N55 - Product Information

Technicaltraining.
Productinformation.
N55Engine.
BMWService
Generalinformation
Symbolsused
Thefollowingsymbol/graphicrepresentationisusedinthisdocumenttofacilitatebettercomprehensionortodrawattentiontoveryimportantinformation:
containsimportantsafetynotesandinformationthatneedstobeobservedstrictlyinordertoguaranteethesmoothoperationofthesystem.
Informationstatusandnationalvariants
BMWGroupvehiclesmeettherequirementsofthehighestsafetyandqualitystandards.Changesin
requirementsforenvironmentalprotection,customerbenefitsanddesignrendernecessarycontinuousdevelopmentofsystemsandcomponents.Consequently,theremaybediscrepanciesbetween
thecontentsofthisdocumentandthevehiclesavailableinthetrainingcourse.
Thisdocumentbasicallyrelatestoleft-handdrivevehicleswithEuropeanspecifications.Somecontrolsorcomponentsarearrangeddifferentlyinright-handdrivevehiclesthanshowninthegraphicsin
thisdocument.Furtherdifferencesmayariseastheresultoftheequipmentvariantsusedinspecific
marketsorcountries.
Additionalsourcesofinformation
Furtherinformationontheindividualtopicscanbefoundinthefollowing:
Owner'sHandbook
IntegratedServiceTechnicalApplication.
Contact:conceptinfo@bmw.de
2009BMWAG,Mnchen
ReprintsofthispublicationoritspartsrequirethewrittenapprovalofBMWAG,Mnchen
TheinformationcontainedinthisdocumentformanintegralpartofthetechnicaltrainingoftheBMW
Groupandareintendedforthetrainerandparticipantsoftheseminar.RefertothelatestrelevantinformationsystemsoftheBMWGroupforanychanges/additionstotheTechnicalData.
Informationstatus:July2009
VH-23/InternationalTechnicalTraining
N55Engine.
Contents
1.
Introduction............................................................................................................................................................................................................................................. 1
1.1.
Highlights............................................................................................................................................................................................................................ 1
1.1.1.
Technicaldata............................................................................................................................................................................ 1
1.1.2.
Fullloaddiagram................................................................................................................................................................... 1
1.2.
Newfeatures/changes....................................................................................................................................................................................3
1.2.1.
Overview............................................................................................................................................................................................. 3
2.
Models..............................................................................................................................................................................................................................................................6
2.1.
N54B30O0enginevariants................................................................................................................................................................... 6
2.2.
History ................................................................................................................................................................................................................................... 7
3.
Engineidentification............................................................................................................................................................................................................. 8
3.1.
Enginedesignationandengineidentification.......................................................................................................... 8
3.1.1.
Enginedesignation............................................................................................................................................................ 8
3.1.2.
Enginedesignation............................................................................................................................................................ 9
4.
Enginemechanicalsystem................................................................................................................................................................................... 11
4.1.
Enginehousing..................................................................................................................................................................................................... 11
4.1.1.
Engineblock............................................................................................................................................................................ 11
4.1.2.
Cylinderhead......................................................................................................................................................................... 15
4.1.3.
Cylinderheadcover..................................................................................................................................................... 16
4.1.4.
Oilpan................................................................................................................................................................................................21
4.2.
Crankshaftdrivesystem......................................................................................................................................................................... 22
4.2.1.
Crankshaftandbearings...................................................................................................................................... 22
4.2.2.
Connectingrodandbearing.......................................................................................................................... 23
4.2.3.
Pistonswithpistonrings......................................................................................................................................26
4.3.
Camshaftdrive....................................................................................................................................................................................................... 28
5.
Valve gear.............................................................................................................................................................................................................................................. 29
5.1.
Design.................................................................................................................................................................................................................................. 29
5.1.1.
Camshafts.................................................................................................................................................................................... 30
5.1.2.
Valvetiming............................................................................................................................................................................... 31
5.1.3.
Intakeandexhaustvalves................................................................................................................................... 32
5.1.4.
Valvesprings........................................................................................................................................................................... 32
5.2.
Valvetronic..................................................................................................................................................................................................................... 32
5.2.1.
VANOS.............................................................................................................................................................................................. 32
5.2.2.
Valvelistadjustment................................................................................................................................................... 35
6.
Beltdriveandancillarycomponents................................................................................................................................................. 42
6.1.
Beltdrive......................................................................................................................................................................................................................... 42
6.1.1.
Vibrationabsorber.......................................................................................................................................................... 43
N55Engine.
Contents
7.
Oil supply................................................................................................................................................................................................................................................ 46
7.1.
Oilcircuit......................................................................................................................................................................................................................... 46
7.1.1.
Oilducts......................................................................................................................................................................................... 46
7.1.2.
Oilreturn........................................................................................................................................................................................ 50
7.1.3.
Oilpumpandpressurecontrol...................................................................................................................52
7.1.4.
Oilfiltrationandoilcooling............................................................................................................................... 54
7.1.5.
Oilspraynozzles............................................................................................................................................................... 54
7.1.6.
Oilmonitoring........................................................................................................................................................................ 54
8.
Airintakeandexhaustsystem....................................................................................................................................................................... 55
8.1.
Airintakesystem................................................................................................................................................................................................55
8.1.1.
Overview......................................................................................................................................................................................... 55
8.1.2.
Airintakesystem.............................................................................................................................................................. 58
8.1.3.
