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      04-27-2010, 12:21 AM   #1
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As you all know, my warranty has been voided late last year because I sent the car in suspecting that something is wrong with the engine. BMW Asia inspected the car and informed me multiple times nothing is wrong with the engine BUT they had to void my warranty which was unusually weird.

They claimed that they checked the car thoroughly and my suspicions about something being wrong with the engine was unfounded. I absolutely am certain there was something wrong because the engine was very rough when revving above 4k rpm and I was losing oil like crazy every 2-3 weeks. They offered to tear down the engine to check and put it back at an astronomically high price and there was absolutely no guarantee that they will be able to fix it if there was something wrong with it especially if the cylinder walls has been damaged already. And I did not want to be caught with a fat bill for everything they change which could end up costing even more than a new engine itself. It just did not make sense at all.

Finally with much considertation, I sent it to a private garage in Germany for them to tear down the block and to rebuild it with better parts. Better parts like Forged Pistons, Carillo H-Beam Rods, after-market rod and crank bearings (Damage in the engine at 20,000KM which is very questionable), etc. I also decided to sleeve the motor with steel liners because the cylinder walls have some damage and it would cost too much to get a new block. Also, the coating on the cylinder walls doest seem to last very long.

I am uploading pictures up here for you guys to take a look at and comment.

While I accept the responsibility of the consequences of this whole incident, I also personally feel that there is another side to the whole story which was withheld from me. What was most interesting is that the warranty was void in less than 3 days and yet a letter in black and white was given to me by BMW Asia stating that my engine is perfectly fine and that the sound was something to do with the air-conditioner having over pressured gas???? I will post the letter here once I am able to capture it as an image file.




















Last edited by elmariachi; 04-27-2010 at 02:55 AM.
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      04-27-2010, 12:23 AM   #2
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Continued...





















Notice the broken pieces of the pistons at the edges?
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      04-27-2010, 12:24 AM   #3
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Continued...





















Main Bearings at 20,000KM. Dont look too good. Even the Rod bearings appear to be quite bad also.
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      04-27-2010, 12:45 AM   #4
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Looks like the motor may have been (1) poorly balanced from the start and harmonics may have begun taking its toll on your motor, or another possible mechanical situation is a (2) overly "tight" assembled motor.

Have you observed the motors natural oil consumption habits?

Chance of prolonged use of bad fuel?
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      04-27-2010, 12:50 AM   #5
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Quote:
Originally Posted by Malekreza11 View Post
Looks like the motor may have been (1) poorly balanced from the start and harmonics may have begun taking its toll on your motor, or another possible mechanical situation is a (2) overly "tight" assembled motor.

Have you observed the motors natural oil consumption habits?

Chance of prolonged use of bad fuel?
The rebuilder told me that the crank when he removed and rebalanced, it was 1.3kgs off. I dont know what that means. I had totally no problems for 6-8 months, even after track days. It only happened at the third track day where I had a misfire on Bank 6 at a high rpm and after that, everything ran funny even after replacing all the spark plugs. Ever since, I had severe oil consumption warnings on the idrive every 2-3 weeks even after filling it to a full level as shown on the idrive.

I would say we have pretty good fuel here in Singapore and I dont think its anything to do with the fuel. Possible but highly unlikely.
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      04-27-2010, 12:54 AM   #6
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hope you get your car back soon! goodluck
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      04-27-2010, 12:59 AM   #7
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Quote:
Originally Posted by elmariachi View Post
The rebuilder told me that the crank when he removed and rebalanced, it was 1.3kgs off. I dont know what that means. I had totally no problems for 6-8 months, even after track days. It only happened at the third track day where I had a misfire on Bank 6 at a high rpm and after that, everything ran funny even after replacing all the spark plugs. Ever since, I had severe oil consumption warnings on the idrive every 2-3 weeks even after filling it to a full level as shown on the idrive.

I would say we have pretty good fuel here in Singapore and I dont think its anything to do with the fuel. Possible but highly unlikely.
Thanks for the reply.

