Here's where the S54 engine in my M Roadster explodes
During a spirited drive back from New Braunfels the engine began making a loud knocking noise when under acceleration. Problem seemed to get worse as car warmed up. I didn't drive on the 10th, and took the car to BMW of Austin on the morning of the 11th. I was fairly certain that it was simply overdue for an oil change, I'd been waiting for the dash indicator to tell me that it was time for service, and that a simple oil change would rectify the issue.
As it turns out, it's likely that I've been struck by an issue common to the S54 engine in my car (also found in the 2001/2002 M Coupe and M3. More details can be found at this site. (click the "detailed overview" link)
I posted messages to the relevant online sites and you can track the discussion generated here and here. It appears that I'm the lucky first instance of failure in an M Z3 Roadster or Coupe. I feel so special.
Timeline
11-Nov-2002
Having been uncomfortable leaving the car parked at the edge of the dealer's lot the night before, I gingerly drove the car in to the dealership on Monday the 11th. Naturally I'd overslept and didn't arrive at my planned 7:00a but rather a few minutes after 8:00a. This put me at the end of a long line of other cars, and Pavel indicated that they probably would not have time to see the car that day. He did take the time to observe the clattering noise and promised to call when they knew more.
He called several times throughout the day to keep me appraised of the progress, but ultimately they were unable to have a technician look at the car.
12-Nov-2002
By mid-afternoon the BoA technicians had decided that the S54 engine would need to be replaced. Although vague on details, Pavel relayed that the noise was coming from the lower portion of the engine and that they'd need to replace the long block. While retrieving my garage door opener from the car I was able to snap a pic of the repair order with some scribbled notes from the technician which provided a bit of insight into the nature of the problems.
They put me into a loaner 325ia and explained that they'd already ordered the replacement engine and expected the car to be down for 1 to 1.5 weeks. So far I have absolutely no complaints about the level of service received from BoA. The situation is unfortunate but their handling of matters to this point has been effective and professional.
15-Nov-2002
Taking me at my word when I told him "Please don't feel compelled to call me each day, even if there is no progress" I didn't hear from Pavel until Friday afternoon. I was told that the replacement engine had arrived and work had begun. He predicted completion as early as Tuesday (the 19th), but stressed that this was not a firm date.
18-Nov-2002
Had to drive to Houston for work and rather enjoyed the 320i for the drive. It was perfect convertible weather, though. I sure miss my car. No news from BoA.
25-Nov-2002
After a few missed dates the car was finished and ready for me to pick it up in the early afternoon on Monday. BoA has swapped the engine, and fixed my hinky driver's side door handle as well. They've also washed and waxed the car so naturally it poured down rain all night and the next day.
Although my cost was naturally $0, this being warranty repair work, I did catch a glance at the internal paperwork which will go back to BMW. BoA is charging out $15,300 or so for the repairs. I'll scan in my paperwork which details the work performed.
The car sounds and feels fine, although I've been treating it gingerly. I've got another 1,000-mile new engine break-in period to undergo. Tentative plans to scoot up to Dallas for some Steak n' Shake (mmmm) which will eat up nearly 400 miles.
FAQ
What does "spirited drive" mean?
The road back from from New Braunfels is about 65 miles of interstate. We made quite good time and enjoyed the sunny 80F weather but at no point was I driving in a manner that would embarass my mom. Just doing what the car was built for. Certainly nothing going on at the extremes of the tachometer, just some above-the-limit highway driving.
Dude, they don't sell 10W60 at AutoZone! You voided your warranty!
There appears to be some variance in what the S54 owners manuals call for from model to model and year to year. I was quite careful to get an oil weight that was specifically listed as acceptable for my car, although the manual did encourage me to get 10W60 if possible. Had I been unable to add a "legal" oil type, I'd have simply gone home and taken the car in for service the next day. As it stands, I added less than a quart of a name brand oil in a weight that my owner's manual approved. Believe me, I felt like a real doofus standing there in the AutoZone with my owner's manual in hand comparing labels. Since the engine lasted an additional three months and several thousand miles I'm skeptical that this contributed to the failure.
What's the production date on your car?
Well, I can't check the door frame -- the car's at the dealer right now. But if you look on the service order picture I snapped it lists as 12/01/01 which certainly puts me right in thick of the most troublesome build months for these S54 engines.
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