2019 i3s AC Compressor Failure, $4k+, Extremely Disappointed

[Dutchi3]

This isn't true - it doesn’t only work when the car needs it. It also works if you set your departure time in the myBMW app or in the car, and also everytime you plug into charge at a DC Charger. This equals much more compressor usage than a combustion only vehicle across a typical year.

O.k. I was referring to battery cooling, not to other usage of the compressor. When DC charging, in my experience also not every time when the weather is chilly or cold. Agreed, it may lead to more compressor usage. That BMW fitted a less than appropriate device isn't great.

 

[i3m3fan]

O.k. I was referring to battery cooling, not to other usage of the compressor. When DC charging, in my experience also not every time when the weather is chilly or cold. Agreed, it may lead to more compressor usage. That BMW fitted a less than appropriate device isn't great.

It's strange because the tesla model 3 and y both use almost identical compressors - hanon systems I believe.

 

[Dutchi3]

Just a thought: it is true that the A/C compressor activates when nessecary, so frequent DC charging sessions may be wearing out the compressor more in the long run. It pleas for avoiding DC charging when possible, especially in warmer climates. DC charging may not be so bad for the battery but it may be for the compressor

 

[rcpmac]

I think it would be difficult to argue that a failed A/C compressor might lead to a catastrophic battery thermal event because an i3 automatically reduces the battery pack's power output when its temperature increases above a certain limit. Reduced power output would reduce battery pack heating. If it gets hot enough, its output power would probably be stopped so that further heating wouldn't occur.

So I don't think that a failed compressor is dangerous other than it could eventually leave one stranded. However, it's a poor design that a compressor that fails by imploding could total an i3 due to the high repair cost. Do A/C compressors implode regularly in other vehicles? Maybe the i3 compressor design is faulty or its quality, low.

It's very rare. 0.04%.

 

[Dutchi3]

t's very rare. 0.04%.

So with 250.000 i3's produced, that is about 10.000 cars.

 

[robthebold]

So with 250.000 i3's produced, that is about 10.000 cars.

I'd say rpcmac's figure works out to more like 100 . . .

 

[JoeCool88]

Just a thought: it is true that the A/C compressor activates when nessecary, so frequent DC charging sessions may be wearing out the compressor more in the long run. It pleas for avoiding DC charging when possible, especially in warmer climates. DC charging may not be so bad for the battery but it may be for the compressor

Sure, the less often a device is used, the longer its life will most probably be. The problem in the discussion about the AC compressor is, that we do not have reliable data. How much compressors of the delivered 250k i3 really failed? Under which circumstances? Under which climatic conditions? Did permanent DC charging increase the failure rate? In some climatic conditions it might even be a solution to make the system inop by pulling the regarding c/b, accepting that DC charging might take a little longer, because the battery management might reduce the current when a cetain battery temperature threshold is reached. After all it seems to be pretty sure that the AC of the i3 is no device that is designed to remain switched on day in and day out for comfort.

 

[Dutchi3]

I'd say rpcmac's figure works out to more like 100 . . .

Yes, I made a calculation mistake but 100 failures is almost nothing, hard to believe.

 

[alohart]

Yes, I made a calculation mistake but 100 failures is almost nothing, hard to believe.

No source was provided for the 0.04% failure incidence, so I'm not very confident that this is accurate.

 

[rcpmac]

No source was provided for the 0.04% failure incidence, so I'm not very confident that this is accurate.

You are correct. I could nor find the source myself even though I posted that number. It may be incorrect and I should have qualified it to say so - but the point still holds, whether it's a 100 or 1000 units, the number is surprisingly low given all of the noise generated. Not surprising in that regard.

 

[oldbimmerguy]

With 7 or 8 part number revisions it is clear the failure rate was on the radar at BMW hq. Not very likely the .04 number is reliable. Zero reason to invest in updating a part that is working.

