Ignition and Recall Timing: A Tale of High Pressure Fuel Pump Failures

Author: Hugo Becker

Well the intertubes are all in a dither now that BMW has recalled cars for the failure of some High Pressure Fuel Pumps (HPFP) on its turbocharged direct injected engines.
 
To begin with the recalled cars have two fuel pumps, a primary low-pressure in-tank pump, and a secondary high pressure pump near the engine itself. The low pressure pump isn’t really all that low pressure, it’s a 5 bar pump (about 70 psi) and if you’ve ever dealt with carburettors you’ll know that’s about 10 times more than you’re used to.

The secondary high pressure fuel pump is the enabling technology on a gasoline direct injected engine. The really high pressures that pump develops can overcome the pressure of the turbocharged slug of air that is then further compressed in the cylinder. The timing sequence of fuel injection and spark is directly dependent on the high pressure fuel pumps operation.

However, if the high pressure fuel pump fails, the engine can still operate on the 5 bar pressure from the primary fuel pump. What it can’t do, at that point, is utilize as much boost pressure or ignition timing that allows such high power from small displacement as its owners are used to. In essence it will still run, but it will run like a four cylinder, automatic transmission, Camry.
 
What BMW and the supplier of the high pressure fuel pump have been doing in the past year or so is isolating the cause of the failures, developing a workable engineering solution to the problem (that won’t introduce additional problems), testing the solution, and the deploying the fix into the field and gather feedback on its effectiveness.

BMW has told BMWBLOG that they have a revision of the HPFP that has been in service since March of 2010 and that they are satisfied that it is providing the reliability they expect.

That leads directly to the buzz surrounding the recall. Cars are not recalled because a couple of executives and a lawyer get scarred after a news story.

Responsible companies that have an issue with a defective part first acknowledge the problem. They then assure customers that they will provide a fix and possibly will reinforce the warranty on the defective part. They will then work closely to identify the cause of failure, engineer a solution, and thoroughly test it. At that point, with a proven solution in hand, they will issue a recall for the superset of potentially problematic parts.

This is what BMW has done. They acknowledged the problem with the high pressure fuel pump, and before they had a fix in hand, they extended the warranty on the HPFP. Then with a fix in hand, they worked with authorities (in the case of US cars,NHTSA) to issue a voluntary recall. At most, the news story pushed up the timing of the announcement.

There are 150,000 cars that are subject to recall, the actual number of defective HPFP is some subset of that. That being said, it’s much more fun to buy into the conspiracy theory that without the dogged pursuit of our media, nothing would have been done about this. But I can guarantee you that most in the media wouldn’t know what a HPFP is if it bit them in the keester. I still wouldn’t monkey with the Cuomo’s though .
Source: BMWBlog

Official Statement: BMW Voluntary Recall

BMW High-Pressure Fuel Pump Voluntary Emissions Recall – models w/ N54

BMW has discovered that certain 2007-2010 model year vehicles may experience partial failure of the High-Pressure Fuel Pump (HPFP) which is part of the direct fuel injection system on certain 1 Series, 3 Series, 5 Series, X6, and Z4 models. Specifically, vehicles powered by the twin-turbocharged 3.0-liter inline-6 engine (internally dubbed ''N54'') are affected. Symptoms include long engine starting times and sometimes the illumination of the Service Engine Soon lamp in the instrument cluster, possibly accompanied by reduced engine performance (''Safe'' operation).

BMW will issue a further voluntary emissions recall. Owners of affected vehicles will be notified in a letter sent by first-class mail. Affected vehicles will receive a software update to reprogram the HPFP and/or a new generation HPFP.

BMW had previously extended the emissions warranty coverage period to 10 years or 120,000 miles, whichever comes first, on affected vehicles in all 50 States.

There have been no reports of injuries related to this issue.

