16 12 001 Removing and installing or replacing fuel gauge sensor (gasoline, left)

WARNING: This page is about a different car, the 2011 BMW M3, 2010 BMW M3, 2009 BMW M3, and 2008 BMW M3. However, it is still accessible from the selected car via links, so may be relevant.

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
Remove rear seat bench See 5226005 REMOVING AND INSTALLING/REPLACING REAR SEAT (THROUGH-LOADING) or 5224005 REMOVING AND INSTALLING OR REPLACING REAR SEAT
Remove RIGHT SENSOR UNIT

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

Fig 1: Identifying Fuel Tank Cover And Screws

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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: Removing Screw Cap Using Special Tool (16 1 020)

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Release screw cap with special tool 16 8 020 LIFTING GEAR and remove service cap.

Installation:

Procedure for tightening screw cap, see next work step.

Fig 3: Removing Screw Cap Using Special Tool (16 1 020)

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Fit screw cap without using a tool and tighten hand-tight.

Then tighten screw cap with special tool 16 8 020 LIFTING GEAR until notch (1) points to marking (2).

NOTE: Illustration shows the tank removed.

Fig 4: Identifying Notch And Marking On Screw 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.

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

Clean sealing faces and install new seal.

Fig 5: Identifying Lug And Opening On Fuel Tank

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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: Identifying Auxiliary Lead And Hose Pack

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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

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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 With Auxiliary Cable

Courtesy of BMW OF NORTH AMERICA, INC.