Fueltankventilationsystem........................................................................................................................... 59
8.2.
Exhaustsystem.....................................................................................................................................................................................................60
8.2.1.
Overview......................................................................................................................................................................................... 60
8.2.2.
Exhaustmanifold.............................................................................................................................................................. 61
8.2.3.
Exhaustturbocharger................................................................................................................................................ 63
8.2.4.
Catalyticconverter......................................................................................................................................................... 66
9.
Vacuumsystem.......................................................................................................................................................................................................................... 68
9.1.
Design.................................................................................................................................................................................................................................. 68
9.1.1.
Vacuumpump....................................................................................................................................................................... 68
10.
Fuelpreparation........................................................................................................................................................................................................................ 71
10.1.
Overview.......................................................................................................................................................................................................................... 71
10.1.1. Fuelpressuresensor................................................................................................................................................. 72
10.1.2. Highpressurepump................................................................................................................................................... 73
10.1.3. Fuelinjectors.......................................................................................................................................................................... 74
11.
Coolingsystem........................................................................................................................................................................................................................... 75
11.1.
Overview.......................................................................................................................................................................................................................... 75
11.1.1. Coolantducts...................................................................................................................................................................... 79
12.
Engineelectricalsystem........................................................................................................................................................................................... 82
12.1.
Connectiontovehicleelectricalsystem....................................................................................................................... 82
12.1.1. Overview......................................................................................................................................................................................... 82
12.1.2. Systemcircuitdiagrams........................................................................................................................................83
12.1.3. Enginecontrolunit........................................................................................................................................................ 89
12.2.
Functions........................................................................................................................................................................................................................ 90
12.2.1. Fuelsupplysystem....................................................................................................................................................... 90
N55Engine.
Contents
12.3.
12.4.
13.
12.2.2. Boostpressurecontrol........................................................................................................................................... 91
12.2.3. Enginecooling...................................................................................................................................................................... 91
12.2.4. Systemprotection.......................................................................................................................................................... 92
Sensors.............................................................................................................................................................................................................................. 92
12.3.1. Crankshaftsensor........................................................................................................................................................... 92
12.3.2. Ignitioncoilandsparkplug.............................................................................................................................. 94
12.3.3. Oilpressuresensor...................................................................................................................................................... 94
12.3.4. Oxygensensors..................................................................................................................................................................95
12.3.5. Hot-filmairmassmeter......................................................................................................................................... 96
Actuators......................................................................................................................................................................................................................... 97
12.4.1. Valvetronicservomotor........................................................................................................................................... 97
12.4.2. Highpressurefuelinjectionvalve.......................................................................................................... 99
Serviceinformation........................................................................................................................................................................................................ 102
13.1.
Enginemechanicalsystem............................................................................................................................................................ 102
13.1.1. Enginecasingcomponents...................................................................................................................... 102
13.2.
Fuelconditioningsystem................................................................................................................................................................. 102
13.2.1. Overview.................................................................................................................................................................................... 102
13.3.
Engineelectricalsystem....................................................................................................................................................................103
13.3.1. Ignitioncoilandsparkplug..........................................................................................................................103
N55Engine.
1.Introduction
1.1.Highlights
TheN55engineisthesuccessortotheN54engine.Re-engineeringandmodificationshavemadeit
possibletonowuseonlyoneexhaustturbocharger.Againstthebackdropofreducedcostsandimprovedquality,thetechnicaldatahaveremainedvirtuallythesame.
1.1.1.Technicaldata
Unit
Configuration
N54B30O0(E71/
X6xDrive35i)
N55B30M0(F07/535i)
6inline
6inline
Cylindercapacity
[cm]
2979
2979
Bore/stroke
[mm]
84.0/89.6
84.0/89.6
[kW/bhp]
[rpm]
225/306
5800-6250
225/306
5800-6400
Poweroutputperlitre
[kW/l]
75.53
75.53
Torque
atenginespeed
[Nm]
[rpm]
400
1300-5000
400
1200-5000
[]
10.2
10.2
[l/100km]
10.9
8.9
g/km
262
209
DigitalMotorElectronics
MSD81
MEVD17.2
ExhaustemissionlegislationEURO,US
EURO4
EURO5
Poweroutput
atenginespeed
Compressionratio
Valves/cylinder
Fuelconsumption,EU
combined
CO2emission
Engineoilspecification
Topspeed
BMWLonglife-01
BMWLonglife-01FE
BMWLonglife-04
[km/h]
240
250
Acceleration0100km/h
[s]
6.7
6.3
Vehiclekerbweight
DIN/EU
[kg]
2070/2145
1940/2015
*=Electronicallygoverned
1.1.2.Fullloaddiagram
Comparedtothepredecessor,theN55engineischaracterisedbylowerfuelconsumptionwiththe
samepoweroutputandtorquedata.
N55Engine.
1.Introduction
FullloaddiagramE90335iwithN54B30O0enginecomparedtotheF07535iwithN55B30M0engine
N55Engine.
1.Introduction
1.2.Newfeatures/changes
1.2.1.Overview
Assembly
Component
Enginemechanical
system
Crankcase
Enginecasingcomponents
Crankshaft
drive
Camshaft
drive
Valvegear
Design
Valvetronic
Cylinder
headcover
Integrationofblow-bypipe.
Crankcaseventilation.
Crankshaft
Asymmetriccounterweightarrangement
andreducedweight.
