Home » How A Tiny $1 Part Killed A $4000 Engine

How A Tiny $1 Part Killed A $4000 Engine

Bmw I3 Range Extender Fail Ts
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New York-based, 54-year-old welding inspector Tom Otto uses his white 2014 BMW i3 every day for his 96-mile round-trip commute. Because his car only gets about 65 miles of EV range (less in the winter), Tom relies on the gasoline “range extender” under his rear cargo floor to get him all the way home.

Unfortunately, in April, while on his way home, the engine just cut out, yielding a “drivetrain error” message on the screen. Trying to restart the engine led to a “horrendous noise coming from the rear of the car, and the engine shut down after about two or three seconds of runtime,” Otto told me. Yikes! So the handy wrencher decided to dig into the problem, ultimately finding that his engine ended up grenaded due to a tiny part probably worth only a buck.

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I noticed this post on one of the BMW i3 pages I frequent on Facebook. “I’m sure many of you saw where my Rex engine failed at 124,000 miles (1103 hours of runtime),” Otto begins. “While I admit this is quite a high number of hours, I was not pleased to find the failure point to be a $65 part.”

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“Upon disassembling the engine, I found the timing chain to have considerable slack in it,” he continued in the post. “This led me to believe that the chain tensioner failed. I disassembled the chain tensioner today, finding that there is a tension spring on the inside that is meant to apply constant pressure to the screw mechanism that keeps tension on the timing chain guide. The end of the tension spring failed where it engages with the screw. A $0.75 part (estimated) caused the failure of a $4000 unit (estimated).”

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To give a bit of background: On an internal combustion engine, the “timing” whatever — whether it’s a timing belt or chain or gears — is what mechanically couples the rotation of the camshaft (which sets the location of the valves at a given point in the combustion cycle) with the rotation of the crankshaft (which sets the location of the pistons at a given point in the combustion cycle). On some engines called “interference engines,” if the timing belt/chain/gears fail and the valves’ positions are no longer properly synched with the pistons’ positions, pistons can actually collide with the valves, causing major damage to the engine.

That’s precisely what happened with Otton’s BMW i3 range extender. The chain that goes over the camshaft/crankshaft sprockets came loose, and thus, the location of the pistons relative to the valves was no longer properly synchronized. The result? Well:

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It may not look like much, but you can see in the top photos that the exhaust valves have bent, and if you look at the bottom photo (particularly towards the bottom of the piston), you can see silver marks from where those exhaust valves hit the piston.

What caused this? Well, the actual chain itself didn’t break, it just got too much slack in it, causing the engine to “jump time,” which means it basically skipped a tooth or or two on one of the sprockets.

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If you look at the image directly above, you’ll see that the timing chain is tensioned via two plastic chain guides, one of which is pushed by a tensioner, which is marked part number 18 in the schematic below:

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Bmw Timing Diagram
Image: BMW

That tensioner, which you can buy for $65, looks like this:

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Image: Wolf Auto Parts (eBay)

But what frustrated Otto so much (and rightly so) is that the reason this tensioner failed, and thus allowed the timing chain to go slack, skipping teeth on sprockets, allowing exhaust valves to collide with a piston, is that a dirt-cheap part within the tensioner failed. This spring:

Failed Spring

 

“I had originally thought that the tensioner might have been a hydraulic unit like I have seen in other engines from other manufacturers,” Otto told me. “But, no, the timing chain tension relies solely upon a mechanical chain tensioner deriving its forces from a very small diameter tension spring.”

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“You can just barely see the coils of the spring within that gap [in the photo of the full tensioner],” he continued. “The top end of that coil spring engages in the body close to the plunger end, the other end terminates in a 90° angle and engages in a slot which is accessible under the 8 mm bolt that is on the end of the unit.”

Apparently getting to the tensioner is no easy job. “It is not conveniently located for easy change out either. The chain tensioner is bolted to the top end of the block on the timing chain side which resides on the end of the engine that is in close proximity to the electric motor,” Otto wrote to me over Facebook Messenger. “It’s also on the backside of the motor engine as you’re looking at it from the back of the car. Though it is only held in by 2 T30 screws and a gasket to maintain an oil tight seal of the engine.”

Otto managed to find a new BMW i3 range extender with starter/generator built in for just $1,500 plus shipping. I took him — someone who has “always been active with Auto repair, small engine repair, wood boat restoration, vintage outboard restoration etc.” (Otto wrote to me that “people often wonder how I came to know all of the things I do about repairing cars, it’s because I never had the expendable income nor time to pay someone else to do something that I could do myself.”) — five days to do the job. Total cost of the repair was $3,000 — significantly cheaper than what BMW charges for a complete new engine.

