Thoughts on coated shell bearings?

frazell

Member
Hi all,

My 2006 Z4MC lunched its engine about a year ago due to a spun conn rod shell bearing and subsequently ended up with an engine swap from an E46 M3.

All is good since then and during the swap the new engine received some uprated ARP conn rod bolts. My replacement engine had supposedly done 56k miles when it was transplanted and has now covered about 15k miles in its new home.

I'm currently carrying out quite a bit of preventative maintenance on the car and I'm thinking about having the shell either inspected/replaced with OEM or upgraded to coated shells.

Question to the wise on the forum is what are the thoughts on coated shells? I have read some mixed views on other forums in that the shells are supposed to be soft to protect the crank and that hardened shells should be avoided. My car isn't tracked but does get the occasional spanking once nice and warm. :driving:
 
In all honesty it's the lubrication that's the most important part. With good oil flow and pressure the OEM are fine. Oil is the life blood of the engine without it the thing will be dead in minutes. There are M engines with over 150k all going strong.
 
Can't offer any advice unfortunately, but out of interest how high was the mileage on your engine when it spun its bearings?
 
TBH if an M car has got to 150k without that sort of preventative maintenance it has done well, rod bearings are a wearable item and a serviceable part.

If i still had my M car I would have the rod bearings changed at around 80-90k just for my own piece of mind and at the same time I would have the engine mounts replaced too.

It depends how the engine has been treated and although this isn't in the service scheme for the S54 from factory, it is a serviceable item as the bearing is a wearable surface, it is between the crankshaft and the rod, if these two surfaces met they would wear each other out very quickly hence the need for the bearing. The tolerances then give enough space for a thin film of oil to add as lubrication, but if the engine is hammered from cold the oil circulation will not work to its potential therefore they wear out quicker. There is also an inherent problem with the engine design too, when the piston is on its compression stroke and the mixture is ignited a tremendous pressure is imparted on the top of the piston, down the wrist pin, through the rod, and into the rod bearing. Some engines have trouble or weakness upwards of this chain but what the S54 does is squeeze out all the oil causing the bearing to wear on the top side.

So even if the engine is treated well, wear is inevitable and as these cars were performance bargains a few years ago a lot have been hammered probably more so M3s as so many more were made and how cheap they are.

What yorkie says is true oil maintenance is key frequent changes etc. What you can have done if you are worried is have an oil analysis, this will show up any tiny metal fragments which will give you an idea of the health of the bearings and you can make a decision from there. You can't really have the bearings inspected as it needs half the engine taking apart to get to them so if they are inspected you might as well swap them while your there.

But this is only half the story, if you haven't owned the car or engine from new you cannot be sure the engine has been treated well all its life, the risk obviously increases as the age and milage of the car increases and buying a high miler is a risk for this reason, but is preventative and knowledge is key and you have to be a bit of a geek with these engines if you want them to run well for the long haul.

TBH its not VERY expensive for preventative measures as your taking the engine apart you may as well have the engine mounts swapped too, depending on their age etc you might as well have them done, so the bearings, mounts and labour will cost around £1500. It is worth it imo simply because… as you know an engine swap is expensive and if your getting a new engine your looking at 10+k before labour.

As to the types of bearings, I would stay clear from a coated bearing as if this adds material to the bearing therefore reducing the bearing clearance on the crankshaft so the tolerance becomes smaller therefore the film will be thinner and even more wear will occur. Some bearings coatings are designed to allow the bearing to retain more oil but that doesn't change the fact that the coating will create a smaller tolerance so whether that is a benefit or not… I can't tell you. The other way of trying to solve the problem which is what BMW did originally when the early models were failing was increase the viscosity of the oil and increase the bearing tolerance. Other options for the more hard core track day oriented people or if you want to race the car is to increase oil pressure preventing oil starvation, a lot of S54s that race have a dry sump. Bit OTT for the road tho and the cost is anywhere from £2.5k upward.

So what I would do is have the OEM bearings replaced and you shouldn't have any more trouble for another 80-90k. But have an oil analysis done first to see if your engine is actually having trouble.

A lot of engine bearing trouble and information comes from race teams who blow engines, especially in the early days and these engines are pressed hard for most of the time they are run. Many sources say you should have the bearings replaced every 50k at that rate… but I think 80-90k on a normal car seems not too bad.

This is actually a great thread. So many people on this forum say how perfect the engine is and for a high performance engine of its type it is reliable but they do go… and like I said these items are replaceable because they wear out!!!

All high performance engines suffer this, it is enviable. From AMGs, Ms, 911s, Lambos, Ferraris etc etc all high performance small tolerance naturally aspirated engines have this issue.
 