Pistonsand
connecting
rods
Formedholeinsmallconnectingrodeye.
Lead-freebig-endbearingshells.
VANOS
Solenoidvalveswithintegratednon-returnvalveand3screenfilters.
Increasedadjustmentspeedandreduced
susceptibilitytosoiling.
Valvetronic
Updatedandintegratedincylinderhead.
3rdgenerationbrushlessservomotor.
Positiondetectionofeccentricshaftintegratedinservomotor.
Oilsupply
Exhaustsystem
Newlydevelopedbeltdriveandvibration
absorber.
Oilcircuit
Airintake
system
Adaptedformonoturbo.
Cylinderborechangesto84mm.
Largelongitudinalventilationholes.
Modifiedoilsupplytovacuumpump.
Integratedwaterchannelforinjector
cooling.
Oilsystem
Remarks
Beltdrive
Airintakeandexhaustsystem
Same
design
Cylinder
head
Beltdriveandauxiliaryequipment
New
development
Intakepipe,oildeflectorandoilcollector
integratedinonecomponent.
OilpumpwithDuroplastslidevalveand
characteristicmapcontrol.
Modifiedoilfilterhousing.
Exhaust
turbocharger
Twinscrollexhaustturbochargerwith
wastegatevalveandelectricdiverter
valve.
Catalytic
converter
Nounderbodycatalyticconverter.
N55Engine.
1.Introduction
Assembly
Component
Vacuumsystem
Vacuum
pump
Design
Fuelconditioning
system
Overview
Engineelectrical
system
Remarks
Modified,similartoN63engine.
Solenoidvalvefuelinjectors.
Connection
tovehicle
electrical
system
Coolant
ducts
Adaptedforoneexhaustturbocharger.
Crankshaft
sensor
IntegratedforMSA.
(DME)
Mountedontheintakemanifoldand
cooledbyintakeair.
Hot-filmair
massmeter
(HFM)
Improvedsignalqualityandtemperature
resistance.
Functions
Sensors
Oxygen
sensor
Actuators
Oilpressuresensor
Newsensorforabsolutepressuremeasurement.
Oiltemperaturesensor
Mountedinmainoilduct.
Ignition
coils
Withhigherignitionvoltageandimproved
EMC
Sparkplugs
Fuelinjectors
Same
design
Overview
Coolingsystem
Fuelinjectors
New
development
AdoptedfromN63engine(LSUADV).
Sparkplug,commonpartwithN63engine.
Solenoidvalvefuelinjectors.
N55Engine.
1.Introduction
N55Engine
N55Engine.
2.Models.
2.1.N54B30O0enginevariants
Model
Version
Series
Displacementin
cm
Stroke/
borein
mm
Power
outputin
kW/bhp
atrpm
Torquein
Nm
atrpm
135i
ECE
E82,E88
2979
89.6/84.0
225/306
58006250
400
13005000
135i
US
E82,E88
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
335i
ECE
E90,E91,
E92,E93
2979
89.6/84.0
225/306
58006250
400
13005000
335ixDrive
ECE
E90,E91,
E92
2979
89.6/84.0
225/306
58006250
400
13005000
335i
US
E90,E92,
E93
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
335ixDrive
US
E90,E92
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
Z4
sDrive35i
ECE
E89
2979
89.6/84.0
225/306
58006250
400
13005000
Z4
sDrive35i
US
E89
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
535i
US
E60
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
535ixDrive
US
E60,E61
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
X6
xDrive35i
ECE
E71
2979
89.6/84.0
225/306
58006250
400
13005000
N55Engine.
2.Models.
Model
Version
Series
Displacementin
cm
Stroke/
borein
mm
Power
outputin
kW/bhp
atrpm
Torquein
Nm
atrpm
X6
xDrive35i
US
E71
2979
89.6/84.0
300SAE
hp
58006250
407(300ft
lbs)
14005000
740i
ECE
F01,F02
2979
89.6/84.0
240/326
58006250
450
15004500
ECE=Europeversion,adaptedtotherespectivemarketswithoptioncode.
US=USversion,adaptedtotherespectivemarketswithoptioncode.
2.2.History
6-cylinderpetrolenginewithexhaustturbochargeratBMW
Unit
745i
745i
Engine
M30B32
M30B32
Series
E23
E23
Cylindercapacity
[cm]
3210
3430
Poweroutput
[kW/bhp]
185/252
185/252
Torque
[Nm/(rpm)]
380/4000
388/2200
DME
DME
Enginemanagement
Compressionratio
[]
7.0:1
8.0:1
Vmax
[km/h]
222
227
Acceleration0-100
km/h
[s]
7.8
7.9
Firstused
1980
1983
Lastused
1983
1986
N55Engine.
3.Engineidentification.
3.1.Enginedesignationandengineidentification
3.1.1.Enginedesignation
ThisPIdescribesthefollowingversionoftheN55engine:N55B30M0.
Inthetechnicaldocumentation,theenginedesignationisusedforuniqueidentificationoftheengine.
Inthetechnicaldocumentationyouwillalsofindtheabbreviatedenginedesignation,i.e.N55,thatonly
indicatestheenginetype.
