1. Nikasil Cylinder Liner Wear(M60B40 — 1992–1996)
Symptoms: Loss of compression, excessive oil consumption, black exhaust smoke, rough running, misfires, eventual engine failure.
Typical Mileage: 60,000–120,000 miles — high-sulfur fuel accelerates wear.
Repair Cost: £2,000–£5,000 (engine replacement with Alusil block).
Replacement Cost: N/A — repair only; if ignored, compression loss makes the engine undriveable.
Urgency: Check — book inspection urgently if symptoms appear.
Our recommendation:
The M60's Nikasil cylinder lining is its fatal flaw. High-sulfur gasoline in the 1990s reacted with the coating, causing bore wear. BMW later switched to Alusil blocks, which are durable. A compression test is essential before buying any early 840Ci. If you experience oil consumption or rough running, have the engine inspected immediately. Most surviving engines have been replaced with Alusil units — verify your car's history.





