Fuel/Fuel Pump Sensor — Removal and Installation (BMW 7 Series E32)

BMW cars have one fuel quantity sensor in each part of the fuel tank. To check the sensors, you need to remove them. In the sensor on the right side of the tank (looking in the direction of travel) the fuel pump is located (tank pump). To remove the pump, you need to remove the right sensor.

Removal

It is necessary to ensure good ventilation of the workplace and observe fire safety measures.

Caution: To remove the fuel quantity sensor, there must be no fuel in the tank. To do this, you must completely use up the fuel or pump the fuel out with a suitable pump into a larger container or canister. Fuel vapors are toxic and explosive, so ensure good ventilation of the workplace.

Disconnect the negative cable from the battery, which is located in the trunk behind the right trim panel.

Remove the rear seat cushion.

Pull out the rubber grommet on the left or right under the seat. Cut the insulating mat with a sharp knife and fold it back.



Unscrew the fastening screws and remove the cover with the gasket.

Right Fuel Tank Sensor with Fuel Pump - Removal

Unscrew the screws and remove the cover.



Remove the plugs (1) and (2) by releasing the clips by squeezing them.

Mark the fuel hoses (3) and (4) and remove them from the fuel quantity sensor, after loosening the clamps.

Caution: The fuel system is under pressure, so the hose should be pulled slowly and any spilled fuel should be collected with a rag.

Loosen the union nut by gently tapping it to the left. You can use a tool, but a wooden block will do just fine.

Note: There should be no sparks.

Lift the fuel tank sensor, tilt it to the side and remove it. Place a rag underneath to catch any dripping fuel.

Squeeze the fuel pump retainer (black case). Remove the fuel pump from the submerged unit (white case).



Disconnect the two plugs (1) from the fuel pump.



Release the wire tapes (2). Release the spiral hose clamp, carefully pull the hose off the fuel pump.

Note: The wire strips are at the level of the white marks, which must be taken into account during installation.

Left Fuel Tank Sensor - Removal

Unscrew the screws and remove the cover.

Remove the plug from the sensor by releasing the retainer by squeezing it.

Loosen the clamp and pull the fuel hose off the fuel tank sensor.

Caution: The fuel system is under pressure, so remove the hose slowly and collect any escaping fuel.

Loosen the union nut by gently tapping it to the left. You can use a special device, but a wooden block will do just fine.

Note: There should be no sparks.

Pull the sensor out a little. From the bottom, squeeze the two protrusions for the pump pipe and pull the pipe off. Take out the sensor. At the same time, put a rag under it to collect the leaking fuel.

Installation

Caution: Be sure to replace the sensor O-rings.

Left sensor: Insert the sensor and hold it about 5 cm above the tank. Secure the pump pipe.

Right sensor: Attach the fuel pump to the sensor and put on the plugs.

Before installing the spiral hose (black spare part with white alignment marks) align the wire (2) between the sensor (1) and the fuel pump (3) to avoid putting too much strain on it.





Align the sensor by turning it. The protrusion on the top of the sensor should fit into the recess on the tank. The sensor should be positioned vertically in the tank, with the lower probe in the center of the bottom of the tank.

Install the union nut and tighten it to 35 Nm. The swivel mount should click into place with a click in the corresponding recess on the tank.

Place the fuel hoses according to the marks made earlier and secure them with new clamps.

Put on the plugs and secure them.

Install the cover and secure it with screws, making sure the gasket is seated correctly.

Install the rear seat cushion.

Connect the negative cable to the battery.

Check the operation of the fuel gauge on the instrument panel.