[toiingg]

This sounds eerily familiar to the noise a bent con-rod makes. Was your car ever driven in waterlogged streets / driveways ?

[Sohail_91]

I am sorry to hear about the ordeal you’re going through, Ashish. Dismantling the engine of an almost new, low-mileage car without a clear diagnosis plan is unacceptable and, in my opinion, downright criminal.

As many have suggested, you should firmly demand a brand-new, crate-packed engine replacement. If the dealer refuses to cooperate, escalate the matter to higher-ups at BMW India.

I had an issue with BMW KUN Bangalore, where they refused to process my refund. After multiple failed attempts with the dealer, I escalated the matter by emailing BMW India’s CEO and the Head of Sales, Customer Support, and Aftersales. The very next day, my refund was processed; something the dealer had flatly denied earlier.

One of the reasons I dropped BMW from my list was the horror stories I have heard about the Ranchi dealer. If you would like, feel free to drop me a message; I would be happy to share the email IDs of the relevant executives.

Hope your issue gets resolved soon, and cheers to our Manipal days!

[eccentric]

This sounds identical to a connecting rod bearing failure in one of the cylinders. Might be owing to the inadequate oil flow to lubricate that necessary part. One could observe the scoring in the inner face of the connecting rod bearing that mates with the crankshaft.

Standard practise is to rebuild the lower block of the engine using Piston A/B/C ascertained by deeming the value of bore diameter according to the SOP prescribed in the workshop manual. Also, if the bore erosion is far worse, then a Half Engine Assembly( engine lower block pre-assembled with pistons, connecting rod and crankshaft) will be prescribed to solve the case.

IMHO, if this is the failure and BMW personnel are insisting to work upon the engine by any modes described above, never let them do it. You car's mileage is less than 10,000 KMS and has all the warranty intact yet. You should by all means make them replace the Engine assembly as a whole.

[Vikash Kumawat]

Sorry for the ordeal sir, I hope you will get your car in perfect condition soon.

Since you mentioned that the service center is 180 kms from your home, you should try to reach out to the BMW service centers located in tier 1 cities like NCR and Mumbai, as they manage and tackle the more number of cars than smaller cities, they might have more trained and experienced employees.

Good luck

[pranavt]

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The ticking noise could be anything. Diagnosing it based on a small 30 second Youtube video is not possible.

However, one thing I do know is that if one wants to find the source of any noise, it is paramount to figure it out BEFORE opening the engine, since, you know, you cannot recreate the conditions of the ticking noise with the parts lying on the floor. What these geniuses are trying to do is have an open engine, then apparently MEASURE parts? How can they guarantee that any fixes they do will solve the problem before they put together the engine? And what happens once the engine is put back together and the sound still persists? Open up the engine again?

Diagnosing mechanical issues by sound takes years, even decades of experience.

I will refrain from speculating on what the source of the noise could be. However, since this was not present earlier, and has only surfaced after the engine has run a few thousand kms, it points to the source being something that has worn out, or loosened over a period of time.

Taking apart engines and putting them back together is not rocket science; and trained mechanics with the right tools should be able to put it all back together. Unfortunately (both for you and them), the service team has taken the nuclear option before they knew what needed fixing. At this point, the smartest thing to do would be to consult with a lawyer and figure out your options. Have the lawyer communicate with them on your behalf. They would have seen dozens of helpless customers messaging/emailing them to ask for updates, etc. Once you loop in their executive team and bring in a third party to bat for you, their behaviour will change. There is no need to go legal yet, but have everything in writing for that eventuality.

PS: Do they not even have an engine stand??!

[peugeot96]

Very sorry for your troubles with your dream car. Did the service center perform a borescope diagnosis? This involves a non destructive method using a specialised scope to check the innards before taking a call to dismantle or replace major components. Insist on a factory engineer to fly down for an inspection. Get in touch with BMW hq and make noise.

[svsantosh]

Originally Posted by ashish2135

Attached video of the inspection process from the Dealer which was received earlier. The ticking noise can be heard in this.

My bet is on fuel injector bust due to desi fuel, flooding the cylinder and causing a misfire. Anyways, sharing a few more of 'If I were there...' pointers.

Pull out the easy to put back things first to be checked/analysed.

1) Oil filter - cut open slowly and scan with a magnifying glass for gold dust, 99% issues will be caught here (rod knock, main bearings, valve slap - any frictional contact/abrasion).