:iagree:

Hardened shells will just damage the crank if the oil film fails. There were originally developed to enable an engine to survive that little bit longer under race conditions when it might otherwise fail and when damage to the crank was less important that the engine continuing to run to the end of race.

I can appreciate that having lost one engine you're now nervous about a repeat performance, but if you're going to replace the shells just replace them with OEM.
 
Hi all,

Thanks for the input and all duly noted. The original engine had 107k miles when it went without any prior warning. It is religiously serviced with regular oil changes so not sure what it was that caused the failure other than age/mileage.

I think i'll go with some OEM replacements when I get it done as it will save costs too. Incidentally I have already had uprated engine mounts done along with uprated gearbox mounts, rear top mounts, RCAB, rear drop links, uprated front droplinks, polybush all round, superflex front bushes, new front lower arms, new exhaust mounts throughout, eibach springs and a strut brace. :D

Well I did say I had been doing some preventative maintenance!!

Thanks all for your input. :thumbsup:
 
I replaced the bearing shells at 50K miles to avoid this problem. Those removed were spotless despite many track days making up a proportion of those miles. I'll change them again at 100K miles. Mine sees a lot of track use so I change the oil at twice the recommended rate and don't drive hard until it's fully warm.
 
Interesting thread, what do a set of oem shells cost and are we talking big ends only or mains as well. do they lift the motor enough to drop the sump and do it from the bottom. i know ends can be done this way but not sure if the main bearings can too. have seen a figure of around six hundred quoted , is this about right from anyones experience ?
 
Just wondering if this is something that crops up occasionally or starting to be more common as mileage creeping up on members motors? I build race engines for a day job and normally I use a race series bearing set. These don't use the top coating normally on oem shells and the underside face is also without coating. This allows heat to transfer to the block quicker so less over heating of shell and oil. They normally run slightly larger clearance so as there's more oil film to protect bearings.
If anyone has pics of standard bearings can you post up? Thanks
 
Stevie.w said:
Just wondering if this is something that crops up occasionally or starting to be more common as mileage creeping up on members motors?

You never heard of connecting rod bearing issues on bmw s50/s54/s65/s85 engines?

To me it all looks like they have cavitation corrosion issues.
Probably because of the high revs and long stroke (especially s50/s54)
 
If you replace the bearing shells, do you have to run the engine in again with run in oil, or is it just a swap then normal servicing?
 
CornishRob said:
If you replace the bearing shells, do you have to run the engine in again with run in oil, or is it just a swap then normal servicing?
I don't know what the run-in period should be for bearing shell replacement only, but I'd give them a couple of hundred miles at least with revs below 5,000rpm.
 
That's all I did when I changed mine.

Mad, I can't give you a cost estimate as I had mine changed at the same time as doing a few other things. I can probably find the cost of the parts on the invoice but the labour will be lost amongst the other work. I do know that they were changed by dropping the bottom of the engine with the car up on a lift, so it wouldn't have been too expensive.
 
tomscott said:
TBH if an M car has got to 150k without that sort of preventative maintenance it has done well, rod bearings are a wearable item and a serviceable part.

If i still had my M car I would have the rod bearings changed at around 80-90k just for my own piece of mind and at the same time I would have the engine mounts replaced too.

It depends how the engine has been treated and although this isn't in the service scheme for the S54 from factory, it is a serviceable item as the bearing is a wearable surface, it is between the crankshaft and the rod, if these two surfaces met they would wear each other out very quickly hence the need for the bearing. The tolerances then give enough space for a thin film of oil to add as lubrication, but if the engine is hammered from cold the oil circulation will not work to its potential therefore they wear out quicker. There is also an inherent problem with the engine design too, when the piston is on its compression stroke and the mixture is ignited a tremendous pressure is imparted on the top of the piston, down the wrist pin, through the rod, and into the rod bearing. Some engines have trouble or weakness upwards of this chain but what the S54 does is squeeze out all the oil causing the bearing to wear on the top side.

So even if the engine is treated well, wear is inevitable and as these cars were performance bargains a few years ago a lot have been hammered probably more so M3s as so many more were made and how cheap they are.

What yorkie says is true oil maintenance is key frequent changes etc. What you can have done if you are worried is have an oil analysis, this will show up any tiny metal fragments which will give you an idea of the health of the bearings and you can make a decision from there. You can't really have the bearings inspected as it needs half the engine taking apart to get to them so if they are inspected you might as well swap them while your there.

