16 12 001 Removing And Installing / Replacing Fuel Gauge Sensor (Left)

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 (1) 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

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IMPORTANT: Do not damage gasket.

Release screws (1) and fold back metal cover.

Fig 2: Releasing Screws And Folding Metal Cover

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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

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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)

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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

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IMPORTANT: Do not bend sensor.

Carefully pull fuel level sensor (1) upwards until suction jet pump connection is accessible.

Unlock connection (2) of suction jet pump and carefully detach towards bottom.

Carefully withdraw fuel level sensor, tilted in direction of travel towards left.

Installation:

Retaining lugs must be completely engaged.
Replace rubber seal on fuel level sensor.
Insert rubber seal before pressing fuel level sensor into tank opening.
Press fuel level sensor into tank opening.

Fig 6: Identifying Fuel Level Sensor And Connection
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Installation:

Replace O-ring (1) on fill level sensor. Before fitting, grease O - ring with a light coating of engine oil.

Check that O-ring is correctly seated when installed.

Connection of suction jet pump is transparent.

Fig 7: Identifying O-Ring

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IMPORTANT: Comply with the following installation instruction without fail.

Installation:

When installing fuel level sensor, comply with the following without fail:

Insert fuel level sensor flange (1) horizontally into tank opening so that sensor foot (2) is positioned vertically in recess (3) in bottom of fuel tank.
Press fuel level sensor flange into tank opening.
Fuel level sensor flange must remain in pressed-in position! When the flange is partially pressed out, the sensor foot (2) is not in the recess (3) in the bottom of the fuel tank.
Line set (5) must not interlock with sensor arm (4).

Fig 8: Identifying Fuel Level Sensor Flange, Sensor Foot And Sensor Arm
Courtesy of BMW OF NORTH AMERICA, INC.