16 12 000 Removing and installing/replacing sensor for fuel gauge (S63)

WARNING: This page does not describe the selected car, but rather 50 other vehicles, including the 2016 BMW M5, 2016 BMW ActiveHybrid 5, 2016 BMW 550i xDrive, 2016 BMW 550i, and 2016 BMW 535i xDrive. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

Recycling

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

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

IMPORTANT: Ensure adequate ventilation in the workbay!
Avoid skin contact (wear gloves)!
Ensure absolute cleanliness when performing repair work on the open fuel system. Dirt contamination in the fuel tank may impair driving or may even result in vehicle breakdown.

Necessary preliminary tasks:

DRAW OFF FUEL .
Remove REAR SEAT BENCH .

Fold both floor trims (1) to the side.

Unfasten screws (2).

Remove cover for service opening (3).

Fig 1: Identifying Floor Cover And Screws

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Release lock (1) in direction of arrow.

Pull off fuel line (2).

Disconnect plug connection (3).

If necessary, disconnect fuel line for auxiliary heating.

Installation note:

Make sure the fuel line engages correctly.

Fig 2: Identifying Fuel Line And Plug Connections

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Release nuts (1) and remove retaining ring (2).

Raise flange cover.

Installation note:

Tighten down nuts (1) in diagonal sequence.

Replace nuts (1).

Tightening torque 16 14 2AZ.

Fig 3: Identifying Retaining Ring And Nuts

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Installation note:

Bulge on flange cover (1) must line up with mark (2) on fuel tank.

Fig 4: Identifying Mark On Fuel Tank

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Disconnect plug connection (1).

Rubber seal (2) must always be replaced.

Fig 5: Identifying Rubber Seal And Plug Connection

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NOTE: Picture does not show the fuel tank outer skin.

Move retaining tabs (1) in direction of arrow through service opening.

Unclip fuel level sensor (2) in the direction of the arrow vertically towards the top.

Installation note:

Insert fuel level sensor (2) into the bracket from the top and press downwards onto the limit position.

The fuel level sensor (2) must engage audibly.

Fig 6: Identifying Level Sensor And Retaining Tabs

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NOTE: Picture does not show the fuel tank outer skin.

Detach cable (1) of the fuel level sensor from the bracket (2).

Installation note:

Ensure correct routing of cable (1).

Unclip the plug connector of the fuel level sensor (3) from the plug connector of the left installation unit.

Remove fuel level sensor.

Fig 7: Detaching Cable Of Fuel Level Sensor From Bracket

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