FUEL GAUGE IN INSTRUMENT CLUSTER REDESIGN
TECHNICAL SERVICE BULLETIN
Reference Number(s): 62 04 90 (3068), Date of Issue: June, 1990
BMW All E32 and E34
GROUP 62 - Instruments
SUBJECT

Fuel Gauge in Instrument Cluster Redesign
COMPLAINT

Fuel gauge sticking.
SITUATION

The instrument cluster redesign was phased into production during February 1989. Refer to S.I. 62 03 89 (1833) , dated May 1990.

With the instrument cluster design, the reserve contact must be closed continuously for approximately 25 seconds before the reserve indicator lamp is activated. This delay prevents flickering of the lamp due to fuel slosh (e.g., hard cornering).

Since February 1990, a new telescopic, immersed fuel level sensor is being phased into production for E32 and E34 vehicles.
PROCEDURE

If this complaint is encountered, remove the fuel level sensor and check the float for freedom of movement. Also check the resistance values at full and empty float positions. These values depend on the part number of the sensor used, and can be compared with the following values:

FUEL LEVEL SENSOR RESISTANCE VALUES
Model Tank Capacity in Liters Sensor P/N Resistance in OHMS: FULL Resistance in OHMS: EMPTY
M5, 525i 535i, 735i 81 16 14 1 180 017 3.2 +/- 0.7 88.7 +/- 2.5
M5, 525i 535i, 735i 81 16 14 1 180 889 3.8 +/- 0.8 88.9 +/- 2.8
735iL 91 16 14 1 180 018 3.2 +/- 0.7 95.7 +/- 2.7
735iL 91 16 14 1 180 891 3.8 +/- 0.8 96.2 +/- 3.0
750iL 91 16 14 1 180 019 3.8 +/- 0.7 95.7 +/- 2.7
750iL 91 16 1 41 180 893 3.8 +/- 0.8 96.2 +/- 3.0

It is also useful to make the measurements (using the 26-pin universal adapter and V-adaptor cable) from the instrument cluster, so that the leads and connections are also checked. Refer to the appropriate ETM, S.I. 04 06 88 (1599) , and S.I. 04 12 88 (1624) . Note whether reserve indicator lamp comes on after a delay of approximately 25 seconds.

NOTE: Some customers may misinterpret the gauge reading. It has been found that the red warning zone in the fuel gauge is sometimes confused with the reserve indicator lamp.

The reserve indicator lamp is only illuminated when there is approximately 7-8 liters (approx. 1.8 - 2.1 U.S. gal.) of fuel left in the tank and the needle is on "R". Customers should be made aware of this fact where necessary.
PARTS INFORMATION

The telescopic fuel level sensors can be retrofitted. After the supply of the present fuel level sensors has been exhausted, only the telescopic type will be supplied.

NOTE: Claims for fuel level sensors, which are returned under warranty and are found to be not defective, will be returned and the claim debited to the dealer.
WARRANTY INFORMATION

Covered under the terms of the BMW New Car Limited Warranty of 3 Years/36,000 Miles.

Any questions regarding warranty coverage should be discussed with your District Service Manager.