: Identifying Plug Connection And Fuel Level Sensor

G04774098

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Fuel level sensor for fuel gauge on right with plug connections.

Fig 7: Identifying Fuel Level Sensor With Plug Connections

G04774099

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Only when changing fuel pump:
Carefully remove cap with spiral hose and fuel pump from fuel tank.

Fig 8: Identifying Cap With Spiral Hose And Fuel Pump

G04774100

Courtesy of BMW OF NORTH AMERICA, INC.