2) All plugs/coils/fuel injectors/nozzles (P/D) - tells a million stories just by inspecting a harmless spark plug. There are beer time folklores around 1 plug - tells you so many things. Same with a HP injector/nozzle.

3) Oil sample analysis - can tell by % of metal/minerals in it, takes 3-4 days for the report to come.

4) Inlet manifold/Outlet manifold/catcon/O2 sensors - all these carry the bulk of a badly firing engine, will either store residue of back compression, or carry sludge and deposition of burnt oil in the honey comb, same with a pre-worn out O2 sensor.

5) Compression check - most basic thing to check. While at it - use a bore scope pin hole camera to inspect the bore/cyl internals.

6) Coolant leak into combustion chamber (mostly non relevant here - but do check for water ingress into cylinder and resulting misfire - again a very basic test to do.

7) The most 21st century thing to do - plug and laptop and record/read/store the codes in idling, city, WOT, highway, day, night - how difficult can it be afterall?

What beats me is - I do not see any mention of these most basic house rules of opening up an engine followed here - Or did the OP not mention it? Or is he not aware of it?

If these tests were done - requesting to please share the findings.

If these tests were NOT done - then wonder what prompted the decision to open up a entire engine. This can make the brand look real bad. I mean, it is not like the chief mechanic of the autho showroom just opens up a BMW engine in India or anywhere in the world - They need a written authorization and workorder/jobcard approval from BMW India to open up and entire engine down it its cast block. That hints they know something - just wish they were a bit transparent and educate the end user about their process and methods.

Not being transparent is the only reason this thread exists - classic failure of PR from the part of the brand owner. If only they have a policy to keep the customer in the know how and reassure their method to madness of stripping a car - the customer wouldnt scurry around for answers which no forum or website can provide easily.

I couldnt help but to point out...

What is the different between a Maruti Engine shop and a BMW engine shop... In INDIA

The section width & Low Profile tyre used shows you are a high class VIP customer.

[Straight6_N54]

This is every car enthusiasts worst nightmare. The only right solution is to file a case in the consumer court, get a strong legal team and raise a case against the dealer. Consumer cases have been quite strong lately and you are likely to get a favourable outcome.

Do no settle for anything less than an engine replacement, the way your engine has been handled is pathetic. FNG's have better equipment than that service center. Email all the authorities with your images and concerns. All this is easier said than done, but the more you delay your car is depreciated way faster due to all the work that has been done in the engine side.

[sharkashwa]

Wholeheartedly agreed with all the posts here. What they have done in regards to your vehicle is breaking the standard operating processes of any self-respecting brand's service handbook, every step of the way!
They should never have broken the seal of that engine unless every other non-invasive method proved futile. They are a myriad BMW diagnostic tools available that could show the health of the engine, I also did not see any automotive stethoscope being used to try to pin-point the source of the ticking noise.
Even if they wanted to take the engine out, this certainly is not the way to do it. I have two BMWs in my garage and have done several engine related services myself; I have always supported its weight through a hoist during work. Even I would never dare placing an engine on a tire.
I think it's too late at this point but when I heard "ticking noise", my mind instantly went to multiple posts regarding premature failure of hydraulic valve lifters on the B48 forums, there were also some cases of timing chain failures on these engines. If this information is available to me, I'm sure it must have been available to the workshop folks along with a tried and tested method to resolve these issues.

I would urge you to get in touch with the higher level supervisors and understand what they are doing to help you. Otherwise, it is time to start demanding for a complete engine replacement.

Sharath

[ashish2135]

Originally Posted by Jeroen

It just baffles me they seem to taking an engine apart without having a clue what the noise could be? It looks they have taken everything apart? Why? How will you find a simple noise like this? Unless they get very lucky and find some visual clues as to what was wrong, which I doubt with a noise like this.

The fact that they had no diagnostic analyser is a bad omen too. You need a lot of experience and knowledge to make use of them. Its rarely as simple as just reading a code.

They way they have taken your engine apart and it sits on a tire in their workshop with parts everywhere is beyond believe! BMW can't do this. It is beyond amateurism.

I'm very sorry but the whole approach screams:
We have no clue
We don't know what we are doing.

