Fuel Level Sensor - Incorrect Gauge Readings
Group 16Fuel Supply Systems
Bulletin Number
16 50 00
Woodcliff Lake, NJ
September 2000
Service Engineering
SUBJECT
Incorrect Fuel Gauge Reading
MODEL
E53 (X5) Vehicles produced before August 17, 2000
SITUATION
The fuel gauge does not read "full" after the tank has been filled. The correct reading may be shown after switching the ignition OFF and ON again. The following faults are stored in the instrument cluster:
-- Fault Code 8 "Fuel-tank sensor 1 (fuel-pump side)" and/or
-- Fault Code 9 "Fuel-tank sensor 2 (without fuel pump)"
CAUSE
The formation of a non-conducting deposit on the conductor surface of the fuel level sensor.
PROCEDURE
In case of a customer complaint, using the DIS, or MODiC
1. Select "Diagnosis"
2. Select "Function Selection / Complete Vehicle / Body / Displays and Information / Instrument Cluster"
3. Select "Test Plan"
4. Select "4 - Expert Mode/ Read Fault Memory" to confirm fault codes 8 and/or 9 are set.
5. Select "3 - Service Functions/1 - Test Code"
6. Press "Test Code" button to save test code.
7. Print "Diagnosis Report."
8. Remove and replace both the right-hand delivery unit and the left-hand fuel level sensor. Refer to Repair Instructions 16 12 000 and 16 12 001. In addition, follow the procedure described below to ensure a correct installation of the left-side sensor:
-- Lubricate the small 0-ring for the fuel transfer pipe using "Power Lube" (made by CRC Industries), or similar product. This ensures that the 0-ring will not push out of position when the fuel transfer pipe is installed.
Note:
If the 0-ring is pushed out of position when the fuel transfer tube is assembled, this will affect fuel transfer, and may result in the engine running out of fuel with fuel remaining in the tank.
-- Lubricate the inside edge of the large 0-ring seal. This ensures that the fuel level sensor slides easily into position when installed
-- When installing the fuel level sensor, do not install at an angle.
IMPORTANT
Note:
When installed at an angle, the sensor misses its locating dimple at the bottom of the fuel tank, causing the float to be out of position. The float can then hang up on the side of the tank, causing the fuel gauge to read approximately 1/2 full when the tank has run dry. It can also cause erratic operation of the fuel gauge.
-- Install the fuel level sensor, keeping the top flange square to the tank at all times. Rotate the sensor so that the lug (1) is located above its recess and then push the sensor vertically down into position in one movement. This ensures that the sensor locates correctly in the dimple at the bottom of the tank.
9. Using the DIS, or MoDiC, select "4 - Expert Model Clear Fault Memory" to clear fault code memory.
10. A copy of the "Diagnostic Report" should be attached to the Repair Order In addition, parts replaced should be stored in the part retention area with a copy of the "Diagnostic Report" pending payment and possible return request to the WPRC.
PARTS INFORMATION
WARRANTY INFORMATION
Covered under the terms of the BMW New Vehicle Limited Warranty.