16 12 001 Removing and installing / replacing fuel gauge sensor (left)

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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. Refer to 16 00 005 Draining and filling fuel tank .
Remove rear seat, refer to 52 24 005 REMOVING AND INSTALLING/REPLACING REAR SEAT (NORMAL) or 52 25 010 REMOVING AND INSTALLING/REPLACING LEFT OR RIGHT REAR SEAT

Fold floor trim (1) forwards.

Fig 1: Folding Floor Trim

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

Fold back rubber mat.

IMPORTANT: Do not damage gasket.

Release screws (1) and fold back metal cover.

Fig 2: Folding Back Metal Cover

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IMPORTANT: Fuel hoses are pressurized.

Unfasten plug connection (1) and disconnect.

Fig 3: Disconnecting Plug Connection

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Unfasten hoses and detach carefully.

Do not damage connecting piece when doing so.

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

Fig 4: Releasing Screw Cap With Special Tool

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Installation:

Replace seal.

Tightening torque 16 14 2AZ. Refer to FUEL SUPPLY SYSTEM - TIGHTENING TORQUES .

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

Fig 5: Identifying Service 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.

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

Replace seal.

IMPORTANT: Do not bend sensor.

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

Fig 6: Removing Fuel Level Sensor

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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.

Installation:

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

Fig 7: Replacing O-Ring On Fill Level Sensor

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Check that O-ring is correctly seated when installed.

Connection of suction jet pump is transparent.

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: Installing Fuel Level Sensor

Courtesy of BMW OF NORTH AMERICA, INC.