 

[JoeCool88]

With 7 or 8 part number revisions it is clear the failure rate was on the radar at BMW hq. Not very likely the .04 number is reliable. Zero reason to invest in updating a part that is working.

The last what I want to do is defending BMW in this case. But the existence of a lot of partnumbers alone does not constitute the proof for the bad behaviour of an assembly or part. Because even if the supplier of an o-ring, seal, washer or any other part changes, BMW is obliged to change the partnumber. The modification list of the compressor would be really interesting, but for different reasons BMW will keep it top secret.

 

[ksnax]

Part number changes are not something to rely on as proof. Does BMW use the same compressor in other cars? Are there portions of it that are shared? Items that are revised merely for production efficiency and cost advantage? BMW can change part numbers for any arbitrary reason they choose regardless.

 

[ImaBigD]

Sorry to read about your distress OP. Just for the record, I recently bought a 2022 i3s with 18500 km on the clock. After a couple of weeks using a poor AC, I booked it in for a check. The compressor needed changing. Thankfully, the car is under warranty and there were no loose metal parts moving through the system. Still love the car. Though it is a bit worrying that the compressor failed after only 2 years.

You couldn't have purchased a 2022 i3s since 2021 was the last model year. I assume you mean 2021?

 

[alohart]

You couldn't have purchased a 2022 i3s since 2021 was the last model year. I assume you mean 2021?

i3 production ended during the summer of 2022 (August?). 2022 i3's were sold in Europe.

 

[ImaBigD]

I think it would be difficult to argue that a failed A/C compressor might lead to a catastrophic battery thermal event because an i3 automatically reduces the battery pack's power output when its temperature increases above a certain limit. Reduced power output would reduce battery pack heating. If it gets hot enough, its output power would probably be stopped so that further heating wouldn't occur.

So I don't think that a failed compressor is dangerous other than it could eventually leave one stranded. However, it's a poor design that a compressor that fails by imploding could total an i3 due to the high repair cost. Do A/C compressors implode regularly in other vehicles? Maybe the i3 compressor design is faulty or its quality, low.

From what I have read, the way the compressor causes battery issues is that the battery is cooled in the same coolant loop as the rest of the cabin. When the compressor goes, depending on the model year because BMW has replaced them in later model years, it sends tiny metal shrapnel into the coolant system which ultimately clogs the very small coolant lines that are providing thermal regulation to the battery which ultimately can cause catastrophic damage that can total the vehicle.

 

[ImaBigD]

i3 production ended during the summer of 2022 (August?). 2022 i3's were sold in Europe.

They may have been sold in 2022 but I wonder if they would have been 2021 model years. I have never seen a 2022 model year listed before, and I have searched high and low. I am, however, in the US.

Edit: I stand corrected. I did not appreciate that in the European market the i3 was sold as a 2022 model. The 2021 was the last model year in the US. I learned something today.

 

[alohart]

From what I have read, the way the compressor causes battery issues is that the battery is cooled in the same coolant loop as the rest of the cabin. When the compressor goes, depending on the model year because BMW has replaced them in later model years, it sends tiny metal shrapnel into the coolant system which ultimately clogs the very small coolant lines that are providing thermal regulation to the battery which ultimately can cause catastrophic damage that can total the vehicle.

The cabin and battery pack coolant loops are 2 independent loops that are both connected to the A/C compressor.

There is more than one A/C failure mode. If the failure involves the rotating portion of the compressor rubbing against its housing (bearing failure?), small metal particles could be pumped throughout the refrigerant system. The passageways in the battery pack cooling plate are indeed tiny and could be clogged by there small metal particles.

If the compressor's electric motor or motor electronics fail, catastrophic damage would not occur.

 

[DavidM3570]

You couldn't have purchased a 2022 i3s since 2021 was the last model year. I assume you mean 2021?

 

[UPGR8D]

For your information, the car has been running great ever since they replaced the AC. I did have to recode the REX menu, but the car has been rock solid ever since. If you live in a carb state, these cars are NO-BRAINERS!