Thanks Jeroen! It has been almost 25 days since they started the engine dismantling work on 13th February. The service centre is still procuring special tools to perform yet another inspection.

Inspite of continuous prodding no one is sharing any data or report as to what might have gone wrong or the parts that may have been causing the noise.

My mail to BMW India has no effect on the process and I just get a response from their Customer care team with no favourable output.

Originally Posted by voldemort

Can you please check such videos on YouTube or something and see if it sounded similar to your car? The keyword you’re looking for is “valve lifter noise”. That may (or may not be!) your problem.

Also just a general piece of advice for everyone reading this: don’t let anybody – including authorized service centers – take apart your engine unless they have an very precise plan on exactly what they’re going to do. They should be able to tell you beforehand that “So-and-so part has this specific problem. This is how we determined that the said part has this problem. We’re going to repair/replace it. It will take X days, and will (depending on warranty situation) cost you approximately this much.”

These things are complicated and built with tight tolerances. Doing exploratory search on a BMW engine by opening it up is a strict NO. It’s akin to throwing things at a wall to see what sticks.

Also, this particular engine is very popular across the world. Whatever problem you face with it has probably already been faced by somebody before you.

The noise seems exactly the same as the Youtube videos for Valve Lifter noise. I had asked several times on call and on mail to share a proper plan for the inspection process and timeline for this whole activity that they intend to follow before I allowed them to open the engine.
Surprisingly, the Service Head at the dealership has already changed during my course of interaction. Getting any concrete information seems to be a futile exercise.

Originally Posted by eccentric

You car's mileage is less than 10,000 KMS and has all the warranty intact yet. You should by all means make them replace the Engine assembly as a whole.

I have been pushing for an engine replacement to end my ordeal but BMW India is just not responding to my mails. Earlier this week I got in touch with someone from BMW Customer Support for my region through a contact, they said they will review my case and let me know about the situation today.

I intend to write to the CEO next week as a last resort if they are unable to help out.

Originally Posted by toiingg

This sounds eerily familiar to the noise a bent con-rod makes. Was your car ever driven in waterlogged streets / driveways ?

No. There is not issue of flooding or water logging in the area where I live.

Originally Posted by pranavt

The ticking noise could be anything. Diagnosing it based on a small 30 second Youtube video is not possible.

However, one thing I do know is that if one wants to find the source of any noise, it is paramount to figure it out BEFORE opening the engine, since, you know, you cannot recreate the conditions of the ticking noise with the parts lying on the floor. What these geniuses are trying to do is have an open engine, then apparently MEASURE parts? How can they guarantee that any fixes they do will solve the problem before they put together the engine? And what happens once the engine is put back together and the sound still persists? Open up the engine again?

Rightly said. I read on many B48 forums about possible issues that could cause the noise. I suggested the Service head to check these parts or even consult with the BMW Technical team for their opinion but they never bothered to pay heed to this. The noise could be from anything but such a common engine which is in so many of their global models and BMW has not yet solved the mystery of the noise.

I even asked them about how they would recreate the noise when the engine is totally taken apart but I was never given any response.

I always got the standard automated response of "We are working on it and will update shortly".
I hope it does not come to the point that I have to pursue this legally as it would be a huge dent to the auto-enthusiast in me.

I don't even want to comment on how the Service centre handles the cars .
My inside screams when the pictures of my car are shared with me:

• No seat protective cover
• No tyre stand
• No engine hoist
• No storage for intricate engine parts
• Window of the car is always open (confirmed by the BMW mobile app)
• No use of protective mats for the body

In my case, there has been a delay of almost 4-6 weeks just because the dealership is not equipped with proper diagnostic tools, first in December and now again.




It just shows that BMW India has not control over how the Service centres operate, there is no SOP followed, no audits conducted, no consequences for the dealer partner. No care for the customer either.

My vehicle is nearing the 2 year mark and I am getting reminders for Insurance Renewal. I do not know what this policy will cover: a car that has been sitting in the service centre rather than my house, a car than has not been driven on the road in the past 2 months, a car that is lying on the operation table with it's heart and guts opened up!

[Driver 33]

Hi Ashish, I'm a fellow 330i pre-facelift owner here, looking at your case it sounds like timing chain slacking sound or premature failure of tensioner as of my experience, the case has been poorly handled I've felt, the ASC has a special tool for locking the camshafts and checking the timing is in place. Taking the call to open the engine without clarity on what to look for seems very clueless.