Item
Description
Index/explanation
Enginedeveloper
M,N=BMWGroup
P=BMWMotorsport
S=BMWMGmbH
W=Other-makeengines
Enginetype
1=Straight4(e.g.N12)
6=V8(e.g.N63)
7=V12(e.g.N73)
8=V10(e.g.S85)
Changetobasicengineconcept
0=Basicengine
1to9=Changes,e.g.combustionprocess
Operatingprincipleorfuel
supplyandinstallationposition
ifapplicable
B=Petrol,longitudinalinstallation
D=Diesel,longitudinalinstallation
H=Hydrogen
Displacementinlitres
1=1litre+
Displacementin1/10litre
8=0.8litres=1.8litres
Performanceclass
K=Smallest
U=Lower
M=Medium
O=Upper(standard)
T=TOP
S=Super
Re-engineeringsubjecttoapproval
0=Newdevelopment
1-9=Re-engineering
N55Engine.
BreakdownofN55enginedesignation
Index
Description
BMWGroupDevelopment
Straight6engine
Enginewithdirectinjection,Valvetronicandexhaustturbocharger
Petrolengine,longitudinal
30
3.0-litrecapacity
Mediumperformanceclass
Newdevelopment
3.1.2.Enginedesignation
Theenginesaremarkedonthecrankcasewithanengineidentificationcodeforuniqueidentification.
Thisengineidentifierisalsorequiredforapprovalbytheauthorities.
TheN55enginefurtherdevelopsthisidentificationsystemandthecodehasbeenreducedfrompreviouslyeighttosevencharacters.Theengineserialnumbercanbefoundundertheengineidentifieron
theengine.Togetherwiththeengineidentifier,thisconsecutivenumberenablesuniqueidentification
ofeachindividualengine.
Item
Description
Index/explanation
Enginedeveloper
M,N=BMWGroup
P=BMWMotorsport
S=BMWMGmbH
W=Other-makeengines
Enginetype
6=V8(e.g.N63)
7=V12(e.g.N73)
8=V10(e.g.S85)
Changetobasicengineconcept
0=Basicengine
1to9=Changes,e.g.combustionprocess
Operatingprincipleorfuel
supplyandinstallationposition
ifapplicable
B=Petrol,longitudinalinstallation
D=Diesel,longitudinalinstallation
H=Hydrogen
N55Engine.
Item
Description
Index/explanation
Displacementinlitres
1=1litre+
Displacementin1/10litre
8=0.8litres=1.8litres
Typeapprovalrequirements
(modificationsthatrequirerenewedtypeapprovaltesting)
A=Standard
B-Z=asrequired,e.g.
RON87
N55engine,engineidentificationandengineserialnumber
Index
Description
08027053
Individualconsecutiveengineserialnumber
Enginedeveloper,BMWGroup
Enginetype,straight6
Changetobasicengineconcept,turbocharging,Valvetronic,directfuel
injection
Operatingprincipleorfuelsupplyandinstallationposition,petrolengine
longitudinal
30
Displacementin1/10litre,3litre
Typeapprovalrequirements,standard
10
N55Engine.
4.Enginemechanicalsystem.
4.1.Enginehousing
Theenginehousingconsistsoftheengineblock(crankcaseandbedplate),cylinderhead,cylinder
headcover,oilpanandgaskets.
4.1.1.Engineblock
Theengineblockismadefromanaluminiumdiecastingandconsistsofthecrankcasewithbedplate.
Crankcaseandbedplate
Thecrankcasefeaturescastcylinderliners(2)madefromcastiron.Anewfeatureisthatthewebsbetweentwocylindersnowhaveagroove(3).Coolantcanflowalongthesegroovesfromonesideofthe
crankcasetotheother,thuscoolingthewebs.
AsopposedtotheN54engine,fiveoilreturnductsontheexhaustside(4)nowpermitoiltoreturn
fromthecylinderheadintotheoilpan.Theseoilreturnchannelsextendintothebedplateuptobelow
theoildeflector.Theyhelpreducechurninglossesasthereturningengineoilcannolongerreachthe
crankdriveevenathightransverseacceleration.
Fiveoilreturnchannelsontheintakeside(5)alsoensurethattheblow-bygassescanflowunobstructedfromthecrankshaftareaintothecylinderheadandtothecrankcasebreatherinthecylinderhead
cover.
Thecoolingduct(1)intheengineblockissplitandcoolantflowsdirectlythroughit.
11
N55Engine.
N55engine,crankcasewithwebcooling
Index
Description
Coolingduct
Cylinderliner
Groove
Oilreturnducts,exhaustside
Oilreturnducts,intakeside
12
N55Engine.
N55engine,bedplatefrombelow
Index
Description
Oilpump
Bedplate
Oildeflector
Intakemanifoldwithoilscreenfilter
Ductsareprovidedfortheoilsupplytothevacuumpumpasitisnowlubricatedbyfilteredoilandnot
byunfilteredoilasontheN54engine.Theoilpressurecontrolvalvehasbeenintegratedforthemapcontrolledoilpump.
13
N55Engine.
N55engine,oilpressurecontrol
Index
Description
Oilpressurecontrolvalve
Oilpump
Thecrankcasehaslargerboredlongitudinalventilationholes.Thelongitudinalventilationholesimprovethepressureequalisationoftheoscillatingaircolumnsthatarecreatedbytheupanddown
movementofthepistons.
14
N55Engine.
N55engine,ventilationholesincrankcase
Inaddition,theconnectionsatthemonoturbochargerhavebeenadaptedfortheoilsupplyand
coolantcooling.
