BMW M3 Forum
BMW M3 Forum BMW M3 Gallery BMW M3 Reviews BMW M3 Social Groups BMW M3 Chat M3Forum Sponsors >>
Loading


Mobile M3forum
Go Back   BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X) > BMW M3 Discussions > E46 M3 (2001-2006)
Tire Rack Buy Winter Tires Now!
Not a member? Register Now!
Register Gallery All Albums Garage Search Today's Posts Mark Forums Read Calendar FAQ

E46 M3 (2001-2006) Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006.


Reply
 
Thread Tools Display Modes
Old Thu, Feb-15-2018, 06:44:17 PM   #1
Rajaie
Registered User
 
Join Date: Oct 2008
Posts: 568
Reputation: 0 Rajaie is on a distinguished road
Location: Raleigh

United States




Default S54 exhaust upper chain guide solution


Beisan Systems has launched an S54 exhaust upper chain guide product. The Beisan chain guide is a shape replica of the BMW chain guide, but has a solid form and is made from a superior Nylon.

The BMW chain guide lasts ~80k miles and a replacement BMW chain guide will likely wear faster. The Beisan chain guide is expected to last 250+k miles.
The BMW chain guide inflicts uneven wear on the mating lower chain guide, damaging it and reducing its functional lifespan. The Beisan chain guide applies even wear and reduced wear on the lower chain guide, which allows it to have a longer functional lifespan.
The chain guide is easily replaced during the Beisan vanos repairs. Its replacement is documented in the Beisan S54 Vanos Rattle Procedure.
The Beisan S54 Exhaust Upper Chain Guide cost is $80.

The following is an in depth discussion of the S54 exhaust chain guidesí problems, engineering solutions considerations, and Beisan chain guide solution and product testing and results.


Most BMW engines receive a one piece guide at each side of the timing chain. With the S54 engine, the exhaust side of the chain has two guides that mate to form the complete guide. There is a lower longer guide and an upper shorter guide. They overlap by ~1Ē. The chain tensioner applies force at this mating location which places tension on both chain guides.

Due to the dynamics of the engine cylindersí compression and combustion cycles and valves opening and closing cycles, the timing chain does not rotate uniformly. The exhaust side of the chain is constantly tightening and loosening. This causes the chain tensioner to constantly compress and decompress. These movements cause the exhaust upper and lower chain guides to continuously slide across each other at their mating surfaces, while at the same time be pressed against each other at this location by the chain and chain tensioner pressure. This constant sliding motion under pressure causes wear on the upper and lower chain guides at their mating surfaces.

The chain guides are made from Nylon. The choice of this material is likely due to chain mating wear tolerance, environment (heat & oil) tolerance, and noise reduction; Also weight, cost, and ability to mold for cost reduction. Fillers can be added to Nylon to change its characteristics. This is usually to affect wear and friction characteristics. The exhaust upper chain guide is made from virgin Nylon, while the lower chain guide has a 20% carbon filler. The carbon filler will cause the chain guide to be more wear resistant, but will also increase its friction.

The chain guides are molded (plastic injection molding) and donít have a solid form. They have a 2.6-2.8mm thick outer surface, while the rest of the guide has a webbed structure to support the thin outer surface. This design technique reduces weight and material cost and eases the molding process.

Due to the higher wear of the upper chain guide virgin Nylon and the lower wear of the lower chain guide carbon filled Nylon, the upper chain guide mating surface wears significantly faster than the lower chain guide mating surface. Further, the carbon fibers of the lower chain guide act as a rough abrasive surface and significantly increase wear on the upper chain guide mating surface.

Once the upper chain guide mating outer surface (2.8mm deep) is worn through, the main body webbing structure (4mm deep) begins to mate with the lower chain guide. The upper chain guide webbing structure at this location has the form of a cross frame. This cross frame mates with a much smaller mating surface on the lower chain guide and this concentrates the load force of the guides mating to a much smaller surface area. These significantly reduced mating surfaces then begin to wear significantly faster. The upper chain guide cross frame wears down, while a cross pattern indentation wears into the lower chain guide mating surface. Once the upper chain guide cross frame is completely worn away, the upper chain guide opposite side outer surface begins to mate with the lower chain guide mating surface. The opposite side surface (2.6mm deep) then also wears. Before this surface is completely worn through, a remaining sliver piece breaks off the upper chain guide and into two pieces. All this upper chain guide wear process and final break occurs in ~80k miles.