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Could Otto have saved those $3000 by pursuing the i3’s humongous 15 year, 150,000 mile warranty in CARB states like New York? Perhaps. But, Otto told me, he’s never taken a car to a dealership, he needed the car to get to work, and he didn’t want to waste the time.

It’s possible that the tensioner has been revised after 2014, and that later i3s won’t have this issue. I’m hoping so. Regardless, Otto concluded by telling me: “My posts are more of a cautionary tale, to hopefully help others not experiencing a catastrophic failure.”

A failure caused by a dirt-cheap spring. How absurd! But it’s yet another example of how, while a well-designed timing chain system is much better than a typical timing belt system, a poorly designed timing chain system is just the worst of all words.

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Danny Zabolotny
Danny Zabolotny
15 days ago

I wonder why BMW didn’t use a hydraulic tensioner for this and just a spring… maybe the little engine doesn’t make enough consistent oil pressure for a hydraulic tensioner?

Joshua Pauly
Joshua Pauly
16 days ago

Sounds like the same story as what BMW did to Gen 2 Mini Coopers.

JTilla
JTilla
16 days ago

Oh look, the perfect argument to counter David’s “Timing belts are trash” post.

Speedie-One
Speedie-One
16 days ago

Any good mechanic will tell you to replace the chain tensioner at 100K miles and some manufacturers even have it listed as a service item at set intervals. I have had hydraulic units fail as often as mechanical (spring) ones. I just replaced the unit on my 2015 fit at 140K miles that the previous owner just ignored even though it was obviously failing (3 second rattle noise on cold startups).

Chartreuse Bison
Chartreuse Bison
16 days ago

his 96-mile round-trip commute. Because his car only gets about 65 miles of EV range

Sounds like Tom is kind of a moron. If you need to use the range extender everyday, you bought the wrong car.

Ecsta C3PO
Ecsta C3PO
16 days ago

What’s the fuel economy while using range extender? As long as it’s around as-good as a normal ICE then his 65:35 split is decent, using all his electrons each day and only using his ICE 35% of the time.

Why lug around a gas motor if you’re not going to use it? If he was at a 99:1 ratio then he should just have an EV.

Chartreuse Bison
Chartreuse Bison
15 days ago
Reply to  Ecsta C3PO

Because lugging around a gas motor is a lot lighter (and cheaper) than another 1000 lbs of battery you never use.
Also, from what I understand, the i3 in extender mode sucks, the engine can’t fully power the car, you have to drive it in some kinda low power mode.

Skurdnin
Skurdnin
16 days ago

He probably uses a gallon of gas to go those 96 miles. Nothing moronic about that.

ADDvanced
ADDvanced
16 days ago

I too, am surprised it isn’t using tension from oil pressure. Early 911s had cam tensioners taht were based on springs, and yep, same thing, spring fails, engine destroyed. Common upgrade is ‘carrera tensioners’ that use oil pressure. Way more reliable.

Jeffrey Antman
Jeffrey Antman
16 days ago

I feel a certain amount of remorse as an engineer that BMW could build and sell this highly engineered range extended electric car and can’t get an extension spring right.I was taught in engineering school how to design an extension spring when I took intro to mechanical design in 1969. Those BMW engineers must have missed that day in engineering school.

LMCorvairFan
LMCorvairFan
16 days ago
Reply to  Jeffrey Antman

They likely had accountants emitting garlicky breath in their ear.

Kyree
Kyree
16 days ago
Reply to  Jeffrey Antman

I doubt BMW designed the part themselves. It probably came from a supplier.

Drive By Commenter
Drive By Commenter
16 days ago

I’d see if any reimbursement is possible. It’s NY so it’s a roll of the dice if anything would be possible. There’s probably some weasel language preventing DIY from reimbursement.

Angry Bob
Angry Bob
16 days ago

The V8 in my 540I has two of these ticking timebombs. It’s on its second engine and this is likely what killed the first one.

Frank Wrench
Frank Wrench
16 days ago

My son bought a 2000 Audi TT the other week, 110k miles, interference engine, second owner who only put 9k miles on it in 14 years, and no record of the timing belt ever changed. Drove it home 60 miles nervous as hell there was a ticking time bomb under the hood but made it. Timing belt job was hell, took around 14 hours over a week or so, and a lot of cursing. But in the end I feel pretty good about it, and that it has a hydraulic tensioner holding things together.

I like the concept of timing chains lasting a lifetime (it was selling point for me for our 2010 Mazda 5) but get nervous about things like plastic wear guides and a simple spring breaking leading to catastrophe. I always figured it was a lot harder for a chain to skip a few gear teeth than a belt, but maybe not…

Zorah
Zorah
16 days ago

We should be heaping scorn on KYMCO, the Taiwan based company with plants in China that probably made the engine there. BMW is the victim here! Leave them alone!! BMW is suffering already as you can see.

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