As suspected, the issue you are experiencing is most likely due to a poorly balanced motor. Harmonic vibration will wreak havoc on the motor and it will do it incrementally depending on how bad the balance is.

Misfires combined with a imbalanced motor will amplify the effect as the motor is already off balance and repeated misfiring will effect the way the motor runs.

Did your engine machinist or mechanic by any chance mic the tolerances of the motor to see how tight or loose it was assembled? Overly tight motors will tend to bind up easier and wear out excessively. This is indicative of your crank bearings.

Bottom line is, you made a good move to have the motor rebuilt with new parts. But just please make sure whoever is doing the re-assembly does it in a controlled dust minimal and contaminant free environment. Engine assembly is a crucial process, especially on high strung, high power motors.
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      04-27-2010, 01:04 AM   #8
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something is definitely not right with your engine. its really too bad your warranty was void. i guess they must have known what was wrong with your engine and decided that it would be too costly to replace so blaming something else for the problem was just easier. i would never buy another bmw again if i had to go through this with them.
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      04-27-2010, 01:05 AM   #9
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Quote:
Originally Posted by Malekreza11 View Post
Thanks for the reply.

As suspected, the issue you are experiencing is most likely due to a poorly balanced motor. Harmonic vibration will wreak havoc on the motor and it will do it incrementally depending on how bad the balance is.

Misfires combined with a imbalanced motor will amplify the effect as the motor is already off balance and repeated misfiring will effect the way the motor runs.

Did your engine machinist or mechanic by any chance mic the tolerances of the motor to see how tight or loose it was assembled? Overly tight motors will tend to bind up easier and wear out excessively. This is indicative of your crank bearings.

Bottom line is, you made a good move to have the motor rebuilt with new parts. But just please make sure whoever is doing the re-assembly does it in a controlled dust minimal and contaminant free environment. Engine assembly is a crucial process, especially on high strung, high power motors.
Thanks for the reply Malekreza. He did not really mic the tolerances of the motor unfortunately as he wanted to clean up the block quickly and salvage the crank. He claims that if i were to have driven the car for another 1-2 months, the crank would have been gone as well. The crank is in perfect shape now after some slight polishing. There were metal bits in the engine oil which wreacked the most havoc on the cylinder walls and it left a piece of metal stamped onto the top of one of the pistons if you look carefully in the photos above.

Yeah the photos of the almost complete motor is done in a very controlled environment and the new motor looks absolutely gorgeous with the new parts, especially the forged pistons and Carillo Rods.
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      04-27-2010, 01:09 AM   #10
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Quote:
Originally Posted by montreal red View Post
something is definitely not right with your engine. its really too bad your warranty was void. i guess they must have known what was wrong with your engine and decided that it would be too costly to replace so blaming something else for the problem was just easier. i would never buy another bmw again if i had to go through this with them.
Yeah for sure its my last BMW. The way they have dealt with this is as though the customer is stupid and doesn't know a thing about engines. While I have spent a fair bit of money on this whole exercise, I would be keeping the car for another 2-3 years as cars here are very expensive in Singapore. Who would pay USD$250k for an M3?

My next logical choice would be Porsche. Well I think time will past fast for that one.
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      04-27-2010, 01:23 AM   #11
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Quote:
Originally Posted by elmariachi View Post
Thanks for the reply Malekreza. He did not really mic the tolerances of the motor unfortunately as he wanted to clean up the block quickly and salvage the crank. He claims that if i were to have driven the car for another 1-2 months, the crank would have been gone as well. The crank is in perfect shape now after some slight polishing. There were metal bits in the engine oil which wreacked the most havoc on the cylinder walls and it left a piece of metal stamped onto the top of one of the pistons if you look carefully in the photos above.

Yeah the photos of the almost complete motor is done in a very controlled environment and the new motor looks absolutely gorgeous with the new parts, especially the forged pistons and Carillo Rods.
No problem.

What pistons did you choose to go with? The carillo rods are flawless and will offer you years of trouble free operation and go well beyond what this motor can produce power wise.