The lower chain guide is not easily replaceable as the engine front timing cover needs to be removed to access and replace it. The upper chain guide is replaceable without removing the timing cover. The upper chain guide is relatively easy to access and replace during the Beisan S54 vanos rattle procedure repair. The crankshaft/exhaust side chain tensioner and exhaust camshaft sprocket are removed. The upper chain guide is then easily accessed and removed and replaced.

A practical solution to the chain guidesí wear problem can be achieved by producing an improved upper chain guide. The lower chain guide does not need to be replaced as it is wearing acceptably and still has a long remaining life. The goal of a new design upper chain guide is to have the guide last significantly longer than the BMW upper chain guide, while not increasing, and potentially even decreasing, the wear on the lower chain guide.

The Beisan upper chain guide is made from Quadrant Nylatron NSM. This is Nylon with a solid lubricant filler. NSM is specified as having 28% less friction and 85% less wear than virgin Nylon. It is the highest rated Nylon available on the market. It is not available in resin form for molding and is only available in cast rod and sheet in varying dimensions. It is extraordinarily expensive.

The Beisan upper chain guide is a shape replica of the BMW chain guide. It is machined from a sheet of Nylatron NSM. Because of this, it has a solid form instead of a webbed form like the BMW chain guide. Due to this solid form the guide mating section with the lower guide has ~4mm more solid surface depth material than the BMW guide.




A test was performed to assess the efficacy of the Beisan chain guide and compare it to the BMW chain guide. Two E46 M3 cars were employed in the test. Both cars had ~100k miles. One car received a new Beisan upper chain guide, and the second car received a new BMW upper chain guide. Both cars were driven for ~1 year and had the chain guide removed at 18k miles after installation. At the inner deepest wear point of the guide mating surface, the BMW guide lost 1.5mm depth surface material, while the Beisan guide lost .5mm depth surface material. Thus the Beisan guide experienced ((1.5 - .5) / 1.5) * 100 = 67% less wear than the BMW guide. This is in proximity of the manufacturer specification of 85% less wear. The mating surface depth (before webbing) of a new BMW guide is 2.8mm. Thus the expected complete wear miles of this surface is (18k miles / 1.5mm) * 2.8mm = 33.6k miles. After this surface is worn, the guide center webbing cross frame, which is 4mm deep, begins to mate with the lower guide and begin wearing an indentation into it. The Beisan guide replaces the 4mm deep center webbing with solid material. Thus the Beisan mating surface material depth is 2.8mm + 4mm + 2.6mm = 9.4mm. The expected wear miles of this surface with the NSM Nylon material is (18k miles / .5mm) * 9.4mm = 338.4k miles.

There are several more aspects of the guidesí function that also influence performance results. The Beisan chain guide Nylatron NSM with specified 28% less friction will enact notably less wear on the lower chain guide mating surface than the BMW upper chain guide, allowing it to last longer. The lower chain guide will normally already have an indented cross patter in the mating surface from the original upper chain guide wear and webbing cross pattern mating. Thus a replacement upper chain guide will develop a cross pattern raised area at the mating surface. The lower guide mating surface will have already worn through the smooth low friction surface finish of the manufacturing molding and the underlying carbon fiber fillers will be exposed. This will likely cause a replacement upper chain guide to wear faster than the original upper chain guide. Thus a replacement BMW upper chain guide will not likely last the usual ~80k miles before it fully wears and breaks. This seems to be indicated by the significant 1.5mm surface wear of the BMW replacement guide in the test. Feedback from installers going forward will provide more complete results on the wear of the guides with the BMW and Beisan upper chain guides.

Irrespective of the lack of long term data, it is quite clear from the 18k miles test that the Beisan guide with Nylatron NSM and solid body is a far superior chain guide to the BMW chain guide for this application.

Special thanks to forum members kuksul08 and bimmerfan08. They both provided great help in the initial assessment of the failure and the modeling of the guide and assessment of materials and choice of replacement material.

