Fuel System - No Start/Erroneous Fuel Gauge Reading
SI B 16 08 06Fuel Supply Systems
February 2007
Technical Service
This Service Information bulletin supersedes S.I. B16 08 06 dated December 2006.
[NEW] designates changes to this revision
SUBJECT
N51 PZEV - Erroneous Fuel Gauge Reading
MODEL
E90, E92 PZEV: 328i, 328Ci with N51
SITUATION
^ Engine cranks but does not start.
^ The fuel level gauge displays a sufficient amount of fuel, although fuel tank is empty.
^ Fault code 2A1C (Fuel level plausibility) is stored in MSV80.
CAUSE
Right side fuel sending unit is dislodged from its bracket due to incorrect assembly.
FIELD
On a customer complaint basis only:
1. Using the Instrument Cluster Test Function (Test 06: Fuel Tank and displayed values; and Test 17: Analog-Digital Converter), or via DIS/GT1 fuel sender test plan, check the fuel senders operation. In 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 trip odometer reset button and switch terminal R ON. Scroll to the test 19 (Unlock) by pressing on the trip reset button. To enter the test, press and hold on the reset button for more then 2 seconds. To unlock test functions, enter the total sum of the last 5 digits of VIN by pressing reset button the appropriate number of times. Then, exit Test 19 (press reset button for more then 2 seconds) and scroll back to Tests 06 and 17.
2. Remove rear seat bench, release screws (1) and remove cover (2) from the right side of a fuel tank.
BEFORE OPENING FUEL TANK SERVICE COVER, FOLLOW ALL LOCAL AND STATE LAWS AND REGULATIONS PERTAINING TO HANDLING OF FLAMMABLE LIQUIDS.
As a safety precaution, when handling fuel tank always wear safety goggles and plastic (not latex) gloves, Nitrile preferred.
3. Disconnect plug connector (1), unlock quick-release connection on vent line (4), and release union nut (2).
4. Release hose clamp (1) completely, spread apart the clamping ring (2) as shown, and remove it from the cover.
5. Carefully raise service cover, disconnect vent and fuel feed lines (1), remove plug housing (3) by unlocking retaining lugs (2).
6. Inspect through tank opening for sender unit not being attached to its bracket.
NOTE:
Illustration shows a fuel sending unit (2) dislodged from its bracket (1) and lying at the bottom of a tank.
IMPORTANT:
For the clarity of a picture, this is an inside view of a PZEV tank with the front wall cut open.
7. In case a right fuel sending unit has been dislodged from its bracket, the black connector (2) with black and blue wires would be visible (hanging loose) in the service opening. Fuel sender bracket (without sender attached) is shown in the left side of the opening (1).
8. By gently pulling on black/blue harness, recover a fuel sending unit and insert it into the bracket (1). Sender will be held by the locking tabs located on the bracket. Make sure that sending unit stays securely attached.
9. Reinstall service cover making sure that it is placed in a correct position.
[NEW] NOTE
The service opening seal must be replaced using Service Repair Kit P/N 16 11 7 194 201.
10. Indentation (2) on a clamping ring must line-up with a raised section (1) of the tank. Pin on the service cover (3) must line-up with an indentation on a clamping ring.
11. If a right side sending unit can't be securely reinstalled, then replace a complete PZEV fuel tank [NEW] (P/N 6 11 7 162 162).
[NEW] IMPORTANT:
Fuel tank (P/N 16 11 7 161 162) is a universal unit (without filler neck), which fits both E90 and E92 vehicles. Prior to tank installation, the filler neck has to be swapped from the original tank. Use the new seal, clamping ring and clamp (as indicated on the illustration) from the Filler Neck Service Repair Kit P/N 16 11 7 194 202.
[NEW] IMPORTANT NOTE:
On a N51 PZEV fuel tank it is possible to service fuel pump unit. In case a fuel pump fails and needs to be replaced, use Fuel Pump Service Kit P/N 16 14 7 194 207
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.
Defect Code Refer to KSD
Labor Operation: Refer to KSD
Labor Allowance: Refer to KSD
Disclaimer