BMW Low-Pressure Fuel Pump Voluntary Safety Recall – X5 models w/ N52

BMW has discovered that some MY 2008 BMW Sports Activity Vehicles equipped with N52 normally-aspirated inline six-cylinder engines may experience a failure of the low-pressure fuel pump. Due to increased wear of an internal component of the fuel pump, the pump could malfunction causing the engine to stall.

BMW will move forward with a voluntary safety recall of affected vehicles to replace the fuel pump in affected vehicles. Owners of affected vehicles will be notified in a letter sent by first-class mail beginning in November.

There have been no accidents or injuries reported as a result of this issue.

Customers who receive a letter for either recall should contact an Authorized BMW Center to schedule a service appointment.

Customers with further questions may contact BMW Customer Relations at a dedicated number, 1-800-563-4269, or email CustomerRelations@bmwusa.com.

12 lucky fans to drive a Prototype BMW 1 Series M Coupe

As Dr. Kay Segler pointed out to us, the new BMW 1 Series M Coupe is a car built and designed for enthusiasts. In our opinion, the 1M represents a turning point for the M Division and future M models would nothing less but exciting, spectacular, fun and Ultimate Driving Machines.

Under the command of Dr. Segler, social and new media, enthusiasts and BMW fans, play an important role in the M strategy, so it is not surprisingly that BMW has just decided to offer the opportunity to drive the new BMW 1M. Twelve lucky fans would get some seat time with the 1M, all BMW’s expense.

Read further…

“We promised that with a little bit of luck you could have the opportunity to be one of the first to drive the BMW 1 Series M Coupé


The time has finally come: twelve interest parties who have registered on M-Power.com will have the chance to drive a prototype of the BMW 1 Series M Coupé themselves on 18 November 2010. Participants will arrive on 17 November 2010, and depart again on 19 November 2010. The event will be held in Germany. BMW will cover all costs for participants at the event itself. If you are traveling from outside Germany, we will book a flight for you.

Please click the link below and send us a photo of yourself and briefly explain why you should be one of first people to have an opportunity to drive the BMW 1 Series M Coupé. Please let us know your size (S,M,L,XL,XXL) as all participants will receive a special outfit from us. You should speak English because the event will mostly be held in English to cater for our international guests

Got the time? Then click on the following link, but before register at M-Power.com Closed Room

I would like to be one of the twelve participants.

Please note that filming and the taking of photographs is prohibited during those parts of the event held on BMW company premises. However we shall, of course, document the event for you and all other interested parties with photos and videos, which we will place online after the event.”

Design Award of Germany goes to BMW 5 Series Sedan

Press Release: The new BMW 5 Series Sedan has won Silver in the 2011 Design Award of the Federal Republic of Germany, presented annually by the German Design Council. The country’s most prestigious prize for product design is one of several honours already bestowed by the Design Council in recognition of the excellence of BMW Group Design. The Design Award of the Federal Republic of Germany is sponsored by the Federal Ministry of Economics and Technology and will be presented at a public ceremony in Frankfurt on 11 February 2011. The presentation forms part of the opening event of Ambiente, the world’s biggest trade fair for consumer goods.\

Since its launch in 1969, the Design Award of the Federal Republic of Germany has been conferred each year on outstanding international achievements in the categories of product and communication design, as well as on a personality from the world of design and on up-and-coming young talent. The winners are chosen by an independent jury consisting of ten representatives from industry, academia, design and the media, who are appointed by the Federal Ministry of Economics and Technology.

The selection criteria for the design award are rigorous: all entries must already have received a national or international award and must embody trends and developments with a defining impact on future design. A further entry criterion is the nomination by the Trade and Industry Ministries and Senators of the federal states or by the Federal Ministry of Economics and Technology.

The design of the new BMW 5 Series Sedan deftly translates the vehicle’s attributes into an authentic formal language. Sheer presence and stylish elegance lend expression to the Sedan’s premium quality and outstanding ride comfort. Its sporty driving characteristics are reflected in the dynamic lines of its bodywork and the overall impression is that of a thoroughly athletic automobile. The superior aesthetics of the new BMW 5 Series Sedan are also conveyed by its perfectly balanced proportions and meticulously executed details.