Apology to some owners. The first very small batch of chain guide prototypes made were received by a handful of people. The second small batch of chain guide prototypes made were received by multiple people. Unfortunately this second batch was made from the wrong material, Nylatron GSM. This was a mistake by the machine shop, but I also misinterpreted the material color change and didnít recognize the mistake. GSM wears 12.5% faster than virgin Nylon but has 20% less friction. This guide will likely last ~100k miles before fully wearing and breaking. But it will reduce wear and prevent uneven wear on the lower chain guide as well as the NSM material chain guide. Thus it is still a superior chain guide to the BMW chain guide. I apologize to the owners that received and installed this guide that they didnít receive the superior NSM material chain guide. As I recall, all these owners received the chain guide at no charge.

Sincere apology to the many owners who installed the Beisan vanos solutions and did not have this chain guide available. Itís unfortunate it has taken this long to have this product available.
Jump to top Rajaie is offline   Reply With Quote
Sponsored Links
Register now and remove these ads
Old Thu, Feb-15-2018, 06:46:08 PM   #2
Brian N
wubalubadubdub
 
Brian N's Avatar
 
Join Date: Oct 2007
Posts: 2,929
In the garage:
Reputation: 0 Brian N is on a distinguished road
Location: Orange County, CA

United States




Default Re: S54 exhaust upper chain guide solution

OMG yes finally. I have been waiting so long!
__________________


-My Journal-
Jump to top Brian N is offline   Reply With Quote
Old Thu, Feb-15-2018, 06:55:25 PM   #3
Obioban
Moderator
 
Obioban's Avatar
 
Join Date: Jul 2003
Posts: 36,011
In the garage:
Reputation: 54 Obioban has a spectacular aura about
Location: SE PA

United States




Default Re: S54 exhaust upper chain guide solution

Finally! I felt guilty installing new OE BMW ones in people's cars!

I've been running the Nylatron GSM one (not as good version) in both my s54s, and even at ~50,000 miles on the wagon, it is not showing any significant wear.
__________________

Current Cars: 2005 IR/IR M3, 2001 LMB/blk M5, 03 530i, 04 M3 wagon, and some boring stuff
Past cars: 04 M3, 96 M3, S50B32 e36 M3 CM race car
Jump to top Obioban is offline   Reply With Quote
Old Thu, Feb-15-2018, 07:04:29 PM   #4
M spec
Rembrandt Audio
 
Join Date: Jan 2018
Posts: 537
Reputation: 0 M spec is on a distinguished road
Location: Irvine, CA

Austria




Default Re: S54 exhaust upper chain guide solution

Damn! Great product but just ordered your full VANOS kit and should have waited an added this to it!
Jump to top M spec is offline   Reply With Quote
Old Thu, Feb-15-2018, 07:10:49 PM   #5
youinreverse
Registered User
 
Join Date: Dec 2016
Posts: 248
In the garage:
Reputation: 0 youinreverse is on a distinguished road
Location: SLC

United States




Default Re: S54 exhaust upper chain guide solution

Is there a link to purchase? I don't see it on your site.
Jump to top youinreverse is online now   Reply With Quote
Old Thu, Feb-15-2018, 08:30:25 PM   #6
Rajaie
Registered User
 
Join Date: Oct 2008
Posts: 568
Reputation: 0 Rajaie is on a distinguished road
Location: Raleigh

United States




Default Re: S54 exhaust upper chain guide solution

Quote:
Originally Posted by youinreverse View Post
Is there a link to purchase? I don't see it on your site.
Refresh the products page to update the server.
Jump to top Rajaie is offline   Reply With Quote
Old Thu, Feb-15-2018, 07:14:16 PM   #7
mrgizmo04
Registered User
 
mrgizmo04's Avatar
 
Join Date: Jan 2017
Posts: 2,298
In the garage:
Reputation: 0 mrgizmo04 is on a distinguished road
Location: Menlo Park

United States




Default Re: S54 exhaust upper chain guide solution

For next time I'm in there! Just finished my vanos rebuild a few months ago .