4.1.2.Cylinderhead
ThecylinderheadoftheN55engineisanewdevelopment.DirectfuelinjectionwithexhaustturbochargingandValvetronicareusedforthefirsttimeonaBMW6-cylinderengine.Thecylinderhead
featuresaverycompactdesignandisequippedwiththirdgenerationValvetronic.
Thecombinationofexhaustturbocharger,ValvetronicanddirectfuelinjectionsisreferredtoasTurbo-Valvetronic-Direct-Injection(TVDI).
15
N55Engine.
ThissystemreducesCO2emissionandfuelconsumptionby3-6%.
TherearenownoconnectionsfortheVANOSnon-returnvalvesastheyhavebeenintegratedinthe
solenoidvalves.Thecylinderheadfurtherfeaturescoolingchannelsaboutthefuelinjectors,providing
indirectcooling.
N55engine,cylinderhead
4.1.3.Cylinderheadcover
Design
Thecylinderheadcoverisanewdevelopment.Thevacuumaccumulatorforthevacuumsystemisintegratedinthecylinderheadcover.
Allcomponentsforcrankcaseventilationandtheblow-bychannelsarealsointegratedinthecylinder
headcover.Theintegratednon-returnvalvesensurethattheblow-bygassesarereliablyaddedtothe
intakeair.
TheN55engineisequippedwithavacuum-controlledcrankcaseventilationsystem.Aregulatednegativepressureofapprox.38mbarismaintained.
16
N55Engine.
N55engine,cylinderheadcoverwithcrankcaseventilation
Index
Description
Connection,blow-bygastocleanairpipe
Connection,vacuumlinetovacuumpump
Reserve,vacuumconnection
VacuumconnectiontoelectropneumaticpressureconverterEPDWfor
wastegatevalve
Ductforblow-bygasfeedintointakesystemwithintegratednon-returnvalve
Blow-bygasductwithsettlingchamber,impactplate,pressurecontrolvalve
andnon-returnvalves
Pressureregulatingvalve
Theblow-bygassesflowthroughtheopeningintheareaofthesixthcylinderintothesettlingchamberinthecylinderheadcover.Fromthesettlingchamber,theblow-bygassesaredirectedthrough
holesontoanimpactplate,againstwhichtheoilimpacts,duetothehighflowrate,andflowsoff.The
blow-bygassescleanedofoilnowflowviathepressurecontrolvalveand,dependingontheoperating
mode,viathenon-returnvalvesintotheintakeareaupstreamoftheexhaustturbochargerorviathe
cylinderheadaheadoftheintakevalves.Theseparatedoilisdirectedviaareturnflowducttobelow
theoillevelintotheoilpan.
Function
Thestandardfunctioncanonlybeusedaslongasavacuumprevailsintheintakeairmanifold,i.e.in
naturally-aspiratedenginemode.
17
N55Engine.
Withtheengineoperatinginnaturally-aspiratedmode,thevacuumintheintakeairmanifoldopensthe
non-returnvalveintheblow-byductinthecylinderheadcover,thusdrawingoffblow-bygassesvia
pressurecontrolvalve.Atthesametime,thevacuumalsoclosesthesecondnon-returnvalveinthe
ducttothechargeairintakeline.
Theblow-bygassesflowviathedistributorrailintegratedinthecylinderheadcoverdirectlyintothe
intakechannelsinthecylinderhead.
N55engine,crankcaseventilation,naturally-aspiratedenginemode
18
N55Engine.
Index
Description
Ambientpressure
Vacuum
Exhaustgas
Oil
Blow-bygas
Aircleaner
Intakemanifold
Perforatedplates
Oilreturnchannel
Crankcase
Oilsump
Oilreturnchannel
Exhaustturbocharger
Oildrainvalve
10
Chargeairintakeline
11
Hosetochargeairintakeline
12
Non-returnvalve
13
14
Throttlevalve
15
Non-returnvalve
16
Channelincylinderheadandcylinderheadcover
Blow-bygassescannolongerbeintroducedviathischannelassoonasthepressureintheintake
airmanifoldincreases.Therewouldotherwisebethedangerthattheboostpressurecouldenterthe
crankcase.Anon-returnvalveintheblow-bychannelinthecylinderheadcoverclosesthechannelto
theintakeairmanifold,thusprotectingthecrankcasefromexcesspressure.
Thenowgreaterdemandforfreshaircreatesavacuuminthecleanairpipebetweentheexhaustturbochargerandintakesilencer.Thisvacuumissufficienttoopenthenon-returnvalveandtodrawoff
theblow-bygassesviathepressurecontrolvalve.
19
N55Engine.
N55engine,crankcaseventilation,turbochargedenginemode
Index
Description
Excesspressure
Vacuum
Exhaustgas
Oil
Blow-bygas
Aircleaner
Intakemanifold
20
N55Engine.
Index
Description
Perforatedplates
Oilreturnchannel
Crankcase
Oilsump
Oilreturnchannel
Exhaustturbocharger
Oildrainvalve
10
Chargeairintakeline
11
Hosetochargeairintakeline
12
Non-returnvalve
13
14
Throttlevalve
15
Non-returnvalve
16
Channelincylinderheadandcylinderheadcover
Ifacustomercomplainsabouthighoilconsumptionandatthesametimetheexhaustturbochargeris
foundtobeoiledup,itshouldnotbeimmediatelyassumedthattheexhaustturbochargerisdefective.
