BMW i8 Air Conditioning compressor problems and costs

UPDATE: NewTIS has been closed. Service Manual data is no longer free. DIY maintain your BMW at your own risk. https://www.youtube.com/watch?v=dIZHyOiLFdw

The Air Conditioning compressor on the BMW i8 is responsible for not only cooling the cabin, but also the high voltage battery enclosure. Refrigerant cools the high voltage batteries. Many BMW i8 owners from the 2014 and 2015 model years, as well as the BMW i3 owners, have reported noisy Air Conditioning compressors, leading to internal failure, resulting in metal being scattered throughout the refrigerant lines. If caught early, this repair can cost $4,000 USD. If allowed to deteriorate, refrigerant lines need to be replaced, costing up to $18,000 USD for dealership service center labor and parts.

Normal Guy Supercar: https://www.youtube.com/user/dbhurlbert

My letter to BMWUSA:

"July 28, 2020: I've received many messages in the past 2 months from i8 owners who have indicated that they hear strange sounds from under the front bonnet, and after I refer them to the shop to have the problem diagnosed, I'm receiving feedback that the Air Conditioning (AC) compressors have failed. BMW service centers are quoting about $3,400 to evacuate the refrigerant, replace the compressor and recharge the system, but also indicate that "the cost would be more if there is metal in the refrigerant lines." It appears that many BMW service centers are aware of problems associated with AC compressor failures, where they distribute broken metal pieces throughout the refrigerant lines.

Upon sharing this information with i8 owners on an online forum, some owners reported to me that AC compressor failure was so catastrophic that metal fragments were scattered inside the refrigerant lines inside of the high voltage battery enclosure. One i8 owner was quoted up to $18,000 by BMW of Nashville to have all the refrigerant lines replaced as these refrigerant lines are used to cool the high voltage battery modules and this is a labor intensive process.

Since we rely on the AC system to keep the high voltage batteries cooled during states of charge and discharge, having a functioning AC system is integral to having the high voltage batteries propel the vehicle as well as provide power to the electric machine electronics and the battery management electronics, which provide power to the 12v system as well. This is because the 12v system is charged directly by the high voltage system (not an alternator). The 12 system is required for mid-engine ignition, cabin electronics, crash detection systems, safety restraint systems, etc. Thus, an AC failure can lead to a cascading, disabling condition.

I've researched the part number for the AC compressor and see that it has had many part number revisions. Has there been a discovery in previous part numbers which warranted an improved part? Can i8 owners with potentially defective parts expect to have an AC compressor failure?

64529496108(11/01/2018 - present)
64526998208(03/01/2018 — 05/26/2019)
64526830621(07/01/2016 — 04/09/2018)
64529364870(11/01/2015 — 07/13/2016)
64529332199(07/01/2014 — 05/09/2016)
64529343808(04/01/2014 — 07/08/2015)

BMW i8 owners with fully functioning cars, that I communicate with, are very concerned that they may have an issue with their AC compressor requiring several thousands of dollars in repairs. Some are currently considering selling their i8's before this problem arises and others are considering taking their cars to the service center to have the AC compressor replaced as preventive maintenance.

I would like to release a video sharing the stories of i8 owners having AC compressor failures, as well as a warning, that owners get their BMW i8's into service centers immediately upon discovery of any type of strange sound coming from the front bonnet, in order to have the problem diagnosed and repaired before the AC compressor sends metal fragments throughout the system. That way owners can avoid a potentially large repair bill. Can BMW provide any additional information which would be helpful to i8 owners experiencing AC compressor failures?

I'm also very curious to hear if BMW has considered, or would consider, extending the limited warranty for the Air Conditioning systems in case the AC compressor fails in the BMW i8, similar to what was done with the fuel pressure sensor (which also had a common failure and and was an expensive repair) under SIB011318: X5 PHEV, I3 REX AND I8 FUEL TANK PRESSURE SENSOR:LIMITED WARRANTY EXTENSION TO 10 YEARS/120,000 MILES."

I haven't received a response addressing this problem. But, I have had some noise coming from my AC Compressor. Hopefully, BMW will consider warranting this part so many owners won't be out of pocket several thousands of dollars.

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