[rastaman777]

Wow, this is terrible!

Today while trying to refuel, the same problem happened, and this time that fuel system error showed up. I manually released after a while, and all was well.
After a solid 3 hour drive (300 miles), I fueled up again, but this time no problem.

Is the worst case scenario just the nuisance of having the manually open the fuel door?
Just wondering what I should prepare myself for since I'm doing a lot of highway driving.
Thanks!

[JasH]

Originally Posted by rastaman777

Wow, this is terrible!


Is the worst case scenario just the nuisance of having the manually open the fuel door?

Yes that's all. But it will begin to happen every single time.

[BanjoPaterson]

Following up on my previous post in this thread. BMW replaced the pressure sensor (and, looking at the invoice, this meant replacing the fuel tank!) under warranty and I've not had the problem since. The cost, if it had not been under warranty, would've been close to $2000... so something to consider if anyone is purchasing this car.

[rastaman777]

Originally Posted by BanjoPaterson

Following up on my previous post in this thread. BMW replaced the pressure sensor (and, looking at the invoice, this meant replacing the fuel tank!) under warranty and I've not had the problem since. The cost, if it had not been under warranty, would've been close to $2000... so something to consider if anyone is purchasing this car.

How long was your car in the shop to get this repair done?

[rastaman777]

Originally Posted by JasH

Yes that's all. But it will begin to happen every single time.

Well I guess that's good to know, that it's just going to be a PIA only.
Yes, it's already starting to be more frequent.

There's really only about 5 months left in the driving season where I live, and and about 10 months on this lease. So, definitely don't want to waste any time of the driving season with the car in the shop.
I'll probably leave the repair for the off season, or to BMW on return of the car.

[Maxxsirrah]

Originally Posted by Maxxsirrah

My 2017 i8 has just started having the fuel tank issues too, the pressure is not working out, so I have had to twice now use the manual emergency release. I hoped that as a later model they may have sorted this, but clearly not. Looks like this could be an ongoing problem for the i8 and unless they find a permanent fix the cars achilles heel. Seems like over engineering to me in the original design, so there must be a simple solution.

Took my i8 into the dealer yesterday, diagnosed as the faulty fuel tank pressure sensor, so in for a couple of days whilst they fix it, no arguments about it being under the warranty and a begrudging nod when I said 'its a common issue this huh?' Amazing that BMW haven't worked out a permanent fix for it, it must be costing them millions.

Do the 3, 5 and X5 series hybrids have a similar system or is it unique to the i8?

[JasH]

Yes, and sadly it will happen again. I'm on my 3rd sensor.

1-2 weeks each time to fix (I think it's a 4-5 day job). All under warranty, but costing BMW a small fortune.

Appalling over-engineering, just for a few emission eco points.

A simple timer + pressure release would do effectively the same job, with virtually no failure risk.

[Mr.SugarSkulls]

Ok...so just to be clear/

I've had 2 i8s and never had this issue. If it were to occur- worst case scenario is using the emergency manual release until serviced right?

Considering driving it down to my home in GDL, so just making sure I'm not going to get stuck without gas in the Mexican desert.

[Maxxsirrah]

Originally Posted by Mr.SugarSkulls

Ok...so just to be clear/

I've had 2 i8s and never had this issue. If it were to occur- worst case scenario is using the emergency manual release until serviced right?

Considering driving it down to my home in GDL, so just making sure I'm not going to get stuck without gas in the Mexican desert.

Yes, correct, pull the emergency release in the right hand compartment of the luggage bay (boot/trunk). Easy to find, just a pita!

[Maxxsirrah]

Picked the car back up today, complete new fuel tank and sensor, lets see how long this one lasts! All done under warranty, no debate at all.

[Mr.SugarSkulls]

For peace of mind- Can I fake it and say I had that issue so that they can go ahead and change it?

Bought mine, but it now has 38k on the odometer, and with my luck- I'll start having the issue when the odometer goes 1 mile over the manufacturers warranty.

[JasH]

Originally Posted by Mr.SugarSkulls

For peace of mind- Can I fake it and say I had that issue so that they can go ahead and change it?

No, because the lie will be obvious.

The i8 reports the fail to refuel, as well as sensor fault codes.

And you will not get stuck. As stated above, the emergency release will open the fuel cover no matter what.

