BMW Cars 1999-06

Removal & Installation 2

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3.2L (S52) Engines



  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Disconnect the connector by pulling it free from the plug.
    NOTE
    Ensure that area around fuel tank screw connection is clean.



    Click image to see an enlarged view

    Fig. The location of the plug-in connector (arrow)

  4.  
  5. Remove the fuel return hose and tank expansion hose. Tank expansion lead is fitted inside fuel tank.

    Click image to see an enlarged view

    Fig. The fuel return hose (1) and the tank expansion line (2)

  6.  
  7. Covering the sensor, there is a rotary ring that must be unfastened.
  8.  
  9. Carefully withdraw the fuel level sensor by pressing the height button slightly towards the housing.
  10.  

To install:

  1. Replace the sealing ring. Check the rotary connection for damage and replace it if necessary.
  2.  
  3. The marker rib on the fuel level sensor must match the mark on the fuel tank.
    CAUTION
    The fuel return hose and the tank expansion line are pressed with preload to the base of fuel tank. The swing-arm and the float must still move easily.



    Click image to see an enlarged view

    Fig. The marker rib on the fuel level sensor must match the mark on the fuel tank

  4.  
  5. Swivel the air valve and float into the fuel tank.
  6.  
  7. Press the fuel level sensor vertically into its correct position with the height sensor perceptibly in contact with the base of the fuel tank.

    Click image to see an enlarged view

    Fig. The installation of the fuel level sensor unit

  8.  

Left Side Sensor



  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Remove the rear bench seat.
  4.  
  5. Fold the floor trim panel forwards and cut the insulating mat at the perforation and fold back and out of the way. This will expose the rubber grommet.
  6.  
  7. Unscrew the hexagon nuts, remove the cover to the fuel level sensor.

    Click image to see an enlarged view

    Fig. The nuts (1) and the cover (2) to the fuel level sensor

  8.  
  9. Unfasten plug connection on the sensor and disconnect it from the unit.
  10.  
  11. Release the hose clamps to disconnect the hose.

    Click image to see an enlarged view

    Fig. The connector (1) on top of the sensor, along with the hose clamp (2) and the hose (3)

  12.  
  13. Covering the sensor, there is a rotary ring that must be unfastened.
  14.  
  15. Carefully withdraw the fuel level sensor.
  16.  
  17. Once out, depress the tab to remove the tank expansion line.

    Click image to see an enlarged view

    Fig. Depress the tab (1) to remove the tank expansion line

  18.  

To install:

  1. Ensure that non-return valve is fitted in tank expansion line.
  2.  
  3. If the air valve does not function, the fuel delivery unit (right) must be removed.
  4.  
  5. After removal of fuel level sensor (left), check whether tank expansion lead (1) has engaged in surge tank (2).

    Click image to see an enlarged view

    Fig. Check whether the tank expansion lead (1) has engaged in surge tank (2)

  6.  
  7. Replace the rubber seal that goes between the tank and the sensor
  8.  
  9. Tighten down the rotary ring
  10.  
  11. When installing the fuel level sensor, ensure that the lug (1) is fitted properly into the recess (2) on to of the tank.
  12.  
  13. When tightening the notch (3) on the screw cap, it can be heard clicking and felt engaging the toothed portion (4) of the tank.
  14.  

  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Remove the rear bench seat.
  4.  
  5. Fold the floor trim panel forwards and cut the insulating mat at the perforation and fold back and out of the way. This will expose the rubber grommet.
  6.  
  7. Unscrew the hexagon nuts, remove the cover to the fuel level sensor.

    Click image to see an enlarged view

    Fig. The nuts (1) and the cover (2) to the fuel level sensor

  8.  
  9. Unfasten plug connection on the sensor and disconnect it from the unit.
  10.  
  11. Release the hose clamps to disconnect the hose.

    Click image to see an enlarged view

    Fig. The connector (1) on top of the sensor, along with the hose clamp (2) and the hose (3)

  12.  
  13. Covering the sensor, there is a rotary ring that must be unfastened.
  14.  
  15. Carefully withdraw the fuel level sensor.
  16.  
  17. Once out, depress the tab to remove the tank expansion line.

    Click image to see an enlarged view

    Fig. Depress the tab (1) to remove the tank expansion line

  18.  

To install:

  1. Ensure that non-return valve is fitted in tank expansion line.
  2.  
  3. If the air valve does not function, the fuel delivery unit (right) must be removed.
  4.  
  5. After removal of fuel level sensor (left), check whether tank expansion lead (1) has engaged in surge tank (2).

    Click image to see an enlarged view

    Fig. Check whether the tank expansion lead (1) has engaged in surge tank (2)

  6.  
  7. Replace the rubber seal that goes between the tank and the sensor
  8.  
  9. Tighten down the rotary ring
  10.  
  11. When installing the fuel level sensor, ensure that the lug (1) is fitted properly into the recess (2) on to of the tank.
  12.  
  13. When tightening the notch (3) on the screw cap, it can be heard clicking and felt engaging the toothed portion (4) of the tank.
  14.  

  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Remove the rear bench seat.
  4.  
  5. Fold the floor trim panel forwards and cut the insulating mat at the perforation and fold back and out of the way. This will expose the rubber grommet.
  6.  
  7. Unscrew the hexagon nuts, remove the cover to the fuel level sensor.

