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      09-01-2019, 11:05 AM   #1
NathanOfSeattle
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Unable to open REX fuel cap

Shockingly, this is a more common topic than I realized, but wanted to ask as I've been searching past posts and haven't found any answers yet.

We recently purchased a pre-owned 2015 i3 Rex. Awesome deal by the way for pre-owned! Since then, we have coded our i3 to allow holding the SOC starting at 75% along with full access to the gas tank. This was to prepare for two 300ish mile road trips we had planned over the summer. For any doubters, yes the i3 can perform just fine on road trips with mountain ranges to cross over. I live in WA state and was able to cross over the Cascades, no problem, coded of course.

For both road trips, I would often let the REX run empty, then fill it at the next gas station while SOC was hovering around 72%. In every instance, I could not open the REX fuel cap without resorting to pulling the green switch thing found in the frunk. I've tried waiting for the fuel cap to open after pressing the fuel button. No luck.

Am I missing something here? It seems odd that I have to use, what I thought was a backup switch, to open up the fuel cap each time.
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      09-01-2019, 12:20 PM   #2
drowningman
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Quote:
Originally Posted by NathanOfSeattle View Post
Shockingly, this is a more common topic than I realized, but wanted to ask as I've been searching past posts and haven't found any answers yet.

We recently purchased a pre-owned 2015 i3 Rex. Awesome deal by the way for pre-owned! Since then, we have coded our i3 to allow holding the SOC starting at 75% along with full access to the gas tank. This was to prepare for two 300ish mile road trips we had planned over the summer. For any doubters, yes the i3 can perform just fine on road trips with mountain ranges to cross over. I live in WA state and was able to cross over the Cascades, no problem, coded of course.

For both road trips, I would often let the REX run empty, then fill it at the next gas station while SOC was hovering around 72%. In every instance, I could not open the REX fuel cap without resorting to pulling the green switch thing found in the frunk. I've tried waiting for the fuel cap to open after pressing the fuel button. No luck.

Am I missing something here? It seems odd that I have to use, what I thought was a backup switch, to open up the fuel cap each time.
I had this happen my 2015 Rex. Might be a known issue as it turned out to be an issue with the system that pressurizes the fuel tank so the gas doesn't go bad. I have the repair order at home I'll post it here this afternoon for reference.
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      09-02-2019, 06:24 PM   #3
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I had the same issue in my previous 2015 REx. Fixed under warranty. Here's what was stated in the invoice:

12096 FUEL TANK PRESSURE SENSOR FAULTY FUEL CAP NOT OPENING PROPERLY DUE TO FAULTY FUEL TANK PRESSURE SENSOR.

PERFORM S.I.B B130117 RECALL - i3 REx Fuel Tank Vent Line
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      09-03-2019, 01:52 AM   #4
drowningman
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As jmg noted here's a bit more detail from the repair order with part numbers. I also found the warranty extension letter from BMW covering 10yr/120000mi for this part while going through the folder for the vehicle. Let me know if you need a copy and I can PM it.
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      09-12-2019, 01:34 PM   #5
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Happened to me twice and think it happened because the tank was full or over filled and because of the pressure it caused the fault and wouldnt let the fuel door open. Dont know if the recall has been performed since, but hasnt happened again in over a year.
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      09-19-2019, 11:48 AM   #6
NathanOfSeattle
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Thank you for your responses! drowningman So you had this fixed under recall? I just checked mine and there are 0 open recalls. I suppose this would mean I'd have to pay for this fix. Did it cost you anything?
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      09-20-2019, 05:23 AM   #7
drowningman
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Quote:
Originally Posted by NathanOfSeattle View Post
Thank you for your responses! drowningman So you had this fixed under recall? I just checked mine and there are 0 open recalls. I suppose this would mean I'd have to pay for this fix. Did it cost you anything?
There's a warranty extension for this problem - I received a letter from BMW after I had mine fixed.
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      09-20-2019, 03:48 PM   #8
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Quote:
Originally Posted by NathanOfSeattle View Post
Thank you for your responses! drowningman So you had this fixed under recall?
I had this issue on my ex-MY'14 REX.
It was fixed under warranty (free to me), not a recall.


Quote:
Originally Posted by NathanOfSeattle View Post
I just checked mine and there are 0 open recalls. I suppose this would mean I'd have to pay for this fix. Did it cost you anything?
It would not hurt to ask the dealer about covering it either under some kind of an extended warranty from BMW NA, or "good will".

As an alternative, have you considered engaging the REX engine to consume some of the gas in the tank (either manually trigger REX if you had it so coded, or just exhaust the battery and get REX to kick in), and lower the pressure that way? Perhaps, it will be enough to get the gas cap to cooperate?

In the worst case, if you are out of the warranty, you will have to pay for it out of pocket. Under the circumstances, I don't think you would want to carry on without having functional use of the gas tank.

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      09-22-2019, 10:24 PM   #9
drowningman
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No goodwill necessary, there is a warranty extension and service bulletin for the fuel pressure sensor, a known issue.

The linked service bulletin should be what you need to get the Service Department to help you.

https://testing-public.carmd.com/Tsb...0B01%2013%2018

To be extra prepared for the trip to the dealership I would call BMW NA (800) 831-1117 and tell them that you have this issue described by the service bulletin (give them the bulletin number) and get them to confirm your car is eligible (it will be). Then forarmed at the dealership tell them you spoke with BMW Corporate and they confirmed you are covered and you would like the issue repaired.
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      02-19-2020, 07:22 AM   #10
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This is the same problem that we're having on the i8. I'm curious the i3 uses the same fuel door lock actuator that the i8 has.

I have removed the operating rod which locks the fuel door, but also left the actuator installed, so the car still operates the fuel depressurizing function and doesn't throw a trouble code, but the door no longer locks so it can be refueled without inconvenience.

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      03-07-2020, 11:40 AM   #11
drowningman
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Good fix patsgarageonline, on our 2014 we were just in the habit of pulling the emergency release from the frunk.

Seriously though everyone who has this should just get it resolved, since there's a warranty extension.
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