Withdrawal
Ensure perfect ventilation of the work area. Fuel vapors are poisonous, no open flames, no smoking, fire hazard! Prepare a fire extinguisher.
Attention: When removing the fuel level sensor, the fuel tank must be empty. Therefore, the contents of the tank should either be used up during the trip, or sucked off with a suitable pump into a suitable large container. Fuel vapors are poisonous, do not inhale. Work should be carried out as far as possible in the open air or take care of good ventilation.
Disconnect ground wire (-) battery. The battery is located in the luggage compartment behind the right side trim.
Attention: This erases the contents of memory devices, such as the engine trouble code memory. Follow the instructions given in the chapter "Removing and installing the battery".
Remove rear seat.
Fold out the rubber insert on the left or right under the rear seat respectively. Cut the insulating mat along the perforation line with a sharp knife and fold back.
Unscrew the cover and remove together with the sealing ring.
Removing the right fuel level sensor together with the fuel pump
Unscrew cover -1-.
1 - plug connector of the fuel pump;
2 - plug connector of the fuel level sensor;
3 - fuel supply hose to the fuel pump;
4 - hose to autonomous heating system (if any).
Unplug connectors -1- and -2-. To detach, squeeze the retaining tabs.
Mark fuel hoses -3- and -4- with tags and disconnect from the fuel level sensor, after releasing the worm or terminal clamps.
Attention: The fuel system is under pressure, so remove the fuel hose slowly and, if possible, collect splashed fuel with a rag.
Carefully loosen union nut -5- using BMW special tool 161020. If there is no special tool, you can use a strong wooden rod.
Caution: When released, no sparks should be produced.
Pull the fuel level sensor up, tilt it to the side and remove it. Before removing, place a rag underneath and catch any escaping fuel.
Remove fuel pump holder (black case 1). Pull the fuel pump out of the glass (white case) with a dovetail guide.
Disconnect both plugs -1- from fuel pump.
Loosen tie-down clamps -2-. Loosen the hose clamp with protective spiral braid and carefully remove it from the fuel pump.
Note: The tie straps are positioned at the white markings, please note during subsequent assembly.
Removing the left fuel level sensor
Unscrew cover -2-, see figure W-2066.
Disconnect the plug from the fuel level sensor. To remove, squeeze the retaining tabs.
Disconnect the fuel hose from the fuel level sensor, after releasing the worm or terminal clamp.
Attention: The fuel supply system is under pressure, so remove the fuel hose slowly and, if possible, collect splashed fuel with a rag.
Loosen the union nut carefully using the BMW special tool 161020. If there is no special tool, you can use a strong wooden rod.
Caution: When released, no sparks should be produced.
Pull the fuel level sensor up a little. From the underside, squeeze the two retaining projections of the fuel pump pipe and remove the pipe. Remove the fuel level sensor. Before removing, place a rag underneath and catch any escaping fuel.
Installation
Attention: The O-rings of the pilots of the fuel level must be replaced.
Left fuel level sensor: insert the sensor and hold it above the fuel tank at a height of approx. 5 cm. Fasten the fuel pump pipe.
Right fuel level sensor
Attach the fuel pump to the fuel level sensor and connect the connectors.
Before installation, hose with protective spiral braid (Spare part in black with white markings) and straighten the wire -2- between the pilot of the fuel level -1- and the fuel pump -3- to avoid tension.
Rotate the fuel level sensor to the correct position, in which the protrusion on the top of the sensor should fit into the recess on the fuel tank. The sensor must be located vertically in the fuel tank, its lower part must fit into the guide located on the bottom of the tank.
Attach the union nut and tighten to 35 Nm. In this case, the nut should be fixed with a clearly audible and tangible click relative to the protrusion on the tank.
Put on the fuel hoses in accordance with the marked marks and tighten with new clamps.
Insert and secure electrical plugs.
Attach and fasten the cover, while paying attention to the correct position of the sealing gasket.
Install the rear seat.
Connect ground wire (-) battery. Set the clock and tune the radio to transmitting radio stations.
Check the operation of the fuel gauge on the instrument panel.