    Click image to see an enlarged view

    Fig. The nuts (1) and the cover (2) to the fuel level sensor

  8.  
  9. Unfasten plug connection on the sensor and disconnect it from the unit.
  10.  
  11. Release the hose clamps to disconnect the hose.

    Click image to see an enlarged view

    Fig. The connector (1) on top of the sensor, along with the hose clamp (2) and the hose (3)

  12.  
  13. Covering the sensor, there is a rotary ring that must be unfastened.
  14.  
  15. Carefully withdraw the fuel level sensor.
  16.  
  17. Once out, depress the tab to remove the tank expansion line.

    Click image to see an enlarged view

    Fig. Depress the tab (1) to remove the tank expansion line

  18.  

To install:

  1. Ensure that non-return valve is fitted in tank expansion line.
  2.  
  3. If the air valve does not function, the fuel delivery unit (right) must be removed.
  4.  
  5. After removal of fuel level sensor (left), check whether tank expansion lead (1) has engaged in surge tank (2).

    Click image to see an enlarged view

    Fig. Check whether the tank expansion lead (1) has engaged in surge tank (2)

  6.  
  7. Replace the rubber seal that goes between the tank and the sensor
  8.  
  9. Tighten down the rotary ring
  10.  
  11. When installing the fuel level sensor, ensure that the lug (1) is fitted properly into the recess (2) on to of the tank.
  12.  
  13. When tightening the notch (3) on the screw cap, it can be heard clicking and felt engaging the toothed portion (4) of the tank.
  14.  

Right Side Sensor



  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Remove the rear bench seat.
  4.  
  5. Fold the floor trim panel forwards and cut the insulating mat at the perforation and fold back and out of the way. This will expose the rubber grommet.
  6.  
  7. Unscrew the hexagon nuts, remove the cover to the fuel level sensor.

    Click image to see an enlarged view

    Fig. The nuts (1) and the cover (2) to the fuel level sensor

  8.  
  9. Unfasten plug connection on the sensor and disconnect it from the unit.
  10.  
  11. Release the hose clamps to disconnect the hose.

    Click image to see an enlarged view

    Fig. The connector (1) on top of the sensor, along with the hose clamp (2) and the hose (3)

  12.  
  13. Covering the sensor, there is a rotary ring that must be unfastened.
  14.  
  15. Remove the sensor.
  16.  

To install:

  1. Replace the rubber seal that goes between the tank and the sensor
  2.  
  3. Tighten down the rotary ring
  4.  
  5. When installing the fuel level sensor, ensure that the lug is fitted properly into the recess on to of the tank.
  6.  
  7. When tightening the notch on the screw cap, it can be heard clicking and felt engaging the toothed portion of the tank.
  8.  

  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Remove the rear bench seat.
  4.  
  5. Fold the floor trim panel forwards and cut the insulating mat at the perforation and fold back and out of the way. This will expose the rubber grommet.
  6.  
  7. Unscrew the hexagon nuts, remove the cover to the fuel level sensor.

    Click image to see an enlarged view

    Fig. The nuts (1) and the cover (2) to the fuel level sensor

  8.  
  9. Unfasten plug connection on the sensor and disconnect it from the unit.
  10.  
  11. Release the hose clamps to disconnect the hose.

    Click image to see an enlarged view

    Fig. The connector (1) on top of the sensor, along with the hose clamp (2) and the hose (3)

  12.  
  13. Covering the sensor, there is a rotary ring that must be unfastened.
  14.  
  15. Remove the sensor.
  16.  

To install:

  1. Replace the rubber seal that goes between the tank and the sensor
  2.  
  3. Tighten down the rotary ring
  4.  
  5. When installing the fuel level sensor, ensure that the lug is fitted properly into the recess on to of the tank.
  6.  
  7. When tightening the notch on the screw cap, it can be heard clicking and felt engaging the toothed portion of the tank.
  8.  

  1. Remove the fuel from the tank. The easiest and safest method is via a suction pump and canister.
  2.  
  3. Remove the rear bench seat.
  4.  
  5. Fold the floor trim panel forwards and cut the insulating mat at the perforation and fold back and out of the way. This will expose the rubber grommet.
  6.  
  7. Unscrew the hexagon nuts, remove the cover to the fuel level sensor.

    Click image to see an enlarged view

    Fig. The nuts (1) and the cover (2) to the fuel level sensor

  8.  
  9. Unfasten plug connection on the sensor and disconnect it from the unit.
  10.  
  11. Release the hose clamps to disconnect the hose.

    Click image to see an enlarged view

    Fig. The connector (1) on top of the sensor, along with the hose clamp (2) and the hose (3)

  12.  
  13. Covering the sensor, there is a rotary ring that must be unfastened.
  14.  
  15. Remove the sensor.
  16.  

To install:

  1. Replace the rubber seal that goes between the tank and the sensor
  2.  
  3. Tighten down the rotary ring
  4.  
  5. When installing the fuel level sensor, ensure that the lug is fitted properly into the recess on to of the tank.
  6.  
  7. When tightening the notch on the screw cap, it can be heard clicking and felt engaging the toothed portion of the tank.
  8.  

 
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