16 12 001 Removing and Installing or Replacing Fuel Gauge Sensor (Petrol/Gasoline, Left)

16 12 001 Removing and installing or replacing fuel gauge sensor (petrol/gasoline, left)

Special tools required:







Recycling
Fuel escapes when fuel lines are detached. Have a suitable collecting vessel ready.
Catch and dispose of escaping fuel.
Observe country-specific waste disposal regulations.







IMPORTANT:
Ensure adequate ventilation in the workbay.
Avoid skin contact (wear gloves).
Before starting the engine for the first time:
- Fill fuel tank with at least 5 litres of fuel.







Necessary preliminary tasks:
- Draw off fuel from fuel tank
- Remove rear seat bench
- Remove right sensor unit







Only for E84, E87, E91:
Only unclip seat bench (1) on the left and right and fold up in direction of arrow as illustrated.
Secure seat bench on front seat (2).







Release screws (1) and remove cover (2) from left side of fuel tank.







Disconnect plug connection (1).
Press grey ring (2) towards sensor unit and pull out fuel feed line (3) straight.

IMPORTANT:
Do not use any tools to release the fuel feed line.
After installing fuel feed line, carry out tensile test and leak test.







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

Installation note:
Procedure for tightening screw cap, see next work step.







IMPORTANT:
Fit screw cap without using a tool and tighten hand-tight.
Then tighten screw cap with special tool 16 1 020 until notch (1) points to marking (2).

NOTE: Illustration shows the tank removed.







Installation note:
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.
Make sure that the lever sensor moves freely before fitting the service cap.
Clean sealing surfaces and install new seal.







Attach an auxiliary lead (1) to hose pack (2) through sensor opening.
The auxiliary lead is pulled through with the hose pack towards the left and facilitates subsequent reinstallation.

Installation note:
Make sure when pulling through the hose pack that the tank ventilation system in the tank tunnel is not damaged.







Carefully lift sensor unit (1) out of tank.
In so doing, press tab (2) against spring force in order to make it easier to feed sensor unit out of tank.

NOTE: Illustration shows the tank removed.







Remove sensor unit (1) and hose pack (2) with auxiliary cable to left

Installation note:
When replacing the sensor unit, modify the end of the auxiliary lead to the new hose pack and carefully pull in through the tank.

NOTE: Illustration shows the tank removed.