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If BMW used polycarbonate for the chain tensioners, no wonder they break. I own an injection molding business. I would NEVER use Polycarb for an interior engine part. Polycarb is good for impact but bad with chemicals. I would start with nylon 66 at a min and work up from there. Now I am going to check my broken pieces, if it is Polycarb, clearly their engineers did not know their business. As well, if someone came to me to mold those parts in Polycarb, I would not do it. As well, now I will examine the design for sharp inside corners and just bad overall design. You would be surprised what a tiny increase in internal radius can do for strength.
We had company tonight so I did not get to have a look at the car tonight.
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