But this is only half the story, if you haven't owned the car or engine from new you cannot be sure the engine has been treated well all its life, the risk obviously increases as the age and milage of the car increases and buying a high miler is a risk for this reason, but is preventative and knowledge is key and you have to be a bit of a geek with these engines if you want them to run well for the long haul.

TBH its not VERY expensive for preventative measures as your taking the engine apart you may as well have the engine mounts swapped too, depending on their age etc you might as well have them done, so the bearings, mounts and labour will cost around £1500. It is worth it imo simply because… as you know an engine swap is expensive and if your getting a new engine your looking at 10+k before labour.

As to the types of bearings, I would stay clear from a coated bearing as if this adds material to the bearing therefore reducing the bearing clearance on the crankshaft so the tolerance becomes smaller therefore the film will be thinner and even more wear will occur. Some bearings coatings are designed to allow the bearing to retain more oil but that doesn't change the fact that the coating will create a smaller tolerance so whether that is a benefit or not… I can't tell you. The other way of trying to solve the problem which is what BMW did originally when the early models were failing was increase the viscosity of the oil and increase the bearing tolerance. Other options for the more hard core track day oriented people or if you want to race the car is to increase oil pressure preventing oil starvation, a lot of S54s that race have a dry sump. Bit OTT for the road tho and the cost is anywhere from £2.5k upward.

So what I would do is have the OEM bearings replaced and you shouldn't have any more trouble for another 80-90k. But have an oil analysis done first to see if your engine is actually having trouble.

A lot of engine bearing trouble and information comes from race teams who blow engines, especially in the early days and these engines are pressed hard for most of the time they are run. Many sources say you should have the bearings replaced every 50k at that rate… but I think 80-90k on a normal car seems not too bad.

This is actually a great thread. So many people on this forum say how perfect the engine is and for a high performance engine of its type it is reliable but they do go… and like I said these items are replaceable because they wear out!!!

All high performance engines suffer this, it is enviable. From AMGs, Ms, 911s, Lambos, Ferraris etc etc all high performance small tolerance naturally aspirated engines have this issue.

The S54 is a fragile engine that needs some care and attention… My car always gets perfect maintenance; I use the correct oil, gets properly driven warm and if something is wrong it will get fixed with my M specialist (most of his clients own a BMW M car). Last year in 2014 I had something of a malfunction with my oil pump and this lead to damage on the camshafts, tumblers, bearing shells :(

I needed to get some major engine work done. I had two options; buy another used S54 engine (from which I don't know the history) or get my own engine completely checked over and everything that was not ok changed.

They stripped and cleaned my entire engine and replaced everything that needed replacement…so it's actually almost like a 65% new S54 engine and better then any OEM S54 engine with the same mileage as my Z4M. When rebuilding the engine; the crankshaft, pistons and engine block went to a specialist who measured everything to see if the values are still 100% correct (they are still 100% like from the factory, so no worries there). The engine feels now stronger and better then ever before…it was a big bill but I had no option. After all I'm happy I went this route and got the car and my own engine fixed. Still love the Z4M :D

Then this year my buddy with his Z4M also had some engine trouble and he also replaced his oil pump and bearing shells. When they pulled the original bearing shells out of the engine it was already time to replace them (they had small damage that could lead to some serious damage)…

So my tip for every S54 owner; get your oil pump and bearing shells replaced at least every 80.000 - 100.000km!

mPMOv2.jpg

XFQ5mB.jpg

My car had needed following engine works done
- New Camshafts (OEM, no Schrick)
- New tumblers (24)
- New bearing shells
- New oil pump
- Complete cleaning of valve cover
- Complete cleaning of engine block
- New head gasket and seals
- Checking the crank on damage or movement
- New multi belts for alternator and airco
- New bolts for Vanos and everything
- Beisan vanos seal & rattle kit
- New engine supports from Vibra-Tech
- 50+ hours of work
 
BMWZ4MC said:
I replaced the bearing shells at 50K miles to avoid this problem. Those removed were spotless despite many track days making up a proportion of those miles. I'll change them again at 100K miles. Mine sees a lot of track use so I change the oil at twice the recommended rate and don't drive hard until it's fully warm.
I'm doing the same thing with the oil change… The bearing shells is something that is now always on the back of my mind.
 
