Removal and Installation of Fuel Level Sensor and Fuel Pump

The BMW 5 Series has one fuel level sensor in each fuel tank compartment. To check the sensors, they must be removed. The fuel pump (tank pump) is located in the sensor on the right side of the tank. To remove the pump, the right sensor must be removed.

Removal

Always ensure the work area is well ventilated. Fuel vapors are toxic. Do not use open flame and do not smoke. Fire hazard! Keep a fire extinguisher ready.

* To remove the fuel tank sensor, the fuel must be drained. Either drive the vehicle until the tank is empty or pump the fuel out. Fuel vapors are toxic. Do not inhale them. It is recommended to perform this work outdoors.

PROCEDURE
1. Disconnect the negative battery cable. The battery is located in the luggage compartment behind the right side trim.

* Disconnecting the battery erases data stored in electronic control module memories, such as engine fault memory. Refer to the recommendations in the Battery Removal and Installation section.

2. Remove the rear seat. Refer to the Rear Seat Removal and Installation section.
3. Push out the rubber grommets on the left and right under the seat. Cut the mats along the perforated line with a sharp knife and fold back. Refer to the accompanying illustration.

4. Remove the mounting bolts and remove the cover with seal. Refer to the accompanying illustration.

Removal of Right Fuel Tank Sensor with Fuel Pump

PROCEDURE
1. Remove the mounting bolts and remove the cover (1). Refer to the accompanying illustration.

2. Disconnect connectors (1) and (2). To do so, open the locks. Refer to the accompanying illustration.
7 Mark fuel hoses (3) and (4) with adhesive tape and disconnect them from the fuel tank sensor by opening the clamps.

* The fuel system is under pressure. Therefore, remove the hose carefully. Wipe up spilled fuel with a rag.

8 Carefully loosen the union nut (5) by tapping it. Workshops use special tool BMW 16 1 020 for this. A wooden block can also be used. Do not create sparks during this work.

3. Lift the sensor, tilt it to the side and remove it. Place a rag underneath and wipe up any leaked oil.

4. Squeeze the fuel pump retainer (black housing). Remove the pump from the reservoir cup (white housing). Refer to the accompanying illustration.

5. Disconnect both connectors (1) from the fuel pump. Refer to the accompanying illustration.
6. Open the clamps (2). Open the spiral hose clamp. Carefully disconnect the hose from the fuel pump.

* The cable clamps are located at the level of the white markings. Pay attention to this during installation.

Removal of Left Fuel Tank Sensor

PROCEDURE
1. Remove the mounting bolts and remove the cover (2).

2. Disconnect the fuel tank connector. To do so, open the locks.
3. Disconnect the fuel hose from the tank sensor by opening the clamps.

* The fuel system is under pressure. Therefore, remove the hose carefully. Wipe up spilled fuel with a rag.

4. Carefully loosen the union nut (5) by tapping it. Workshops use special tool BMW 16 1 020 for this. A wooden block can also be used. Do not create sparks during this work.

5. Lift the sensor. From the underside, squeeze the two retainers of the pump tube and remove the tube. Remove the fuel tank sensor. Place a rag underneath and wipe up any spilled oil.

Installation

* Always replace the fuel sensor O-rings with new ones.

PROCEDURE
1. Left tank sensor:
18 Insert the sensor and hold it approximately 5 cm above the tank. Insert the tube into the pump.
Right tank sensor:
19 Secure the fuel pump to the fuel sensor and connect the hoses.

2. To prevent binding, before installing the tank sensor, position the spiral hose and cable (2) between the level sensor (1) and the fuel pump (3). Refer to the accompanying illustration.

3. Position the tank sensor. The tab at the top of the fuel sensor must engage the slot in the tank. The sensor must be vertical in the tank. The bottom measuring probe must be located in the groove in the bottom of the tank.
4. Tighten the union nut to 35 N·m. The rotary lock must click audibly into the corresponding recess in the tank.
5. Connect the fuel hoses according to the markings and secure them with new clamps.
6. Mate the connectors and lock them.
7. Install the cover and secure it. Make sure the seal is positioned correctly.
8. Install the rear seat.
9. Connect the negative battery cable. Set the clock. Program the radio stations.
10. Check the operation of the fuel reserve indicator on the instrument panel.