Wow, that's uncommon, usually people are exactly 1/2 a tank off when they have fuel gauge problems. BMWs have a 2 sided saddle tank and have a fuel level sender on each side. Did you change both sides already? If you did I would want to know the level readings from each side at full tank when reading correctly, and from each side when full and it is still showing empty... reason being to see if the problem is with the sensors themselves or with the instrument cluster interpreting the readings.

I wish I had my training books handy so I could scan some pages on unlocking the service menus in the cluster allowing you to get the readouts of what it is seeing in liters from each side of the tank.

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2003 4.6is