:cry: i'm currently on 79,700 so waiting for the grind & bang shouldn't take long :o
Its good to be made aware what these engines are up to & what they need to continue operating into higher miles
I think the majority of forum M users do minimal miles per week/year but even so owners should treat their cars properly by thoroughly warming before any high revving & changing the oil more regularly than asked for by the service regime .
Ultimately it will work out to percentages the way the Porsche engine fail rate has , it won't affect all & some may have low miles on & some may have high ?
Being honest at around £1500 i wonder how many owners will have the shells changed as routine :?
How many have already done so ?
 
mr wilks said:
:cry: i'm currently on 79,700 so waiting for the grind & bang shouldn't take long :o
Its good to be made aware what these engines are up to & what they need to continue operating into higher miles
I think the majority of forum M users do minimal miles per week/year but even so owners should treat their cars properly by thoroughly warming before any high revving & changing the oil more regularly than asked for by the service regime .
Ultimately it will work out to percentages the way the Porsche engine fail rate has , it won't affect all & some may have low miles on & some may have high ?
Being honest at around £1500 i wonder how many owners will have the shells changed as routine :?
How many have already done so ?

There's a lot of speculation and opinion on this thread so I wouldn't go worrying too much yet. If you have the correct oil at the correct level and the oil pump is working correctly along with everything else, I see no reason why you would change the bearing shells out at 80-100km like it's a routine job. Unless you track your car a lot pushing into the 8k rev limit regularly then yes of course your going to risk accelerated wear but if you've no evidence of any damage why would you change them out? Sure, go for an oil sample report when you next change the oil out if your worried and go from there. Otherwise your just changing very expensive - labour intensive bits out for the sake of it.
I swear the M forum has turned into the panic/worry/engine's gonna blow at any second forum. Speaking to James at Redish the other day, the cam/followers issue for example, are they really just disintegrating for no reason, or is it more to do with incorrect oil grade / old oil / incorrect oil level (starvation), all things the engine are very sensitive too.......
 
Sounds like mine should have had 3 rounds of shell bearing by now then :o

Maybe my 'over-servicing' and steady motorway driving has mitigated it somewhat - although at the 'trade' value that mine demands it's probably not worth stripping it down to find out.
 
AndyBeech said:
mr wilks said:
:cry: i'm currently on 79,700 so waiting for the grind & bang shouldn't take long :o
Its good to be made aware what these engines are up to & what they need to continue operating into higher miles
I think the majority of forum M users do minimal miles per week/year but even so owners should treat their cars properly by thoroughly warming before any high revving & changing the oil more regularly than asked for by the service regime .
Ultimately it will work out to percentages the way the Porsche engine fail rate has , it won't affect all & some may have low miles on & some may have high ?
Being honest at around £1500 i wonder how many owners will have the shells changed as routine :?
How many have already done so ?

There's a lot of speculation and opinion on this thread so I wouldn't go worrying too much yet. If you have the correct oil at the correct level and the oil pump is working correctly along with everything else, I see no reason why you would change the bearing shells out at 80-100km like it's a routine job. Unless you track your car a lot pushing into the 8k rev limit regularly then yes of course your going to risk accelerated wear but if you've no evidence of any damage why would you change them out? Sure, go for an oil sample report when you next change the oil out if your worried and go from there. Otherwise your just changing very expensive - labour intensive bits out for the sake of it.
I swear the M forum has turned into the panic/worry/engine's gonna blow at any second forum. Speaking to James at Redish the other day, the cam/followers issue for example, are they really just disintegrating for no reason, or is it more to do with incorrect oil grade / old oil / incorrect oil level (starvation), all things the engine are very sensitive too.......

Whatever you want to do on your car is fine by me ;) The things I talked about is zero speculation and only based on facts! I strongly advice everyone with a s54 engine to get the bearing shells replaced every 80.000 - 100.000km. I know 5x people with a s54 engine in their car. We are talking about 2x s54 engines with zero tracktime and 3x s54 that do trackdays.
Around 100.000 - 120.000km we all decided to get our bearing shells and oil pump replaced. Believe it or not; every engine allready had slight damage and to much wear on the bearing shells to be on the safe side. We have pictures of the damaged bearing shells, but I have no reason to lie about this. If those bearing shells wear out to much (or your oil pump fails) you can get a lot of engine damage with major bills. For me; I stay on the safe side with this engine. I had my oil pump fail @ 100.000km and I know the price you pay. Replacing the bearing shells + oil pump every 100.000km is not something you do every year. The price of new bearing shells and a new oil pump (every 100.000km) is not the end of the world and a full engine rebuilt is a lot more expensive. Better safe the sorry is my opinion with the s54 engine... Off course you want to enjoy the high rev's this engine makes otherwise there is no point in buying a car with this engine.
 
My bearing shells were immaculate when I changed them at 50k miles and that's despite heavy track use and a fair amount of hard driving on the road. I'll still be swapping them again at 100k miles though as the cost of failure would be huge.
 
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