The unique quality of BMW Group Design has already been recognised several times over by the Design Award of the Federal Republic of Germany. In 2010 this “prize of prizes” went to the Kinetic Sculpture of the BMW Museum (Gold), in 2009 it was awarded to the BMW HP2 Sport motorcycle (Silver), in 2008 to the BMW G650 Xcountry motorcycle (Gold), and in 2007 to the BMW Cruise Bike (Silver). For the new BMW 5 Series Sedan this is not the first award of the year: in 2010 its exceptional design already resoundingly persuaded the jury of the internationally renowned red dot awards.

[Source: BMW ]

BMW's Mini E drivers lead the electric-car wave

Todd Crook, a 42-year-old television advertising producer from California is convinced. So is Tom Mologhney, a 43-year-old New Jersey restauranteur. They're sold on the Mini E, BMW's first electric car to be put in the hands of consumers in the U.S.

For 15 months, they've been part of a select group of drivers in New York, New Jersey and California who have driven the fully-electric Mini E as their main commuting vehicle. And, as Laura Bruno from the Daily Record in Morris County, N.J., reports, these drivers could be in the forefront of showing their fellow motorists that electric vehicles are worth a try. She writes:

Tom Moloughney has been test driving a Mini Cooper E, an all electric car, his home has solar panels on the roof, which powers his home and car. CAPTIONBy the Daily RecordNow, with other electric cars poised to enter the market — the Chevrolet Volt and Nissan Leaf in November and December, respectively — the Mini E drivers are vocal advocates for battery-powered vehicles.

"I'm hooked," says Crook.

When BMW set out to test the Mini E, a lithium-ion battery powered two-seater, the goal was to see if an electric car could withstand the real-life commuting needs of urban settings, says Mini E spokesman Dave Buchko.

Mini E feedback would inform BMW's work on the four-seat Active E, which is planned for a summer 2011 release, and the Megacity planned to premier in 2013.

BMW found the Mini E 100-mile battery range was suited to daily commutes, Buchko says. "We've gained valuable insight, insight that we are putting into play with our other vehicles," Buchko says.

The drivers say they found a car they don't want to give up.

"It's the car of choice, the one everyone in the family fights over," says film art director Jim Dow, 67, of Newport Beach, Calif. Dow has a BMW X3 and a Ford F250 in addition to the Mini E, but he says he, his wife and a son all vie to drive the electric car.

"The first six months I didn't touch the other cars," Dow says. "The truck sat for six months before I went to use it and then the battery was dead."

Peder Norby, 48, who lives near San Diego in a home powered by solar panels, bought a Gem e4 in 2007, an so-called neighborhood electric car that cruises at less than 30 miles per hour and has a 20 mile range. He wanted to test if electric cars could really stand up to a daily commute.

A San Diego County planning commissioner, Norby has driven his Mini E across the county from the Mexican border to the desert. "I can tell you today that for the rest of my life I'll be driving electric," says Norby. "I'm sold 100 percent."

The Mini E has about a 100 mile range when fully charged , says the drivers and Buchko. The Volt is advertised as being able to run an an electric charge for up to 40 miles, but after that it uses gas to power it. According to Nissan, the Leaf will have a similar 100-mile range.

The Mini E test drivers say they simply plug in to a 220 volt (three-pronged) outlet when the arrive home at night and it's ready to drive each morning.

Dow says he once drove his Mini E for a weekend trip that would have exceeded the range. He was contemplating running an extension cord from his hotel room, but found an outlet in the landscaping next to the parking lot and had no problems charging.

Crook's employer moved his parking spot next to an outlet so he can charge at work, if necessary. "It's fun to drive ... I've zipped up right next to a Porsche," says Crook.

Moloughney, who has put more than 41,000 miles on his Mini E in 15 months, keeps a Porsche Boxster in his Chester Township, N.J. garage as his other car. But he prefers to commute in the the Mini E seven days a week, at least 65 miles roundtrip, to his Montclair, N.J. restaurant.

