All posts by Martin Banks

Car Care, Editorial

How Far I Pushed My BMW’s Tank and What I Learned From It

Most drivers would instinctively head to the nearest gas station to refill when the low fuel light comes alive. Letting your Bimmer’s tank go bone-dry will put you in an inconvenient situation — regardless of the location.

While it’s a given that an internal combustion engine vehicle with an empty tank won’t move, are there more consequences of ignoring the low fuel light? I pushed my Bimmer’s gas tank past “E” to know what would happen, and what I learned has made me a wiser BMW owner.

My Bimmer Ran for Dozens of Miles More

A BMW running on fumes can still run for tens of miles. That’s because the “E” in the fuel gauge actually means nearly empty, not absolutely empty.

A warning light will come on when your tank is 10%-15% below its capacity. For sedans, coupes and hatchbacks, it usually means you have 20-30 miles of range. If you drive an SUV or a pickup truck, you may stretch every drop of fuel left up to 50 miles. 

I heard a chime after my vehicle switched to the fuel reserve setting. After that, a distance-to-empty readout appeared on the dashboard — an approximate calculation of the mileage I could expect before my Bimmer would die on me.

The In-Dash Display Is Helpful — But Can Be Inaccurate

Thanks to advances in in-vehicle computers, the distance-to-empty figure is helpful. However, — although the figure takes multiple variables into account in real time — it makes assumptions based on historical data. Whatever happens next may drain your remaining gas more quickly.

For instance, driving more aggressively to quickly find a place to top off your tank can prove counterproductive and accelerate fuel consumption.

Hitting a curb is another example. This action can deflect a tire, compromising its structural integrity or causing it to lose air faster. A drop in tire pressure by 1 PSI reduces gas mileage by 0.2%, meaning an underinflation of 5 PSI renders your Bimmer 1% less efficient. Although it’s not astronomical, it’s big enough to move the needle closer to “E.”

Aside from roadworthiness, age and road conditions are vital factors affecting a vehicle’s fuel efficiency.

Consumer Reports tire program leader Ryan Pszczolkowski recommends cross-referencing your vehicle’s mpg against your in-dash fuel estimate to make a more realistic guess. I would agree with him because my prediction was closer to reality than my BMW’s distance-to-empty reading after factoring in my car’s recent mpg.

Most BMW enthusiasts — including myself — love Bimmers because they’re the epitome of German engineering excellence. However, we should balance common sense and faith in innovation. Modern auto technology only becomes more sophisticated over time, but it’s still fallible.

If you drive a 2023 BMW M2 coupe and remember that its highway mpg was 23, it’s probably less than that now. Note your mileage the next time you fill your tank to the brim.

Top up your tank, and set your trip odometer to zero before driving. When you return to a gas station, divide the amount of gas it takes to top up your tank by your trip counter’s reading. The answer reflects your Bimmer’s mpg at its age.

My Technician Found Signs of an Ailing Fuel Pump

It generally takes more than 100,000 miles before an average fuel pump fails. I haven’t covered that much distance with my Bimmer yet, but my BMW technician told me that my fuel pump looked prematurely worn out.

From what I gathered, driving on empty increases the risk of overheating. The small amount of gas can’t adequately lubricate and cool the fuel pump when driving. This component draws air in place of some of the gas, causing less fuel to move through the mechanism.

It didn’t help that my fuel filter is due for replacement. I normally change it at home every 20,000-30,000 miles, but it was apparently dirty enough to cause my fuel pump to suck up more sediment into the system. The little gas flowing through it while I was on the road with the low fuel light on was more concentrated, so it had to work harder.

I confessed what happened, and my technician advised me against pushing my luck the next time my BMW detects the gas level is low. Such a gamble could severely compromise my fuel pump, engine and catalytic converter.

I Learned My Lesson the Easy Way

Any Bimmer enthusiast knows that ignoring the low fuel warning light won’t lead to a happy ending. My experience satisfied my curiosity on some level, but I dodged a bullet. Quantifying the effects of driving on low fuel is challenging without making it a habit. Still, I nearly felt its impact on my pocket during my Bimmer’s annual full-car service at a dealership.

Make it a mission to refill as soon as your car begins to tap its fuel reserve to prolong its life and avoid hefty maintenance bills.

Editorial, Information

BMW’s Innovative Use of Automation Is Enhancing Their Manufacturing Process in These 4 Intriguing Ways

What Bimmer enthusiasts love about BMW is its unique combination of old-world charm and tech-forward culture. Few things embody this fact as well as the German brand’s leadership in Industry 4.0.

