I AM AN ENGINEER WHO PERFORMS FAILURE ANALYSIS - MY OBSERVATIONS ARE BASED ON SIGNIFICANT EXPERIENCE IN THIS FIELD. THE CAR IS A 1996 BMW 318TI WITH A 5 SPD MANUAL TRANSMISSION. THE ENGINE IS STOCK. I WAS DRIVING MY 318TI ON THE INTERSTATE HIGHWAY AND NOTICED THAT THE SPEED WAS INCREASING WITHOUT THROTTLE INPUT. I TURNED THE…
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I AM AN ENGINEER WHO PERFORMS FAILURE ANALYSIS - MY OBSERVATIONS ARE BASED ON SIGNIFICANT EXPERIENCE IN THIS FIELD. THE CAR IS A 1996 BMW 318TI WITH A 5 SPD MANUAL TRANSMISSION. THE ENGINE IS STOCK. I WAS DRIVING MY 318TI ON THE INTERSTATE HIGHWAY AND NOTICED THAT THE SPEED WAS INCREASING WITHOUT THROTTLE INPUT. I TURNED THE CRUISE CONTROL OFF THINKING THAT IT SOMEHOW HAD MALFUNCTIONED - THE SPEED CONTINUED TO INCREASE. WHEN THE SPEED PASSED 80 MPH, I DEPRESSED THE CLUTCH, WHICH OF COURSE ALLOWED THE CAR TO SLOW, BUT THE ENGINE IMMEDIATELY ATTEMPTED TO REDLINE - AS THE TACH GOT CLOSE TO THE RED LINE, I SHUT THE IGNITION OFF, AND STEERED THE CAR TO THE SHOULDER. WITH THE CAR IN NEUTRAL, I TRY TO START IT AGAIN, AND THE ENGINE SPEED INCREASED VERY RAPIDLY TO REDLINE. I TRIED THIS 3-4 TIMES OVER 5 MINUTES WITH THE SAME RESULT EACH TIME. I FINALLY OPENED THE HOOD AND FOUND THAT THE THROTTLE CABLE HAD COME LOOSE FROM THE PLASTIC BUSHING ON THE LEVER HOUSING. THIS PROBLEM WAS THE SUBJECT OF A 1997 RECALL, AND MY CAR HAD THE REPAIRS MADE (METAL RINGS) THAT WERE SPECIFIED IN THE RECALL. THEY SEEM TO BE FAILING NOW. THERE IS A NEWS ARTICLE FROM ENGLAND THAT SEEMS TO SHOW AN IDENTICAL FAILURE IN A 318. THE DRIVERS NAME IS KEVIN NICOLLE, AND THE STORY APPEARED ON THIS WEB PAGE ( HTTP://WWW.TELEGRAPH.CO.UK/NEWS/MAIN.JHTML?XML=/NEWS/2006/03/11/NTRAPPED11.XML ). THE RECALL EFFECTED 410,000 CARS - THIS RECALL SHOULD BE REVISITED AS THE REPAIR SEEMS TO HAVE CREATED ANOTHER FAILURE MODE THAT LEADS TO UNEXPECTED ACCELERATION. I HAVE A PHOTO OF THE THROTTLE CABLE / CABLE BUSHING AT THE TIME OF THE FAILURE - I CAN FORWARD IT TO ANY INTERESTED PARTIES. *NM
THE CRUISE CONTROL AND THROTTLE CABLES ARE ATTACHED TO THE SAME THROTTLE VALVE ACTUATING LEVER AT THE THROTTLE HOUSING. IT IS POSSIBLE THAT THE PLASTIC BUSHING ON EITHER CABLE COULD BREAK DUE TO ENVIRONMENTAL INFLUENCES COUPLED WITH VIBRATION. IF THE BUSHING BREAKS, THE OUTER CABLE HOUSING CAN SEPARATE FROM THE BUSHING. IN THIS CASE, DURING APPLICATION OF THE THROTTLE PEDAL WITHOUT CRUISE CONTROL BEING ENGAGED, THE OUTER TUBE COULD CATCH ON THE EDGE OF THE BROKEN BUSHING.
Consequence & remedy
Consequence: THIS COULD CAUSE THE THROTTLE VALVE TO REMAIN PARTIALLY OPEN. IT HIS WERE TO OCCUR, THE CAR MIGHT NOT DECELERATE AS EXPECTED INCREASING THE RISK OF A VEHICLE CRASH.
Remedy: DEALERS WILL INSTALL A SPRING STEEL CLIP ON THE OUTER TUBE OF EACH CABLE IN THE AREA OF THE ADJUSTING SCREW AND PLASTIC BUSHING. THE CLIP IS DESIGNED TO PREVENT THE OUTER TUBE FROM DISLODGING FROM THE BUSHING.
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