Iftheoilingalreadyexistsaftertheintroductionoftheblow-bygassesthentheentireengineshould
becheckedforleaks.Defectivegasketsordefectivecrankshaftsealsmaybethecauseofexcessively
highblow-bygasthroughput.Leakingcrankshaftsealscancauseanoilconsumptionofupto3l/1000
km.
4.1.4.Oilpan
Theoilpanismadefromanaluminiumcasting.Theoildeflectorandtheintakepipetotheoilpump
aredesignedasonecomponent.Tofacilitateattachmenttothebedplate,theoilreturnductsaredesignedsuchthattheyextendovertheoildeflector.Consequently,theoilreturnductsendintheoil
sump.
21
N55Engine.
N55engine,bedplatewithoilpumpandoildeflector
Index
Description
Oilpump
Bedplate
Oildeflector
4.2.Crankshaftdrivesystem
4.2.1.Crankshaftandbearings
Crankshaft
Thecrankshaftisdesignedwithoptimumweight.At20.3kg,thecrankshaftintheN55engineisapprox.3kglighterthanthecrankshaftintheN54engine.Thecrankshaftisalsoknownasalightweight
crankshaft.Thecrankshaftismadefromcastiron(GGG70).Thecounterweightsarearrangedasymmetrically.Noincrementalwheelisinstalled.ThetimingchainsaremountedbymeansofanM18centralbolt.
22
N55Engine.
N55engine,crankshaft
Index
Description
Counterweights
Mainbearingjournal7
Oilholefrombig-endbearingtomainbearing
Oilholefrommainbearingtobig-endbearing
Big-endbearingjournal,cylinder4
Crankshaftmainbearings
AsontheN54engine,themainbearingsonthecrankshaftaredesignedastwo-componentbearings
freeoflead.Thethrustbearingismountedatthefourthbearingposition.
4.2.2.Connectingrodandbearing
ThesizeoftheconnectingrodoftheN55engineis144.35mm.Aspecialfeatureistheformedholein
thesmallconnectingrodeye.Thisformedholeoptimallydistributestheforceactingfromthepiston
viathegudgeonpinoverthesurfaceofthebushandreducestheloadattheedges.
23
N55Engine.
N55engine,smallconnectingrodeye
Index
Description
Bush
Connectingrod
Thefollowinggraphicshowsthesurfaceloadonastandardconnectingrodwithouttheformedhole.
Duetothepistonpressure,theforceexertedviathegudgeonpinismainlytransmittedtotheedgesof
thebushinthesmallconnectingrodeye.
24
N55Engine.
N54engine,smallconnectingrodeyewithoutformedhole
Index
Description
Lowsurfaceload
Highsurfaceload
Whenthesmallconnectingrodeyehasaformedhole,theforceisdistributedoveralargerareaand
theloadontheedgesofthebushisreducedconsiderably.Theforceisnowspreadoveralargerarea.
25
N55Engine.
N55engine,smallconnectingrodeyewithformedhole
Index
Description
Lowsurfaceload
Highsurfaceload
Lead-freebig-endbearingshellsareusedonthelargeconnectingrodeye.ThematerialG-488isused
ontheconnectingrodsideandthematerialG-444onthebearingcapside.
ThesizeM9x47connectingrodboltsarethesameontheN55andN54connectingrod.
4.2.3.Pistonswithpistonrings
AfullslipperskirtpistonsuppliedbythecompanyKSisused.Thepistondiameteris82.5mm.The
firstpistonringisaplainrectangularcompressionringwithachrome-ceramiccoatingonthecontact
surface.ThesecondpistonringisatapefacedNapierring.Theoilscraperingisdesignedasasteel
bandringwithspringthatisalsoknownasVFsystem.
26
N55Engine.
N55engine,pistonwithgudgeonpinandpistonrings
Index
Description
Plainrectangularcompressionring
TaperfacedNapierring
VFsystemring
Steelinlayforfirstpistonring
Grooveforfirstpistonring
Grooveforsecondpistonring
Grooveforoilscraperring
Holeforlubricatingoildrain
Graphitecoating
27
N55Engine.
Combustionchambergeometry
Thefollowinggraphicshowsthearrangementoftheindividualcomponentsaboutthecombustion
chamber.ItcanbeseenthattheBMW(spray-guided)highprecisioninjection(HPI)systemisnotused
butratheraBoschsolenoidvalvefuelinjectorwithmulti-holenozzle.Thefuelinjectoriscombined
withturbochargingandValvetronicIII.Forbetterillustration,avalvewithvalvesethasbeenremovedin
thegraphic.
N55engine,combustionchamberwithcomponents
Index
Description
Valveseat,exhaustvalve
Exhaustvalve
Sparkplug
Fuelinjector
Intakevalve
Valveseat,intakevalve
4.3.Camshaftdrive
ThecamshaftdrivecorrespondstothecamshaftdriveontheN54engine.
28
N55Engine.
5.Valvegear.
5.1.Design
ThefollowinggraphicshowsthedesignofthecylinderheadontheN55enginewiththeValvetronicIII
anddirectfuelinjectioncombination.
N55engine,overviewofvalvegear
Index
Description
VANOSunit,intakecamshaft
VANOSunit,exhaustcamshaft
Injectorwell
Sparkplugwell
Camshafthousing
Valvetronicservomotor
Inletcamshaft
Torsionspring
Gate
10
Eccentricshaft
29
N55Engine.
5.Valvegear.
