[SchillerM]

Few weeks back we took wife's CPO 2011 E90 335i (57k miles) in for an oil change, I pointed out a coolant leak in the reservoir tank and scheduled an appointment, during the oil change they noticed some oil leaks and added that to the warranty appointment.

Dropped the car off last Monday (23rd), picked up 328i loaner (ugg, miss the 335i already). Got a call Tuesday afternoon from our SA who said the repairs were done BUT during the test drive afterwards "the belt slipped off and broke the block" "will need a new motor". My initial thoughts were it was a catastrophic failure, oil everywhere. Thankfully that wasn't the case. Somehow where the idler pulley bolts into the block broke. Pics below.

BMW has approved the repair, waiting to hear if long or short block will be done.

Anyone seen a failure like this before? I don't know what the oil leaks were, is the idler pulley something that would have to be removed for anything? Is it possible tech did not assemble it back properly? I find it VERY suspicious that this happened at dealership after a repair, hell of a coincidence if so.

I plan to visit dealer today and talk to SA about getting head and intake cleaned up of carbon build up while it is apart, figure a new motor should be done right.
On the plus side, I get the radiator/coolant flush that they wanted massive $$ to do

Matt

[torr]

WOW,
No reason to be in that area to work on coolant reservoir and oil change. I'll bet you they dropped a tool while the engine was running. Best of luck.

[BeastMode335i]

Originally Posted by torr

WOW,
No reason to be in that area to work on coolant reservoir and oil change. I'll bet you the dropped a tool while the engine was running. Best of luck.

x2..

"Oh we were checking your washer fluid and your charge pipe snapped" lmao..

[Fundguy1]

Uh, he did it. Lol. Somebody did something really wrong. Get a new engine, laugh, and never let that tech work on your car again. Lol

[robthewrench]

Only a dealer would recommend replacing the motor to fix a broken threaded boss on the block. Any indy would be sending this to a machine shop to get it welded and re-tapped.

[Efthreeoh]

Originally Posted by robthewrench

Only a dealer would recommend replacing the motor to fix a broken threaded boss on the block. Any indy would be sending this to a machine shop to get it welded and re-tapped.

Agree this. Looks like someone over torqued the bolt at some point and cracked the boss and it finally failed.

[335commuter]

Originally Posted by Efthreeoh

Agree this. Looks like someone over torqued the bolt at some point and cracked the boss and it finally failed.

Fair enough, but if they didn't do this everyone here would be telling this guy to demand a new engine, saying how BMW shouldn't weld an engine back together, and calling the dealer a stealership. Surprised they replaced it as well, but if OP gets a new engine out of it that's a pretty good deal for him.

[redline2001]

Originally Posted by 335commuter

Fair enough, but if they didn't do this everyone here would be telling this guy to demand a new engine, saying how BMW shouldn't weld an engine back together, and calling the dealer a stealership. Surprised they replaced it as well, but if OP gets a new engine out of it that's a pretty good deal for him.

My thoughts exactly

[ctuna]

When the belt breaks it takes out the front main seal and chunks of
it go into the Oil Pan and can get sucked up into the motor. The belt
has a spring tensioner that some say should be replaced every 60k
to prevent this from happening.
Never heard of it breaking a block before though.
But the picture show it.

[Welcome to NBA Jam]

Originally Posted by 335commuter

Fair enough, but if they didn't do this everyone here would be telling this guy to demand a new engine, saying how BMW shouldn't weld an engine back together, and calling the dealer a stealership. Surprised they replaced it as well, but if OP gets a new engine out of it that's a pretty good deal for him.

It sounds like they're aware that they're at fault and won't make a big deal out of it, which is exactly how it should be done. Minor expense compared to poor publicity and possible court. They've saved themselves a lot of time and money.

[Efthreeoh]

Originally Posted by ctuna

When the belt breaks it takes out the front main seal and chunks of
it go into the Oil Pan and can get sucked up into the motor. The belt
has a spring tensioner that some say should be replaced every 60k
to prevent this from happening.
Never heard of it breaking a block before though.
But the picture show it.

I don't think the tensioner failed, the block did. The idler pulley bolt broke the threaded boss and the belt slipped off.

[cybermgm23]

Originally Posted by Efthreeoh

I don't think the tensioner failed, the block did. The idler pulley bolt broke the threaded boss and the belt slipped off.

And likely at a very high load. All techs love going WOT to "check their work".

[robthewrench]

Originally Posted by 335commuter

Fair enough, but if they didn't do this everyone here would be telling this guy to demand a new engine, saying how BMW shouldn't weld an engine back together, and calling the dealer a stealership. Surprised they replaced it as well, but if OP gets a new engine out of it that's a pretty good deal for him.

I agree with this. The dealer charges top dollar for repair work, so zero excuses. But, only a dealer has the over-head cost margin and parts discount to be able to offer a new engine vs. a repair of the boss via welding/tapping.

[roundle]

So did you get a short or long block?

[Welcome to NBA Jam]

Originally Posted by roundle

So did you get a short or long block?

I think he got the extra medium block.

[E90ALLMANUAL]

Those idle pulley/tensioner are known to fail. I replaced a few front crank seals because the pulley broke and the belt cut the front seal.

Keep an eye on your belt. If you see the belt off center it's time to replace the pulley.

My guess is that the tensioner is too strong for the aluminum bolt that is holding it.

[SchillerM]

Originally Posted by roundle

So did you get a short or long block?

They replaced the long block. Should have car early next week they said.
I will update once I have paperwork.
Wife is definitely missing the car. 328i just doesn't cut it.. although on these horrible Houston roads the base suspension is pleasantly plush vs the MSport stuff. Luckily the house we are buying is in an area with a lot better roads.
Matt

[trk06]

congrats on the new engine

[Hacksaw]

Indeed! Good to hear its a story with a happy ending and you get it repaired.

[SchillerM]

Picked up car this afternoon on my lunch break. SO nice to be behind the wheel of that again. Loaner 328i was just so bland... Nice thick wheel and throttle response was missed!

I snapped this photo in the dealers stack of papers, the ones they gave me just say N/C for everything... Parts total on top, labor on bottom, obviously both are inflated numbers and not true cost to BMW.

I noticed that there was no hood insulation, I asked and was told this is normal. Is that accurate? My M5 has insulation, and I see where it would be on the 335i. I haven't looked under the hood enough to know if its normal.. I see pictures on google of cars with and cars without so

Matt

[tlow98]

Consider it a blessing this happened while at the dealership! Looks like a poor casting and could have happened to you at anytime...

[pcjackson06]

No hood insulation on mine.