I just removed my In-Tank Fuel Pump / Sender unit from my 740 GLE SEDAN, and replaced the cracked rubber-hose in it.

When installing it back in, I expected to have trouble getting it into the tank - but found it was fairly easy if I rotated it carefully to get all the sharp-edges past the edge of the round-opening.

HOWEVER: I found that though the bottom part of the round-plate (which engages with the 6 bolts on the tank) sat flush with the fuel-tank, the top part stayed out - leaving a gap of about 8 mm between the plate and the tank. Didn't want to try forcing it in, so I removed the sender unit to check whether I could find any obstruction. I noticed that the foot of the sender unit (along with the pump) is spring-loaded so that the foot can be pushed in about 10 mm, after which the bellow-type rubber-hose gets fully compressed. I made sure the bellow-hose was oriented just right so that it didn't get twisted in this compressed-position.

After reinstalling the sender-unit, the top part of the plate was still not flush with the tank. This time however, I pushed the plate in, and I could hear the spring compressing almost fully. If I removed pressure from the top-plate, it would spring back out again leaving the 8mm gap. I tightened everything down and started the car - but it soon stopped as if it had run out of gas. The tank was almost empty to begin with, but I didnt think it is totally dry. Maybe some gas evaporated away during the repair-process.. I can hear the pump running fine, so there's no problem with the electrical connections.

SO: Has anyone out there replaced their sender unit on a 740 sedan, and had to force the top part of the plate down so that it is flush with the tank ? If not - are there any tricks to getting this to fit easily ?

Also - I noticed that there is a small crack in the filter-sock where it meets the round aluminum-connector. How advisable is it to try mending this with hot glue from a glue-gun until I get a new one ? I didn't as I thought the gas might dissolve the glue..

Thanks as always,

Noel