Engine rebuild by specialist has turned into disaster. Your opinions welcome.

Bluebottle

Member
 Plymouth
https://z4-forum.com/threads/should...ilt-your-opinion-welcome.155001/#post-2149243

See above for initial post last year.

Apologies as this is about my E39 525i that I have owned for 13 years, not my Z4, but I really value your opinions.

No compression so car was transported to garage May 25 to have oil rings replaced and other worn/dirty parts replaced. Estimate was £2500.

After endlessly chasing garage owner/mechanic for seven months I was eventually told I needed rebore, new pistons, cylinder head decoke, etc. I gave go ahead last November expecting bill in excess of £5000!

More chasing and eventually got car back February with new MOT. Nine months later.

Apart from a few miles I did not drive car for a month because of the following issues.

ABS and ASC warnings coming on after few miles that garage told me "just came on the morning I collected car" . Code readers said NSF signal fault so I replaced that sensor with two genuine BMW and one new Bosch sensor but no improvement. ABS module had probably gone faulty while with garage

Investigating condensation on windows identified leak from rear door barrier thst over a very wet winter while with garage had soaked rear carpet so I had to remove all seats, centre console and HVAC controls to remove carpet and dry in the house for a week. Then repair vapour barrier.

No windscreen washer as hoses had been very poorly bodged with incorrect colour/bore pipe with super glue and bits of copper! I had to replace them from pump to jets with proper black hoses/junctions.

I had to replace all four three year old 5mm treaded tyres as the sidewalls had cracked and were misshapen from standing for many months. I also took the opportunity to have the wheels refurbished by South West Wheel Repairs in Exeter that did an excellent job.

Engine under tray was missing. Garage assured me this would be found and replaced when I returned for 500 mile engine oil and filter change, so I left it at that.

Rear bumper had been resprayed (actually quite well) but I was not told about any incidents.

Once back to commuting gently and running engine in for 500 miles, I noticed other issues.

Aircon was not working at all, just hot air.

Engine was very tight, easy to stall and consumption down from 31 to 26 mpg. Mechanic told me this was to be expected and would improve after 5000 miles.

Vibration/misfire while driving and progressively worse over 65mph and worryingly bad over 70mph. I have had all four wheels swapped around, changed pressures, had wheels balanced, tyres off, wheels checked and rebalanced but no improvement so issue is elsewhere.

Oil leaking from sump gasket. A job I spent three days doing for MOT 7 years ago, and not something I was ever going to tackle again.

I am not enjoying driving what should be a smooth comfortable old 5series.

Anyway car is back with garage today to have oil changed and remedy issues. I have been looking at images I took last year for insurance and found this one that clearly shows aluminum heat shield protecting ABS module from exhaust; another item that I now realise has not been refitted to my car whilst with garage. As I understand it omission of this shield is the primary cause of the circuitry in module breaking and causing expensive time consuming repairs.

So I await the return of my beloved E39 in goodworking order but honestly expect a vast host of problems, bills and excuses.

Please feel free to advise/give opinions.

Thanks.
 

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Evening

First off I’m gutted for you. I know how much you love that 5 series and if you like a car that much and it’s not ‘good’ it’s sh1te

It’s easy to say do this or do that re the garage- but reading that account from your view it would appear they didn’t really want to do the job?

Have you expressed your disappointments with the things you are unhappy with? If done well you can state your case clearly and ask for them to consider doing things to remedy…

But- would you be happy letting them?

I feel your pain. I am sure others will chip in with opinions
 
This must be gutting, you have my sympathies, but I can only give you a few over observations from rebuilding an engine the other year.

There is no such thing as an engine being "tight" after a rebuild. Start it, hold 2500rpm for a few minutes, then get it on the road and working hard to bed the rings in to avoid glazing them and getting a life of oil consumption. It's actually hard to get these big engines doing enough work (up to 3/4 revs and big throttle openings) without needing a fresh license. Running in properly takes minutes, not hours or days. "Running in, Please Pass" died out decades ago.

The engine I rebuilt got immediately thrashed up the hill behind me. Several times. Maybe 3 miles total. After that, I did 30 modestly hard miles but that made no difference, it was already run in. Never uses any oil either.

Anyway, hopefully they took the block to someone who knows about these things because Alusil is not something you re-bore. They can be refinished and that's fairly specialised in it's own right.

So, by now, the engine is running as well as it ever will, which means they've put it together wrong. If there's no errors, my money's on the timing being out.
 
Evening

First off I’m gutted for you. I know how much you love that 5 series and if you like a car that much and it’s not ‘good’ it’s sh1te

It’s easy to say do this or do that re the garage- but reading that account from your view it would appear they didn’t really want to do the job?

Have you expressed your disappointments with the things you are unhappy with? If done well you can state your case clearly and ask for them to consider doing things to remedy…

But- would you be happy letting them?

I feel your pain. I am sure others will chip in with opinions
Thanks bigwinn,

I have been polite and clearly given them my list of issues : the car is still with them now, but again nobody has called me to keep me updated so I will call them tomorrow.