Sent from my SM-G950U using Tapatalk
__________________
'85 528e 164k miles (sold)
'05 M3 6MT coupe

All DIY: 330 ZHP steering rack, diffsonline 4.1 diff with rem polish, E60 short shifter lever, AKG black diff bushings/subframe bushings, Rogue rtab, WPC rod bearings, Beyer driveshaft, full SS (SS stepped V1, catted S1, resonated S2, SS sport), Sachs clutch/flywheel, rear main, VANOS bullet proofing with anti-rattle, valve adjustment, cooling refresh, Ohlins R&T/Swift 448f 672r/GC street tops and camber plates, AFD E85 Proflex kit.
Jump to top mrgizmo04 is offline   Reply With Quote
Old Thu, Feb-15-2018, 07:15:52 PM   #8
tjkenny15
Registered User
 
tjkenny15's Avatar
 
Join Date: May 2012
Posts: 914
In the garage:
Reputation: 0 tjkenny15 is on a distinguished road
Location: Tysons Corner, Virginia

United States




Default Re: S54 exhaust upper chain guide solution

Awesome! Just in time. I remember you telling me about this like 4 years ago!
__________________
2005 BMW M3 INDIVIDUAL - Estoril Blue
Jump to top tjkenny15 is offline   Reply With Quote
Old Thu, Feb-15-2018, 07:32:24 PM   #9
WyattH
Registered User
 
Join Date: Dec 2002
Posts: 8,894
In the garage:
Reputation: 0 WyattH is on a distinguished road
Location: San Francisco

United States




Default Re: S54 exhaust upper chain guide solution

Cool to see this finally released. I put an OE piece in last year so I guess I'll keep this in mind in another 80K, ha!
__________________

Dinan | CSL | RAC | TCK | Brembo | \\\WyattH's Journal
Jump to top WyattH is offline   Reply With Quote
Old Thu, Feb-15-2018, 07:35:40 PM   #10
Dr M3an M3
GroupBuyingPower@outlook. com
 
Dr M3an M3's Avatar
 
Join Date: Mar 2016
Posts: 3,015
In the garage:
Reputation: 0 Dr M3an M3 is on a distinguished road
Location: Columbia, SC

United States




Default Re: S54 exhaust upper chain guide solution

Awesome update! Wish this was available a few months ago when I ordered my full Beisan-Systems VANOS lockdown parts.
__________________
2004 E46 ///M3 - Oxford Green Metallic II + Cinnamon SMG
IG: DrM3anM3

Mods: Genuine OE CSL Bumper, Karbonius CSL Airbox, OE CSL Snorkel w/ working Flap, OE Map Sensor + OE Air Rail, Paul Claude Custom Tune, CSL Engine management with CSL converted DME, Supersprint V1 Stepped Headers w/ Oversized Catless section 1, SS 2.5" Twin-Piped Oversized section 2, Supersprint LW Race Muffler, WPC treated rod-bearings, VinceBar (weld) + Redish Plates, Full Beisan VANOS lockdown, BBS LMs w/ PSS, CSL style CF diffuser, Vorsteiner CF CSL Bootlid, CSL SMG Engine DME tune, CSL '255' SMG DME tune.
Active Group-Buys (PM if Interested): OE CSL Bootlids, Supersprint Headers/Exhaust MEGA thread, ...and more to come!
Please PM me - In search of: Nothing at the moment.
Jump to top Dr M3an M3 is offline   Reply With Quote
Reply

Bookmarks

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



All times are GMT. The time now is 05:46:44 AM.


Powered by vBulletin® Version 3.8.6
Copyright ©2000 - 2018, Jelsoft Enterprises Ltd.
M3Forum.com and M3forum.net is in no way sponsored, endorsed or affiliated by or with BMW NA / BMW AG or any of it's subsidiaries or vendors.
BMW and M3 (E90 M3 | E92 M3 | E93 M3 | E46 M3 | E36 M3 | E30 M3) are registered trademarks of BMW AG.
M3Forum Terms of Service
Copyright ©1999-2017 M3Forum.com
Discussing S54 exhaust upper chain guide solution in the E46 M3 (2001-2006) Forum - Engine: S54 - Max Hp: 333 hp at 7,900 rpm / 262 lb/ft at 4,900 rpm
Total Produced: 45,000+ - Years Produced: 2001 to 2006. at BMW M3 Forum.com (E30 M3 | E36 M3 | E46 M3 | E92 M3 | F80/X)