[Mr.SugarSkulls]

Originally Posted by JasH

No, because the lie will be obvious.

The i8 reports the fail to refuel, as well as sensor fault codes.

Thought so.

Oh well, let's hope I was one of the few lucky ones with a hassle free gas tank

[Coastali8]

This whole fuel door lock is turning out to be a pain. Considering leaving the car for days at the dealer and still having the possibility of the pressure sensor failing again after the repair.... thinking of a permanent solution.

The fueling system knows that the fuel door is closed because of a small magnet located on the door that trips a reed switch when the door is closed. After the door is closed the system activates a small plastic pin that passes through a hole on a plastic tab on the door to lock the door shut. If you block the hole, the pin mechanism is unable to extend and lock the door, but the check engine light illuminates.

But if you open up the hole in the small plastic tab, then the pin can be activated when the door is closed and the system is happy, but the door won’t be locked.

The door is then never locked and there is no reason to activate the refueling button on the drivers door panel ever again. The fuel door will stay closed just like the door on the charging port which has no locking mechanism. Just press on the fuel door and it will pop open as always, then remove the fuel cap for refueling.

I don’t need to lock the fuel door for vandalism or fuel theft concerns.

Opening the fuel tank while it might still be pressurized or under a vacuum, ( not sure which) is not an issue. The locking mechanism is likely only for emission reasons to keep a few hydrocarbons from escaping.

I think this will be my solution when the system starts to fail on a regular basis.

It’s a free, permanent fix that takes 2 minutes to accomplish.

[Maxxsirrah]

Originally Posted by Coastal i8

This whole fuel door lock is turning out to be a pain. Considering leaving the car for days at the dealer and still having the possibility of the pressure sensor failing again after the repair.... thinking of a permanent solution.

The fueling system knows that the fuel door is closed because of a small magnet located on the door that trips a reed switch when the door is closed. After the door is closed the system activates a small plastic pin that passes through a hole on a plastic tab on the door to lock the door shut. If you block the hole, the pin mechanism is unable to extend and lock the door, but the check engine light illuminates.

But if you open up the hole in the small plastic tab, then the pin can be activated when the door is closed and the system is happy, but the door won’t be locked.

The door is then never locked and there is no reason to activate the refueling button on the drivers door panel ever again. The fuel door will stay closed just like the door on the charging port which has no locking mechanism. Just press on the fuel door and it will pop open as always, then remove the fuel cap for refueling.

I don’t need to lock the fuel door for vandalism or fuel theft concerns.

Opening the fuel tank while it might still be pressurized or under a vacuum, ( not sure which) is not an issue. The locking mechanism is likely only for emission reasons to keep a few hydrocarbons from escaping.

I think this will be my solution when the system starts to fail on a regular basis.

It’s a free, permanent fix that takes 2 minutes to accomplish.

I'd come to the exact same conclusion and would be my solution if I had the issue on a car out of warranty.

[stressdoc]

Has anyone w a 2019 had this problem?

[JasH]

Originally Posted by Coastal i8

Opening the fuel tank while it might still be pressurized or under a vacuum, ( not sure which) is not an issue. The locking mechanism is likely only for emission reasons to keep a few hydrocarbons from escaping.

Pressurised, not vacuum.

Yes, it's just to stop hydrocarbons escaping (emissions).

Over-engineering at its very finest

[BanjoPaterson]

Originally Posted by rastaman777

How long was your car in the shop to get this repair done?

Sorry for delay in replying. From memory, it was in the shop for 3-4 days since they had to go to a major city (Melbourne) to get the part. It's also a fairly big job, from what they said.

[Jo-Sta07]

It's crazy BMW is still having issues with this.

[ken997]

My car is saying "Refueling Possible" but the fuel door remains locked. Even pulling the
Green tab in the boot doesn't release the door. Any ideas or do I
Just need to pull the green cord harder? Im afraid I might pull the green cord out!

[Maxxsirrah]

The green cord should release it, unless the spring has gone which pops the door open. Not heard of this issue before, so perhaps it is a broken release spring. What happens when you push the door to 'pop' it open? Does it release and then can you lever it gently open?

[ken997]

Yes the door pops open a few millimeters when I phsh the botton on the driver's door, but it wont fully release the door. Ill try have a mate pull on the door while i pull the cord. That should do it..