The problem here is basic diagnosis fundamentals have been missing. The following technician should first carry out the compression test, if this ticks off need to move onto checking the ignition system and if this ticks off then the engine should be rotated manually to check for unusual tightness or loosens when rotating and re-adjust the timing if required if necessary. There could be a spun bearing or scorching on main bearing or rod bearing as well for which still the engine doesn't need to be opened and can be accessed by opening the oil sump and checking it.

This generation we have all the necessary tools to check engine health with least disassembly required. The valves and pistons can be checked as well without removing the engine head and using a endoscope which is a minimum for a BMW ASC to let hold of that tool. If any of the following cases were found such as spun bearing, bent valves or so it makes sense to open the engine and see what can be done, repair or replace engine under warranty.

I was expecting BMW ASC to have much better tools. Laying down a B48 engine on a tyre is disgrace and a engine stand is least expected tool to get hold of cause most BMW engines need to be removed from the vehicle to perform major maintenance such as timing chain replacement or so, good tools makes life less stressful for the technician - following people and diagnosis can be carried out with much more composure.

[kushagra452]

Has this issue been resolved?

[ishaan_jc]

Hello sir, any update with the progress of your vehicle? I’m a fellow 340i owner, and have bought the same from Titanium Auto. I’m concerned with their ability to deal with proper service and maintenance of such high end cars. I hope its going good and hope you update us all on this thread as soon as possible.

[White bird]

A colleague of mine brought a X5. After a few months some noise started from the engine. The car started making noise like a diesel engine. Took it to the service center. They claimed that the sound was from the turbo charger. I could not believe it so we took a turbo charger from another colleague's x5 and fixed on this . No change in the sound while the other car didn't make any extra sound . Took both the cars to the service center and showed them. They again took the car , kept it for a week and returned it . No change in sound. Got fed up and took the car to UAE. They checked the car and said that they will not do anything because the car was not sold in UAE. Took it to a independent service center in AlAin. The mechanic told that there was some problem with the engine and nothing could be done without opening the engine. Returned without doing anything. Now five years and around 150,000 kilometers. Car still makes sound like a diesel engine. No other problems. Got used to the sound now

[ashish2135]

UPDATE: Engine replaced under warranty, noise problem resolved

Hi everyone, thank you so much for the support and the kind words. I am glad to inform you all that the engine was replaced under warranty and the car has been returned to me. I got my car back on 12th April and I have been meaning to update the forum. I have driven approximately 200 kms after the delivery and I am happy to inform that the engine noise has gone.

Having a new engine in the car, I am still in the break-in period and I am getting lower fuel economy than expected. I was not told the root cause of the engine noise by the Service team or BMW India. My car spend almost 75 days at the service centre this time.

To elaborate on the process of successfully getting my car back, things took a positive turn only after I reached out to a close contact at BMW HQ. I explained my situation to him and he then put me in touch with the correct person who looks after Service cases for the entire region. I was confident that things would be resolved soon by the sheer confidence of the Service personnel. There must have been a push internally to resolve this case.

The approval for engine replacement came on 22nd March and the car was ready for delivery by 8th April. This was made possible only because my friend could locate a spare engine at the plant and it was allocated to me. I reckon that my car would have been at the Service Centre for far longer if it were not him. I can't thank my friend enough.

I had bought a 5 year BRI & BSI Inclusive pack at the time of purchase of my vehicle. My 2nd year service was missed due to this fiasco. As compensation I has asked for a 5 year Warranty on the new engine from the date of installation, effectively extending my EW to 7 years. Also, extend the BSI Inclusive Plus pack to the 6th year for the missed service.
BMW stated that the EW cannot be approved due to issues at Bajaj who handle the Extended warranty for BMW now. The dealer reached out to me that they can refund the 3rd year EW amount to me as compensation, which is the lowest possible amount.

This seemed quite unfair to me for the sheer displeasure of this experience and the mental harassment I has to go through. However, I have accepted the same as I want to put this incident in the rear view mirror and enjoy my car. I am still waiting for their confirmation on the Service part.

Other than this, the RC card and Insurance policy needs to be updated with the new engine no. I hope these formalities can be completed by the dealership soon. Till such time, I hope I can put many miles on the car and enjoy the fabulous machine that it is meant to be.