Fuel pump and fuel level sensors — removal and installation (BMW 3 Series E46)

Removal

1. There are two fuel level sensors installed in the fuel tank - on the left and right sides of the tank. The fuel pump is combined with the right level sensor. At the time of writing, the pump together with the right sensor could only be replaced as a single unit.

Right level sensor with fuel pump

2. Before removing the sensor with the pump, the tank should be completely emptied. Since there is no drain plug in the tank, it is advisable to start repair work when almost all the fuel has been used up from the tank.

3. Remove the rear seat.

4. To access the tank hatch, fold back the rubber mat.

5. Unscrew the four nuts and remove the hatch (Fig. 9.5).



6. Pull out the retainer and disconnect the electrical connector. Cut the clamp and disconnect the hose (Fig. 9.6). Be prepared for fuel to flow from the hose.



7. Unscrew the ring securing the pump unit with the level sensor. There is a BMW 16 1 020 device for unscrewing, although it is possible to make a completely acceptable substitute (Fig. 9.7). Rotate the ring counterclockwise, like a regular nut.





8. Carefully pull the pump assembly with the sensor out of the tank opening. Do not bend the sensor arm. If necessary, the fuel baffle can be disconnected from the assembly for cleaning (fig. 9.8,a,b), but no other disassembly is recommended.

Left sensor

9. Removing the left sensor is similar to removing the right one. Lift the unit and disconnect the hose going to the expansion tank from it by pressing the latch (Fig. 9.9).

Installation

10. Installation is carried out in the reverse order of removal, taking into account the following notes.

• a) Replace the sealing rings.
• b) To allow the assembly to pass through the hole in the tank, press the float lever against the fuel baffle.
• c) Turn the unit in the tank opening so that the mounting protrusion of the unit fits into the corresponding cutout in the tank opening (Fig. 9.10).
• d) Use new clamps to secure the hoses.

(The original text is available on the website BMWman)