Index
Description
11
Intermediatelever
12
Rollerlevertappet
13
Valvehead
14
Oilspraynozzle
15
Holeforintroducingblow-bygas
5.1.1.Camshafts
CastorlightweightcamshaftswereusedsimultaneouslyontheN54engine.Thismadeitpossibleto
uselightweightcamshaftsaswellascastcamshaftsoramixtureofbothinanN54engine.
OnlylightweightconstructioncamshaftsareusedontheN55engine.Thelightweightcamshaftsfor
theN55enginearemanufacturedinaninternalhighpressureformingprocess.Theexhaustcamshaft
featuresbearingracesandisencapsulatedinacamshafthousing.Thecamshafthousingreducesoil
foamingduringoperation.
N55engine,assembledcamshaftmadeinaninternalhighpressureformingprocess
Index
Description
Shell-shapedcam
Corrugatedtube
30
N55Engine.
5.Valvegear.
5.1.2.Valvetiming
N55engine,valvetimingdiagram
N54B30O0
N55B30M0
Intakevalve
[mm]
31.4
32
Exhaustvalve
[mm]
28
28
Maximumvalvelift,
intakevalve/exhaust
valve
[mm]
9.7/9.7
9.9/9.7
Intakecamshaft
spread(VANOSadjustmentrange)
[crankshaft]
55
70
Exhaustcamshaft
spread(VANOSadjustmentrange)
[crankshaft]
45
55
Intakecamshaftopeningangle(max.-min.
spread)
[crankshaft]
125-70
120-50
Exhaustcamshaft
openingangle(max.min.spread)
[crankshaft]
130-85
115-60
Openingperiod
Inletcamshaft
[crankshaft]
245
255
Openingperiod
Exhaustcamshaft
[crankshaft]
261
261
31
N55Engine.
5.Valvegear.
5.1.3.Intakeandexhaustvalves
Thevalvestemhasadiameterof5mmontheintakevalveand6mmontheexhaustvalve.Thereason
forthelargerdiameteristhattheexhaustvalveishollowandisfilledwithsodium.Inaddition,thevalve
seatoftheexhaustvalveisarmoured.
5.1.4.Valvesprings
Thevalvespringsaredifferentfortheintakesideandexhaustside.
5.2.Valvetronic
5.2.1.VANOS
Overview
TheVANOSsystemhasbeenoptimisedtoprovideevenfasteradjustmentspeedsoftheVANOS
units.Theoptimisationhasalsofurtherreducedthesusceptibilitytosoiling.Itcanbeseenfromthe
followingcomparisonoftheVANOSontheN54engineandtheVANOSontheN55enginethatfewer
oilchannelsarerequired.
32
N55Engine.
5.Valvegear.
N54engine,VANOSwithoilsupply
Index
Description
Mainoilduct
VANOSsolenoidvalve,intakeside
VANOSsolenoidvalve,exhaustside
Chaintensioner
Returnshut-offvalve,exhaustside
Returnshut-offvalve,intakeside
VANOSadjustmentunit,exhaustside
VANOSadjustmentunit,intakeside
33
N55Engine.
5.Valvegear.
N55engine,VANOSwithoilsupply
Index
Description
Mainoilduct
Chaintensioner
Thesensorwheelsarenowpuredeep-drawnsheetmetalcomponentsandnolongermadefromtwo
parts.Thisdesignincreasesproductionaccuracywhilereducingmanufacturingcosts.
34
N55Engine.
5.Valvegear.
N55engine,camshaftsensorwheel
Index
Description
Rearview
Frontview
VANOSsolenoidvalves
Thereturnshut-offvalvewithscreenfilterusedontheN54enginehavenowbeenintegratedinthe
VANOSsolenoidvalvesontheN55engine.Thismeasurehasmadeitpossibletoreducethenumber
ofoilductsinthecylinderhead.Inaddition,thenon-returnvalveshavebeenintegratedintheVANOS
solenoidvalves.ScreenfiltersontheVANOSsolenoidvalveensuretrouble-freeoperationandreliably
preventtheVANOSsolenoidvalvefromstickingastheresultofdirtparticles.
5.2.2.Valvelistadjustment
Overview
Ascanbeseenfromthefollowinggraphic,theinstallationlocationoftheservomotorhaschanged.A
furtherfeatureisthattheeccentricshaftsensorisnolongermountedontheeccentricshaftbuthas
beenintegratedintheservomotor.
35
N55Engine.
5.Valvegear.
N55engine,valveliftadjustment
Index
Description
Oilspraynozzle
Eccentricshaft
Minimumstop
Maximumstop
TheValvetronicIIIsystemisused.ThedifferencesbetweenValvetronicIIIandValvetronicIIareinthe
arrangementoftheValvetronicservomotorandtheValvetronicsensor.AsinValvetronicII,theturbulencelevelisincreasedinValvetronicIIIforthepurposeofoptimisingthemixtureformationwithphasingandmaskingattheendofthecompressioncycle.Thismovementofthecylinderchargeimproves
thecombustionduringpartialloadoperationandincatalyticconverterheatingmode.Thequenchareasalsocontributetomixtureformation.
Phasing
Phasingresultsinaliftdifferencebetweenbothintakevalvesofupto1.8mminthelowerpartialload
range.Consequently,theflowoffreshairisdistributedasymmetrically.
36
N55Engine.
5.Valvegear.
