On 80s and modern era BMWs right up until the late 90s and early 00s the level sensor for the windscreen/headlight washer fluid sometimes fails to work for various reasons. Using my E30 as an example I'll show you today how to replace it.

Step 1 - Symptoms and Preparation

This is a familiar view for 80s and 90s BMW drivers - the ominous "CHECK" :). In my case there's one light I couldn't manage to extinguish in the panel...

"Waschwasser" a funny sounding German word for 'washer/wiper fluid'. Usually when it lights up you fill up the tank and it goes away but in my case it didn't. Hence, the level sensor must be broken.

To replace it you need a new one as you cannot buy spare parts separately. Alternatively, use a good used one but given the low price of below 20 bucks and the lifetime of around 20-30 years I figured I'd go for a new one.

It's not an original part but manufactured by a certified supplier.

Tools you don't actually need any except if you want to remove the fluid tank to clean it then you'll need a screw driver.

Step 2 - Removal

The sensor sits at the front of the tank:

It's best to pump the container empty then it won't be as messy upon removal. Once it's empty simply pull the sensor out of its sealing by turning slightly left and right until it pops out and then remove the connector by pulling on the small clamp (carefully as 30 year old plastic tends to break).

This is what it looks like once it's out:

The sensor itself was simply missing the floating connector - no idea where that went, it wasn't inside the tank. Eternal questions looming...:)

Step 3 - Optional Tank Removal

While we're at it let's clean the tank and the pump. To start simply unscrew the black plastic nut:

Then pull the pump straight up and remove the cable connector:

Also remove the hose that runs to the hood washer nozzles. Let's clean that pump!

There we go then. Some pressurized air spray, contact spray for the connector and plastic refresher and we got an as good as new pump.

Rerouting the washer fluid hose

I always had this issue here:

The hose incorrectly runs above the headlights straight to the hood and is somewhat loosely hanging in the way. For some reason the hose from the pump to the hood connector is not long enough so luckily after 10 years and countless BMWs I have a piece of fitting hose which is slightly longer than this one...

Simply unplug the hose from the hood connector...

...and fit your new piece to the pump:

There we go then.

Now clean the tank and potentially the headlight cover:

Step 4 - Installation

Put the tank back in and get your cable and new sensor ready:

Connect the cable and carefully fit it into the sealing, in my case the sealing was a bit worn so some twisting and turning helps so as to not damage it:

And snap it in, there's an indentation on one side so there's only one way for it to go in. Take your clean pump with the new hose and snap that in as well:

Quick look inside to check for residue or dirt:

And the filter can go back into the filler opening:

Now in the E30 the hose usually runs to the bottom front below the headlight cover, around the high beam (the inside light) and up to the hood connector:

Snap the cover back in and reconnect the pump cable and voila:

Fill it up with washer fluid/water and there we go then:

Step 6 - 'CHECK'-ing the result

Remove any tools, clothes and other residue from the engine bay and check that your hose has enough freedom of movement when opening and closing the hood and close it all up.

Get in and turn the key into position 2 and be happy that your new sensor accurately reports that there is no lack of fluid in the tank:

And...

Press the brake pedal and we got a cleaaaan check control panel:

Let me tell you this is clean for the first time since at least 2008 in this car as that was the date it was de-registered.

Hope you enjoy reading as much as I have creating this tutorial!

Steem on!