BMW is years away from fully realizing its vision of tomorrow’s car production. But the evolution of the automaker’s manufacturing process is gaining steam. Discover the four mind-blowing ways the home of Bimmer innovatively uses automation to celebrate its century-old tradition of excellence.

1. Supercharging Quality Control With Artificial Intelligence (AI)

BMW envisions this emerging technology to streamline every aspect of its car production over the long term. Quality control is one of the first areas to become AI-supported.

The auto manufacturer press shop in Dingolfing, Germany, uses AI-powered software for component inspection. The self-learning program only needs to study 100 employee-picked images of parts with a microcrack or pseudo defect — like dust and oil droplets — to understand what problem components look like. Once ready, it can assess live images in milliseconds and identify the ones with errors so human employees can sort them out accordingly.

AI also plays a vital role in BMW’s closed-loop stud welding process in a plant in Spartanburg, South Carolina. AI-powered robots meticulously weld half a million studs onto vehicle frames daily. The computer detects stud placement errors and tells bots to make the necessary adjustments to finish the task precisely without human intervention.

At BMW’s Munich plant, AI complements surface inspection technology to catch specks of dust and other customer-relevant defects on a vehicle’s topcoat.

The computer’s algorithm detects particulate matter indoors by comparing live data captured by dust particle sensors and information gleaned from automated optical inspection tools. AI’s findings inform employees whether to replace air pump filters to minimize the contaminants that can ruin a Bimmer’s paint job.

2. Improving Production Logistics With Autonomous Systems

Autonomous logistics underpins the BMW iFACTORY — a futuristic factory optimized for digitalization, efficiency and sustainability. Automated Driving In-Plant offers a glimpse of what this ultramodern production floor looks like.

Automated Driving In-Plant moves Bimmers in production along a predetermined route using cloud architecture. BMW blends lidar sensors, digital model environments and a motion planner to guide the movements of automobiles — regardless of specifications — throughout the facility without human intervention.

The automaker launched this pilot project at its largest European plant in 2022. After years of testing, Automated Driving In-Plant has earned CE certification and is ready for series production.

BMW aims to implement this technology in all facilities within its production network. It also plans to expand its use into outdoor distribution areas and other production environments.

Moreover, the automobile manufacturer is considering various innovations to enable autonomous logistics in the BMW iFactory. The company is cautious about adopting and implementing mobile robots because it lives by its guiding principles for dealing with digital technology.

The automaker goes beyond adherence to internationally recognized safety standards — like the ANSI B56.5 by the American National Standards Institute — when choosing guided industrial vehicles and autonomous in-plant transport systems. It also prioritizes human oversight, data control, cybersecurity, traceability and transparency.

3. Enabling Toolless Manufacturing With 3D Printing

In 2023, BMW 3D-printed more than 400,000 components — about three-fourths of them took shape at the company’s Additive Manufacturing Campus in Oberschleissheim, Germany.

The auto group has integrated 3D printing into its auto production for more than 30 years. However, the construction of this learning center in 2020 speaks volumes about BMW’s commitment to taking the technology to new heights and showing the auto industry what’s possible with toolless manufacturing.

Aside from fabricating prototypes and series components with dozens of industrial systems for processing plastics and metals, the facility is also home to researchers of 3D technologies and associates in training.

In 2024, BMW made history when its 3D-printed center console carrier won the top Automotive Award from the Society of Plastics Engineers, marking the first time a 3D-printed component earned this prestigious recognition.

This distinction validates the German carmaker’s efforts in pushing the envelope of additive manufacturing, which could make it possible to custom-design vehicles from the ground up someday.

4. Mapping Future Manufacturing Structures With Virtual Reality (VR)

BMW uses 3D human simulation to visualize the new assembly lines for the Neue Klasse class of electric vehicles. The company leverages VR to map complex manufacturing structures in digital twins and create comprehensive virtual simulations of employees working in production.

The automaker taps the NVIDIA Omniverse Enterprise platform to power this ambitious project, consisting of more than 1,000 square meters — or over 10,000 square feet — of assembly space with a complete line section with 41 operating cycles.

This immersive technology allows BMW to build ergonomic manufacturing facilities and shorten the learning phase of employees as they transition into the assembly line.

BMW — A Trailblazer in Car Production Automation

The German automaker’s foray into automation is worth commending and emulating. Considering how dedicated BMW is to elevating its car manufacturing process, Bimmer enthusiasts have plenty of reasons to be optimistic about the future.