Moloughney put solar panels on his home after getting the Mini E because he plans to have an electric car in his garage into the foreseeable future.

"This is not a golf cart," Moloughney says of misconceptions about electric cars. "This car is really powerful."

These drivers rave about the torque. They barely have to use the brake pedal. As soon as their foot comes off the accelerator the car slows down, they say.

"It's so much fun to drive and the fact that it is all electric is wonderful," says Dow.

Despite a lease cost of $800 a month the first year, now down to $600 in the second year, the drivers say they believe they either broke even or saved money with the program. BMW paid for their insurance and any maintenance required, mostly just new tires, they say.

Dow says it cost him about $35 a month to drive the Mini E daily. With Norby's solar powered home and car, fueling the car costs him nothing out of pocket. The cost of installing the solar panels will be recouped after four years of not buying gasoline, he says. After that, he's only saving money.

"The sun has never raised its price," Norby says.

Bruno reports for the Daily Record in Morris County, N.J.

BMW's Electric Car Innovation

Melissa Hincha-Ownby

Megacity Vehicle could drive a longer distance than other electric cars.

BMW's Megacity Vehicle won't be the first mass-produced electric vehicle on the market, but it will be the first mass-produced vehicle to use a passenger cell made from carbon, specifically carbon fiber-reinforced plastic (CFRP).
 
Carbon is known for its light weight and likely will allow BMW to offset the additional weight that comes with an electric vehicle drive train. And a lighter vehicle will probably lead to an extended driving range. With American consumers focused on being able to drive longer distances on one tank of gas or one electric battery or electric charge, this could lead to more interest in the Megacity Vehicle as its 2013 release date nears.

Yahoo! BuzzBMW is creating this vehicle from the ground up and completely in-house, using what it calls "the LifeDrive concept." The company says electrifying its vehicles requires a completely new approach to vehicle architecture and body construction in order to optimize the electric vehicle platform.

"The LifeDrive concept consists of two horizontally separated, independent modules," the company said in a statement. "The Drive module integrates the battery, drive system and structural and crash functions into a single construction within the chassis. Its partner, the Life module, consists primarily of a high-strength and extremely lightweight passenger cell made from CFRP. Furthermore, the new vehicle architecture opens the door to totally new production processes, which are both simpler and more flexible and use less energy."

Although the success of future electric vehicles will depend on the consumers' adoption of the technology, automakers like BMW are continuing with their plans to bring all-electric vehicles to market. As the technology improves we are likely to see longer driving ranges, which is one of the key factors that will influence Americans' electric vehicle purchase decisions.

BMW does not yet have details on the possible range of the Megacity Vehicle, but with several years to fine-tune this process, we may very well see a vehicle with an all-electric range near the 200-mile mark--the sweet spot for American buyers.

Source:forbes.com

Yet Another Rumor: Next BMW M3 Sedan Replaced by Hatchback M3 Gran Turismo?Posted on: 23.10.2010

Author: Horatiu B.

Roundel stirs up debate in the BMW world. In the latest issue of the magazine, an article around the BMW M3 Sedan being replaced by an M3 Gran Turismo has already begun to create controversy in the BMW world.
 
Following the same principle as the 5 Series GT, the designers are looking to create an M3 Gran Turismo vehicle that would be able to compete with cars like the RS4 Avant or Mercedes-Benz C63 AMG T-Modell.

It is not the first time we hear about the M3 Sedan being phased out in the next generation, but it is certainly a premiere that an M3 Gran Turismo is thrown into the mix. We have already learned that the company will be producing a 3 Series Gran Turismo vehicle when the new generation 3 Series launches.

Despite being published and republished by respectable automotive magazines, we still advise you to take these rumors with a grain of salt.
 
InsideLine goes even further and creates an atrocious looking rendering of an M3 Gran Turismo, using as the starting point the current M3 Sedan bodystyle.

Source: bmwblog.com