16 12 001 Removing And Installing Or Replacing Fuel Gauge Sensor (Petrol/Gasoline, Left)

WARNING: This page is about a different car, the 2010 BMW 135i, 2009 BMW 135i, and 2008 BMW 135i. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

For the following special tools, refer to FUEL SUPPLY SYSTEM .

16 1 020

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 fuel from fuel tank . See 16 00 005 DRAINING AND FILLING FUEL TANK .
Remove rear seat bench . See SEATS - REPAIR (CONVERTIBLE) or SEATS - REPAIR (COUPE) .
Remove right sensor unit . See 16 12 000 REMOVING AND INSTALLING OR REPLACING FUEL GAUGE SENSOR (PETROL/GASOLINE, RIGHT) .

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

Fig 1: Identifying Fuel Tank Cover

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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: Pressing Grey Ring Towards Sensor Unit

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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 3: Removing Service Cap

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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 4: Identifying Screw Cap Notch

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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.

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

Clean sealing faces and install new seal.

Fig 5: Identifying Service Cap Lug

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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: Attaching Auxiliary Lead To Hose Pack Through Service Opening

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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: Lifting Sensor Unit Out Of Tank

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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: Removing Sensor Unit And Hose Pack

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