No, I have already lost faith with them even before reading Scott's post above..................

I don't think getting blunt with them will change their work ethics. We shall see.
 
This must be gutting, you have my sympathies, but I can only give you a few over observations from rebuilding an engine the other year.

There is no such thing as an engine being "tight" after a rebuild. Start it, hold 2500rpm for a few minutes, then get it on the road and working hard to bed the rings in to avoid glazing them and getting a life of oil consumption. It's actually hard to get these big engines doing enough work (up to 3/4 revs and big throttle openings) without needing a fresh license. Running in properly takes minutes, not hours or days. "Running in, Please Pass" died out decades ago.

The engine I rebuilt got immediately thrashed up the hill behind me. Several times. Maybe 3 miles total. After that, I did 30 modestly hard miles but that made no difference, it was already run in. Never uses any oil either.

Anyway, hopefully they took the block to someone who knows about these things because Alusil is not something you re-bore. They can be refinished and that's fairly specialised in it's own right.

So, by now, the engine is running as well as it ever will, which means they've put it together wrong. If there's no errors, my money's on the timing being out.
Thanks Scott,

God, it just keeps getting worse. Yes, nobody " runs in" their new cars engine. I shall keep you updated.
 
Sorry if there was any teaching of egg sucking in that. I was trying to dispel anything along the lines of "give it another few months to get it run in" that they may have spun.
 
Sorry if there was any teaching of egg sucking in that. I was trying to dispel anything along the lines of "give it another few months to get it run in" that they may have spun.
Not at all Scott, I was just saying what I really knew, but when you pay someone doing something you have never done then you start to believe them.
Driving 5000 miles will take me over a year, and by then out of their warranty period 🙄
 
I'd be very, very angry. So kudos for keeping your cool.

Ask why the bumper has been repainted, and then ask why the tyres were knackered. Surely they're aware of leaving a car standing?

I'd get a second opinion somewhere else. Yes, it's more money but if it's your baby, then long term it makes sense
 
@Bluebottle
I don't understand how you can be so 'calm' about all this TBH.
If it were me, I would have burned down the garage owner's house and workshop long ago.

Sounds like a typical modern 'we don't give a shite as long as we get paid' attitude to me. It is everywhere.
 
@Bluebottle
I don't understand how you can be so 'calm' about all this TBH.
If it were me, I would have burned down the garage owner's house and workshop long ago.

Sounds like a typical modern 'we don't give a shite as long as we get paid' attitude to me. It is everywhere.
Thanks Pondy.

I am not normally calm, however all your opinions are helping me know that I am within my rights to kick off, but will it get me anywhere?

I suppose there is only one way to find out, what have I got to Lose?
 
That sounds like a nightmare OP. :(

Do you go back to them to sort out their cock-ups knowing they don't seem to give a sh1t and maybe get it back even worse?

Or go to a proper specialist that will involve more cost, but hopefully sort things out properly?

I think I'd go for the latter option however painful it felt.
 
Gutted for you as I read through this thread. I fear the best way forward is going to cost you even more money. Making it clear to the garage that you think they are shafting you won't come as a surprise to them. They are after all. It will however give them an excuse to actively wash there hands of your problems. So I would tread lightly there.

Clearly they have done a poor job. Give them a chance to rectify what they are willing to. But it sounds like you will then need to get others things sorted.

The way it reads from here, that is probably going to mean drawing a line under current work and paying someone else to fix the issues that may or may not have been caused by the car being neglected/damaged whilst sat in the current garage/workshop. Simply too hard to prove what caused those issues and they know it.
 
It sounds like they took on a job for which they lack the experience and ability to do. I would recover the car and ask for a full refund. When they refuse, take the car somewhere competent and ask them to rebuild the engine, documenting all of the failings of the original garage. Armed with that, I would ask for a refund a second time. When they still refuse, I would take legal advice. If a lawyer is of the opinion that legal action is a waste of time, I would post the contents of the report on every review site and forum I could think of before asking for a refund a third time. If that fails too, leave the reviews in the public domain and consider Pondy's approach...
 
Thanks to you all for sympathising and your considered advice.

Yes, we all seem to be of the same opinion, but the problem of finding a reputable specialist is the same issue I had 18 months ago and led me to regrettably choose the "best" one that was keen to do the job. I shall have to look further afield.

Sorting all this out will require money, time, energy and mental health along with some heated exchanges with garage owner; I am seriously considering just getting shot of the car and moving on. I had dreamt of having my comfortable E39 with silky smooth new engine, not an old car with vibrations and complicated MOT failing problems to rectify. 😣
 
There are far too many companies these days that don’t have a clue and are criminally incompetent in all trades. As said above it’s all about the money.
 
There are far too many companies these days that don’t have a clue and are criminally incompetent in all trades. As said above it’s all about the money.
Yes I agree, Mike. I try to do as much on cars as my old, broken body can manage, as I simply don't trust garages to do a "quality" job. But my BMW is 25 years old and relatively simple compared with a new 7 series, nevertheless they cannot even get the basics right.
 
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