Take more pictures if you can as well. Pictures speak a thousand words if the observer knows what to look for.

Good luck. She will be better than new when put back together.
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      04-27-2010, 01:25 AM   #12
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      04-27-2010, 01:30 AM   #13
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Sorry, I know your pain.
For me now, pain is a function of immunity.
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      04-27-2010, 08:46 AM   #14
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What was the reason for the void warranty?
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      04-27-2010, 09:06 AM   #15
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are you gonna get anything done at the same time...like stroker or somehting?
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      04-27-2010, 09:10 AM   #16
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Quote:
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What was the reason for the void warranty?
Modifying the original equipment?
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      04-27-2010, 09:12 AM   #17
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Quote:
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What was the reason for the void warranty?
Top Speed delimited though I did something like 278km/hr and from factory it was limited at 255 or something so that was a giveaway that the ECU was "touched".
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      04-27-2010, 09:15 AM   #18
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Quote:
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are you gonna get anything done at the same time...like stroker or somehting?
Wanted to but I did not want to change the configuration away from stock too much because there wont be any support here. Also, the increased cost as well not to mention the transportation back and forth costs a bomb!nSo I just make do with the stock standard configuration but with much better parts. Compression is also expected to increase slightly. I am contented with this setup so I went for it.
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      04-27-2010, 09:16 AM   #19
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Quote:
Originally Posted by Malekreza11 View Post
Misfires combined with a imbalanced motor will amplify the effect as the motor is already off balance and repeated misfiring will effect the way the motor runs
Damn strait...and prematurely wear out the bearings. However, he would have felt an imbalance right from the start at certain RPM ranges.
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      04-27-2010, 09:20 AM   #20
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The cranks are supposed to be spun on a lathe to check for balancing. I'm sure the crank went into the motor this way at the factory, and there was absolutely nothing you could do, or know about it. This is a clear cut fuck up from BMW and they should have replaced the motor. They covered it up because they didn't want to pay and got away with it by voiding your warranty with no just cause.

Driving the car hard or going to track days, did nothing to your motor. The motor ate itself and resulted in two broken pistons, and scoured cylinder walls.

I would be calling a lawyer real soon! Good luck with the rebuild! Maybe you could try those new schrick cams?
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      04-27-2010, 09:25 AM   #21
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Quote:
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Damn strait...and prematurely wear out the bearings. However, he would have felt an imbalance right from the start at certain RPM ranges.
Most definitely. As I past 4k rpm, there is vibrations within the cabin and as I rev higher, it just gets rougher and rougher. Initially when I was told nothing was wrong, I thought maybe I was acting up due to the misfire. But as I drove it more and more, it became MUCH WORSE. Thats when I approached BMW Asia multiple times and they kept insisting nothing was wrong. They never got back to me even once on their own accord. I had to chase them and they responded. They only told me they would be more than happy to address new problems. WTF? Anyway, its a lost cause trying to mitigate with them. I found an exit and took it at my discretion. However, I know for sure something was being withheld from me the day the warranty was voided. More so, after their royal fuck up of the wrong DCT oil change at 1,200 mile, they also took this chance to void the gearbox too. WOW.
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      04-27-2010, 09:35 AM   #22
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Quote:
Originally Posted by M3Captain View Post
The cranks are supposed to be spun on a lathe to check for balancing. I'm sure the crank went into the motor this way at the factory, and there was absolutely nothing you could do, or know about it. This is a clear cut fuck up from BMW and they should have replaced the motor. They covered it up because they didn't want to pay and got away with it by voiding your warranty with no just cause.

Driving the car hard or going to track days, did nothing to your motor. The motor ate itself and resulted in two broken pistons, and scoured cylinder walls.

I would be calling a lawyer real soon! Good luck with the rebuild! Maybe you could try those new schrick cams?
Wow thats some insight. I did check the price of those Schrick cams. I decided I was in the wrong business after hearing the price! They cost a shitload. From what I know from some people, Schrick cams are basically stock cams that Schrick reprofiles with higher lift, etc and sells them. Dont know how true it is though.
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