CSP
Posts: 15
Joined: Mon Sep 19, 2016 7:52 am

Metal shaving in cylinder 2

Wed Jan 09, 2019 7:48 am

Year : 2016 Country : Canada Model : i3REX Warranty : YES Mileage : 52K

Description :
Long distance run outside temperature -2 deg C, when REX switched on the engine sound was unusually loud. After refueling stop, started displaying "DriveTrain error use electric". Had it towed to dealership.

Service :
a) Replaced temperature sensor
b) Replaced FLAP (no idea what that is)
c) Called Service to check if car is ready, they indicated that metal shavings were found in cylinder 2 and engine needs to be replaced. They are working with BMW Canada.

Questions : Anybody experienced this issue ?

Thanx

CSP
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PBNB
Posts: 103
Joined: Sat Jul 21, 2018 11:28 am
Location: Vancouver, BC

Re: Metal shaving in cylinder 2

Wed Jan 09, 2019 10:10 am

With 22,000 kms on our 2015 i3 Rex and about 1,300 kms of Rex use (and a good portion of that coming in the last 6 months after coding), the motor is still near new and breaking in! How much use does your Rex have on it?

I wonder why they would be looking in the cylinder?

Perhaps they were looking for something that they were expecting to find.

Did they pull the plugs and look inside with a scope. I have heard of techs cross threading spark plugs and then trying the drill and tap out the hole to put a heli-coil in. That can be a source for shavings.

Did they find metal shavings in the oil?

Where these steel or aluminum shavings? Knowing that could help determine where the shavings came from as this could be something that others might experience.
2015 i3 REX

CSP
Posts: 15
Joined: Mon Sep 19, 2016 7:52 am

Re: Metal shaving in cylinder 2

Wed Jan 09, 2019 10:55 am

Service said the spark plugs were changed; guessing based on the appearance of the plug a scope may have been used to check the cylinder.

PBNB
Posts: 103
Joined: Sat Jul 21, 2018 11:28 am
Location: Vancouver, BC

Re: Metal shaving in cylinder 2

Wed Jan 09, 2019 1:43 pm

CSP, do you use the Rex very much?

I wonder if the plugs were seized and when they pulled them out, the surrounding aluminum broke off and fell into the spark plug hole. I guess you didn't have an opportunity to look at the Rex in its current condition. You had also mentioned spark plugs. Did any of the spark plug material break off and fall into the plug hole?

I am asking a-lot of questions because I think this type of failure is very rare and want to know if it was something that the service centre caused or if the engine material is just falling apart.
2015 i3 REX

Atv
Posts: 26
Joined: Thu Dec 20, 2018 10:14 pm

Re: Metal shaving in cylinder 2

Wed Jan 09, 2019 11:37 pm

How was your oil level, and what oil were you using?

CSP
Posts: 15
Joined: Mon Sep 19, 2016 7:52 am

Re: Metal shaving in cylinder 2

Tue Jan 15, 2019 6:39 am

More info

1. REX usage - It gets used once a month on a round trip for 1800 km.
2. The dealership sales guys said that this has happened to 6 REXs in Canada and also in US for which he did not know the numbers.
3. The only thing noticed prior to this failure was the following :
a) On last REX trip, it took longer for the charge to come up to 4% when REX was on
b) On the trip of the failure; when REX kicked in it sounded loud (dealership confirmed the same)
4. Call from dealership - engine ordered; should be delivered in a week.

CSP
Posts: 15
Joined: Mon Sep 19, 2016 7:52 am

Re: Metal shaving in cylinder 2

Tue Jan 15, 2019 6:40 am

Oh yes - forgot, vehicle was due for oil change next month.

PBNB
Posts: 103
Joined: Sat Jul 21, 2018 11:28 am
Location: Vancouver, BC

Re: Metal shaving in cylinder 2

Tue Jan 15, 2019 8:03 am

CSP, thanks for the update.

Seems like a serious problem with the Rex if it has occurred repeatedly.

I guess they didn't tell you what they think is going on with the engine?

What sort of loud noise did you hear at the end?
2015 i3 REX

CSP
Posts: 15
Joined: Mon Sep 19, 2016 7:52 am

Re: Metal shaving in cylinder 2

Fri Jan 25, 2019 7:53 pm

The engine sounded louder but with the regular beat

MKH
Posts: 171
Joined: Fri Nov 02, 2018 5:48 am
Location: Dallas

Re: Metal shaving in cylinder 2

Sat Jan 26, 2019 7:10 am

Seems like a serious problem with the Rex if it has occurred repeatedly.


2. The dealership sales guys said that this has happened to 6 REXs in Canada and also in US for which he did not know the numbers.


Sounds like a manufacturing Q/C failure somewhere in the process, likely on a set/small batch of engines. Shavings left in the engine after drilling/tapping for spark-plugs when a clean-out process/step failed or was missed, maybe?
Mark H.
2015 i3 Rex, Capparis White, Tera World, Technology & Driving Assistant, Parking Assistant, Harman Kardon Audio System, 20 inch wheels, EVoInnovate EVSE

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