Fuel System - No Start and or False Fuel Gauge Reading
SI B 16 08 06
Fuel Supply Systems
August 2010
Technical Service
This Service Information bulletin supersedes S.I. B16 08 06 dated October 2009.
[NEW] designates changes to this revision
SUBJECT
N51 PZEV - Erroneous Fuel Gauge Reading
MODEL
E82 and E88 (1 Series) 128i with PZEV N51 engine
E90, E92 and E93 (3 Series) 328i with PZEV N51 engine
SITUATION
^ Engine cranks but does not start.
^ The fuel level gauge displays a sufficient amount of fuel, although the 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.
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 350
PARTS INFORMATION
WARRANTY INFORMATION
Field
FIELD
1. 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.
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 351
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).
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 352
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.
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 353
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:
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 354
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.
Overview
Overview:
1. Swirl pod quick-release connection
2. Fuel supply quick-release connection, push inward to release, do not remove clip
3. Right access cover
4. Fuel pump
Fuel line quick-release connection:
The blue locking clip (1) must not be removed from the connector housing. Removing the clip will result in damage to the clip and the quick-release
housing.
The blue clip must be expanded (1) to release the quick-release line from the fuel system component. Pushing inward on the side of the housing (2)
will expand the clip (1), and allow the line to be removed from the component free of damage.
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 355
Line Release Damage
The fuel lines and quick-release components damage due to incorrect removal will not be covered under Warranty. Technical Service
Bulletin # 630201 Date: 100801
Light Bulb - Replacement Guidelines
SI B 63 02 01
Lights
August 2010
Technical Service
This Service Information bulletin supersedes SI B63 02 01 dated March 2001.
[NEW] designates changes to this revision
SUBJECT
Light Bulb Replacement - Incandescent and Halogen Light Bulbs
MODEL
ALL excluding Xenon light bulbs and light-emitting diodes (LEDs)
[NEW] SITUATION
Functional testing of incandescent and halogen light bulbs replaced under warranty and returned to the Warranty Parts Return Center (WPRC) along
with the analysis of light bulb claim data shows that some of these light bulbs are:
^ Being replaced unnecessarily;
^ Incorrectly handled during a previous repair or replacement; or
^ Not replaced, as a set, when they should have been
This can result with unnecessary additional warranty costs, service visits and reduced customer satisfaction.
Note:
The situation above does not apply to Xenon bulbs that may only be replaced as instructed after running the corresponding ISTA test plan.
[NEW] PROCEDURE
When replacing incandescent and halogen light bulbs, always follow the guidelines listed below:
1. Before replacing these light bulbs, confirm that they are defective (most times a broken filament can be seen visually). If there is no visual
confirmation, test the bulb using a multimeter or 12-volt power supply with a suitable bulb holder to confirm that the bulb is defective.
2. A failed light bulb with distinctly "blackened" glass indicates a failure. In situations where the failed vehicle bulb as a "twin" with the same
function (for example, left and right parking lights), replace the other bulb as well if it also found to be "blackened" in the same way.
3. Only replace light bulbs when the lighting system is switched off or when the vehicle is powered down.
4. Do not touch any bulb glass directly with your fingers - this will cause local overheating spots and premature bulb failure. The best practice is to
hold the bulb using a clean cloth or while wearing clean gloves. Clean off any dirty bulbs as necessary.
5. Before installing the replacement light bulb, check the bulb holder contacts for traces of oxidation and clean if necessary. Check for adequate
contact force.
6. In cases where a vehicle has had repeated light bulb failures, check the wiring system supply voltage using ISTA diagnosis.
2010 BMW 128i Convertible (E88) L6-3.0L (N51) Page 356
7. Use only genuine BMW replacement light bulbs sourced through the BMW NA Parts department to help avoid bulb compatibility issues.
[NEW] WARRANTY INFORMATION
For information only
The bulb replacement reason including the applicable guidelines listed above must be stated on the repair order and in the corresponding claim
comment section.
Please follow the standard warranty parts documentation and retention procedures for all bulb replacement repairs.
