Field
FIELD1. Using the Instrument Cluster Test Function (Test 06: Fuel Tank and displayed values and Test 17: Analog-Digital Converter) or via the DIS/GT1 fuel sender test plan, check the fuel sender(s)' operation. In the case of implausible fuel sender readings (left side 50 ohm, empty; right side indicating sufficient fuel amount from 300 ohm up to 990 ohm), proceed to inspect the fuel tank's right-side sending unit according to the procedure below.
Note:
Both tests 06 and 17 have to be "unlocked" to enter instrument cluster test functions. Press and hold the trip odometer reset button and switch terminal R ON. Scroll to test 19 (Unlock) by pressing the trip reset button. To enter the test, press and hold the reset button for more than 2 seconds. To unlock the test functions, enter the total sum of the last 5 digits of the VIN by pressing the reset button the appropriate number of times. Then exit Test 19 (press the reset button for more than 2 seconds) and scroll back to Tests 06 and 17.
2. Remove the rear seat base; release the screws (1) and the remove the cover (2) from the right side of the fuel tank.
BEFORE OPENING THE FUEL TANK SERVICE COVER, FOLLOW ALL LOCAL AND STATE LAWS AND REGULATIONS PERTAINING TO THE HANDLING OF FLAMMABLE LIQUIDS.
As a safety precaution, always wear safety goggles and plastic (not latex) gloves, preferably Nitrile, when handling the fuel tank.
3. Disconnect the plug connector (1); unlock the quick-release connection on the vent line (4); and release the union nut (2).
4. Release the hose clamp (1) completely; spread apart the clamping ring (2) as shown; and remove it from the cover.
5. Carefully raise the service cover; disconnect the vent and the fuel feed lines (1); and remove the plug housing (3) by unlocking the retaining lugs (2).
6. The illustration shows a fuel sending unit (2) dislodged from its bracket (1) and lying on the bottom of the tank.
IMPORTANT:
This is an inside view of a PZEV tank with the front wall cut away.
7. In case a right fuel sending unit has been dislodged from its bracket, the black connector (2) with the black and blue wires would be visible (hanging loose) in the service opening. The fuel sender bracket (without the sender attached) is shown in the left side of the opening (1).
The fuel sender bracket (without the sender attached) is shown in the left side of the opening (1).
8. By gently pulling on the black/blue harness, recover the fuel sending unit and replace it with a new fuel level sensor from repair kit P/N 16 11 7 248 295 (1). Install it into the mounting bracket. The new sender will be held by the locking tabs located on the bracket.
9. After the fuel level sensor (1) is locked into its proper position, a locking clip (2) must be installed.
The locking clip (2) is included with the Fuel Level Sensor Repair Kit P/N 16 11 7 248 295.
IMPORTANT:
This is an inside view of the PZEV tank with the front wall cut away.
Note:
The locking clip (1) places additional pressure on the level sensor bracket locking tabs (2).
10. Once installed, ensure that the electrical harness and hoses inside the fuel tank do not interfere with the level sensor (1) arm movement.
11. Reinstall the service cover, making sure that it is placed in the correct position. The indentation (2) on a clamping ring must line up with the raised section (1) of the tank. The pin on the service cover (3) must line up with the indentation on the clamping ring (4).
NOTE:
Included in repair kit P/N 16 11 7 248 295 is a new service opening seal and clamping ring.
ADDITIONAL INFORMATION REGARDING FUEL TANK REPLACEMENT, FUEL PUMP REPLACEMENT AND QUICK DISCONNECT FUEL LINES RELEASES
IMPORTANT:
If the fuel tank needs to be replaced, then the universal fuel tank will be used (without the filler neck) that fits both the E90 and E92 (P/N 16 11 7 162 162) and the E82 and E88 (P/N 16 11 7 190 559) vehicles. Prior to tank installation, the filler neck has to be swapped from the original tank to the new tank. Use the new seal, clamping ring and clamp (as indicated on the illustration) from Filler Neck Service Repair Kit P/N 16 11 7 194 202.
IMPORTANT NOTE:
On an N51 PZEV fuel tank, it is possible to service the fuel pump unit. If a fuel pump fails and needs to be replaced, use Fuel Pump Service Kit P/N 16 14 7 194 207.