Editorial

Prepare for an Extended BMW Car Trip With These 6 Tips

Your powerful BMW and the open road — the temptation to head out on an extended trip is huge. However, preparation comes first and with good reason. You certainly don’t want to end up with car troubles because you didn’t do your basic checks or unhappy passengers since you didn’t pack snacks. 

These tips are sure to make your next long-distance drive an enjoyable experience as you and your Bimmer become besties. 

1. Service History Follow-Up

Your vehicle’s service history needs to be on schedule before you hit the freeway or “autobahn,” as the Germans would say. However, any responsible driver knows that they should always ensure that their car’s systems meet safety requirements. These are some of the things your service department should confirm before you head out.

  • Assess the brake system: Replace it if worn or making sounds and remember to replace the pad and rotar simultaneously to avoid vibrations and uneven wear.
  • Wheel specs: Check the tread depth, run surface and tire pressure rating — when correctly inflated, this can save you up to 11 cents per gallon on fuel.
  • Cabin filter and AC unit: Even blowing these out can improve the cabin environment, especially if you often drive on dirt roads.
  • Service book and date of the next service: If it’s due soon, book the service before the trip.

2. Pre-Trip Check 

You should always monitor your Bimmer’s engine systems. Inspect them when the car’s been stationary for an hour. Top up on the necessary fluids to ensure your vehicle continues purring down the highway. You should check:

  • Engine oil 
  • Brake fluid
  • Power steering fluid 
  • Battery water or polarity for sealed batteries
  • Cooling fluids
  • Windshield wiper fluid

3. Emergency Kit

Even though you’ve taken every precaution to ensure your car runs smoothly, you should also anticipate when it doesn’t. A tire could burst, run flat or even bend if you hit a large hole. You must have a spare and a repair kit for emergencies in the trunk. Your emergency prep should include:

  • A correctly inflated spare tire or emergency donut tire
  • A jack and the required tools to change a tire
  • Jumper cables in case you need a jump-start
  • Emergency road sign

4. Passenger Care 

Once you’ve taken care of your Bimmer’s essentials, look after you and your passengers’ needs. If you or a passenger develops motion sickness, you should know how to treat it and prevent discomfort. Keep a stocked first aid kit onboard. Some medications can help alleviate symptoms.

  •  Anti-nausea medication: Add over-the-counter treatments like Scopolamine and antihistamines.  
  • Nausea tips: Keep ice packs and snacks like saltine crackers and whole grain cereal bars on hand instead of eating heavy or greasy foods that can worsen motion sickness.
  • Energy conservation: When you are driving long hours, it’s important to rest, too. If you don’t alternate with another driver or stop frequently, it will exhaust you and compromise your immune system, possibly ruining your trip if you become ill. 
  • Extra water: Having extra drinking water is super helpful. The CDC recommends you travel with one gallon of water per person per day. 
  • Sundries: Hungry people get grumpy, so stock up on snacks and sodas before even leaving the driveway. Add a few comfortable pillows, blankets, towels, magazines and road-friendly games — especially if you have children onboard. 

5. Other Essentials

Additionally, you should take an updated map because you may not have reception for Google Maps everywhere. Check your music downloads don’t require connectivity to avoid awkward silences. 

Pack a sun visor for your Bimmer’s windshield to protect the dashboard if you park in the sun while sightseeing. While you’re busy packing, ensure you distribute the vehicle’s load evenly. Load equal weight on all sides to prevent disrupting the car’s center of gravity or applying too much pressure on one set of tires. 

The load distribution includes passengers, and you should balance it equally, with both sides of the car carrying similar “body load.”

White BMW driving down the road

6. Pit Stops

Every traveler needs pit stops, not just racing drivers. Stop for 15 minutes every two hours and relax for 45 minutes every four-and-a-half-hour section. Drivers need time to refocus, stretch their legs and recharge with a healthy snack. 

Use pitstops to cool your Bimmer’s engine, check coolant in excessively hot climates and clean the windshield so you have excellent visibility when continuing the journey. It’s tempting to confirm your tire pressure again, but after driving several miles, your tires are hot, affecting the reading. You should wait at least two hours for the tires to cool before getting an accurate reading. 

Enjoy the Drive

Your Bimmer is your pride and joy, and taking an extended trip is absolutely magical when you’ve done all your preparations. A vehicle with an updated service book, basic fluid and tire check in place and loads of delicious road snacks aboard is where journeys and memories start. 

Now you are ready to purr along one of the interstates or even a country backroad.