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Car Forum / BMW Cars / February 2008

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Z3 Coupé 3.0i fuel gauge & DTE issues

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frischmoutt - 14 Oct 2007 21:03 GMT
I know that I must not insist filling the tank when it's full. Unfortunately
for some reason the gas pump wasn't working correctly and I did it again.
I already had issues around 50000 km with erroneous values on the DTE only,
however the fuel gauge was OK. The DTE recovered by itself after I filled up
4 or 5 times.

Last week, the DTE began to display "- - - " while the fuel gauge was a
little bit below the middle. I stopped in a gas station, added around 25
liters (correlating the covered distance) and started with the DTE still
displaying "- - -" as well as a gauge pointing to the same figure as before.
It normally continued to decrease down to zero then the light went on for
the rest of the journey. I made 1900 km stopping every 450 km.

Now comes the troubleshooting preceeding the dismantling:
Should the connections be bad, I assume that the gauge would display
non-consistant values or zero if the contact is open. This is not the case,
at least not abruptly.
The fact that it immediately continued to decrease normally is quite
puzzling but it may depend on the transducer design. I don't know how it's
built and this is one of the purposes of this message. Assuming that this is
something like a potentiometer actuated by a float, it might be blocked by
some particles avoiding any further upwards motion. In this case it should
have been stuck at the same value as before until the level of fuel was low
enough.
_ It was decreasing although the tank was full _and did not recover further
on.
May a specialist detail the design of this stuff ?

Second, the DTE was displaying a still "- - -". Normally when the fuel level
is very low, with a DTE less than 15 km, the "- - - " are blinking.
Two transducers might provide an explanation. Same question as above.

Are there any software known issues ?

Third, the carpet is cut behind the passenger seat following a dotted line.
This is to provide access to the fuel pump. Does this cut also provide an
access to the transducer (s) ? Are there any precautions to take for the
cutting (wires below, tubes, ...) ?

Anticipated thanks for the help.
frischmoutt - 16 Oct 2007 19:40 GMT
Anybody here ?
Thks

> I know that I must not insist filling the tank when it's full. Unfortunately
> for some reason the gas pump wasn't working correctly and I did it again.
[quoted text clipped - 36 lines]
>
> Anticipated thanks for the help.
Ed - 15 Feb 2008 18:19 GMT
I have an '03 Z4 that is doing the same thing. The local dealer
replaced the fuel tank but the problem is worse now than it was
before.

Have you had any luck figuring out what is wrong or what part(s)
failed?

Thanks!
Ed

>I know that I must not insist filling the tank when it's full. Unfortunately
>for some reason the gas pump wasn't working correctly and I did it again.
[quoted text clipped - 36 lines]
>
>Anticipated thanks for the help.
frischmoutt - 15 Feb 2008 20:25 GMT
If you are comfortable with French language there's a site describing such
repetitive failures otherwise Babelfish is your friend !

http://www.z3club.fr/modules.php?name=Forums&file=viewtopic&t=9593&postdays=
0&postorder=asc&start=0.
In this thread you'll see the pics of my gauge.

http://www.z3club.fr/modules.php?name=Forums&file=viewtopic&t=1272&highlight
=jauge
This thread contains the fuel pump dismanteling procedure and several
descriptions of different failures, including one that is very similar to
yours.

My problem ended with the fuel pump replacement.
I did begin the job, making the proper tool (that I described on the site
above) to dismount the big pump's nut. I found the ceramic substrate, where
the thick film resistors are deposited, broken into several parts, some of
them remaining in the tank.
Looking under the car, I noticed that the two rubber bands placed between
the thank and the clamps were almost completely out of their normal
position. Afraid of what might have been at the origin, I asked BMW to check
a possible thank distortion, the venting hole and the fuel distribution
checking the pressure at different places. Fortunately for me (and my
wallet), the fuel pump only (including the gauge) had to be replaced. They
had also to reprogram the OBC giving DTE errors.
Since I initiated the repair, I didn't place any claim at BMW France !

In the second post above, you'll read the history of a guy owning a Z3,
don't remember if it was a coupé or a roadster, who is at his second thank
replacement. The gauges keep breaking driving him nuts.

In addition, search for "venting hole" in this group, Nov. 2007. I got some
interesting clues from Jeff Strickland and Fred W.

The gauge issue is an old and common problem on the bimmers.
I classified them under several categories :
* The fuel, especially if containing sulphur, may corrode the tracks of the
gauge. In this case a dismounting and a cleaning solves the issue. Then the
gas needs to be selected as sulphur free. Some people put an additive in the
thank. In my opinion, this might be harmful wrt other parts of the engine if
not homologated by BMW.
* The gauge, when the thank is completely full, may touch the upper wall of
the thank, especially if you don't take care of those f.cking speed bumps
they put almost every where, shocks might result. I also think that
cornering might, in some conditions, provoke shocks of the gauge against the
tank. The result of these shocks may either be a ceramic displacement or a
damage. Removing the pump is easy. The repair as well. Some pictures
illustrate the gauge dismounting on the site above.
* The thank, for some reason already discussed in this group, may be under
severe depression causing the walls to get closer, possibly jamming the fuel
gauge and further on its damage.
* erratic and random readouts. I didn't manage to correlate them to any
reason. I had issues at 500000 km (now it has 102000 on it). Whilst the fuel
level was correctly indicated, the Distance to End was unconsistent and
varying for several fillings. Once I even couldn't start the engine. Opening
the thank cap and opening and closing the hood solved the problem? Either an
overpressure (due to the sun in summer) or a stuck relay released bu the
shock of the hood.

About the parts and the drawings, you may have access to the ETK/EPC on
line. Have a look on these sites:
http://bmwfans.info/original/E85/ or
http://www.realoem.com/bmw/select.do?vin=&kind=P&series=E85&arch=0

Also worth to buy the TIS on ebay. Associated to the ETK, it's less than 10
Euros. TIS help to troubleshoot the failures. However don't expect a miracle
!

Feel free to ask more if needed.
Good luck

BTW, what model of Z4 do you have ?
May you describe a little bit more what your problem is and what did the
dealer diagnosed ?

> I have an '03 Z4 that is doing the same thing. The local dealer
> replaced the fuel tank but the problem is worse now than it was
[quoted text clipped - 46 lines]
> >
> >Anticipated thanks for the help.
 
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