Masking
Maskingreferstothedesignofthevalveseats.Thisshapingensuresthattheincomingfreshairis
alignedinsuchawayastogiverisetotherequiredcylinderchargemovement.Theadvantageofthis
measureisthatthecombustionretardationisreducedbyapprox.10crankshaft.Thecombustionprocesstakesplacefasterandalargervalveoverlapcanbeachieved,thusconsiderablyreducingNOx
emissions.
N55engine,combustionchamberroof
Index
Description
Quencharea
Exhaustvalves
Sparkplug
Fuelinjector
Intakevalve
Masking
Quencharea
37
N55Engine.
5.Valvegear.
Thefollowinggraphicshowstheeffectofthepreviouslydescribedmeasures.Thesemeasures
achieveimprovedandfastercombustionintheredarea.Technically,thisisknownastheturbulentkineticenergy.
Influenceofphasingandmaskingonflowinthecombustionchamber
Index
Description
ValvetronicI
ValvetronicII+IIIwithphasingandmasking
TKE
Turbulentkineticenergy
EngineresponseisimprovedbythecombinationofValvetronicIII,directinjectionandturbocharging.
TheresponseuptonaturallyaspiratedfullloadisshortenedonanaturallyaspiratedenginewithValvetronicasthereisnownoneedwaitfortheintakeairmanifoldtobefilled.Thesubsequenttorque
build-upastheturbochargerstartsupcanbeacceleratedwiththepartialliftsettingatlowengine
speed.Thiseffectivelyflushesoutresidualgas,thusresultinginfastertorquebuild-up.
38
N55Engine.
5.Valvegear.
N55engine,valveliftadjustment
Index
Description
Oilspraynozzle
Eccentricshaft
Minimumstop
Maximumstop
Valvetronic
AnewbrushlessDCmotorisused.TheValvetronicservomotorexhibitsthefollowingspecialfeatures:
Openconcept(oilthrough-flow)
Theeccentricshaftangleisdeterminedbyangleincrementsfromtheintegratedsensorsystem
Powerintakereducedbyapprox.50%
Higheractuatingdynamics(e.g.cylinder-selectiveadjustment,idlespeedcontrol,etc.)
Weightadvantage(approx.600gramme)
39
N55Engine.
5.Valvegear.
ThethirdgenerationValvetronicservomotoralsocontainsthesensorfordeterminingthepositionof
theeccentricshaft.AfurtherfeatureoftheValvetronicservomotoristhatengineoilflowsthroughand
aboutit.Anoilspraynozzlelubricatesthewormdrivefortheeccentricshaft.
N55engine,designofvalveliftadjustment
Index
Description
Oilspraynozzle
Eccentricshaft
Torsionspring
Gate
Inletcamshaft
Intermediatelever
Rollerlevertappet
Hydraulicvalvelashadjustment
Valvespring
40
N55Engine.
5.Valvegear.
Index
Description
10
Intakevalve
11
12
Exhaustvalve
13
Valvespring
14
15
Rollerlevertappet
16
Exhaustcamshaft
17
Sealingsleeve
18
Socket
41
N55Engine.
6.Beltdriveandancillarycomponents.
6.1.Beltdrive
Twoversionsofthebeltdriveareused.Theversionfortheautomaticenginestart/stopfunctionhas
threedeflectionpulleysandonedoubleribbedbelt.
N55engine,versionwithoutMSA
Index
Description
Beltpulley,alternator
Deflectionpulley
Deflectionpulley
Beltpulley,A/Ccompressor
Beltpulley,powersteeringpump
Deflectionpulley
Vibrationabsorberwithbeltpulley
Belttensioner
ThankstothemodifiedlayoutoftheA/Ccompressoritispossibletouseaone-sidedpoly-V-belton
vehicleswithMSA.Themodificationsalsoincludeanewplainbearinginthebelttensioner.
42
N55Engine.
N55engine,versionwithMSA
Index
Description
Beltpulley,alternator
Deflectionpulley
Beltpulley,A/Ccompressor
Beltpulley,powersteeringpump
Deflectionpulley
Vibrationabsorberwithbeltpulley
Belttensioner
6.1.1.Vibrationabsorber
Asingle-massvibrationabsorberisusedontheN55engine.Thebeltpulleyismountedonthesecondarypulley.ComparedtotheN54engine,thisdesignlayoutadditionallyreducesthebeltloadasthe
vulcanisationdecouplesthebeltpulleywithflywheelmassfromthecrankshaft.
43
N55Engine.
N54engine,vibrationabsorber
Index
Description
Vibrationabsorber,N55engine
Vibrationabsorber,N54engine
Crankshaft
Bolts
Primarypulley
Vulcanisation
Secondarybeltpulleywithflywheelmass
Primarybeltpulley
Flywheelmass
44
N55Engine.
N55engine,vibrationabsorber
Index
Description
Secondarybeltpulleywithflywheelmass
Flange
Vulcanisation
45
N55Engine.
7.Oilsupply
7.1.Oilcircuit
7.1.1.Oilducts
ThefollowinggraphicsshowanoverviewoftheoilcircuitintheN55engine.ComparedtotheN54engine,thereareconsiderablyfeweroilductsinthecylinderhead.Thisismainlyduetotheuseofthe
newVANOSsolenoidvalves.
46
N55Engine.
7.Oilsupply
N55engine,oilducts
47
N55Engine.
7.Oilsupply
Index
Description
Intakepipe
Oilpump
Unfilteredoilduct
Oilfilter
Mainoilduct(filteredoilduct)
Chaintensioner
10
11
Oilductforintakecamshaftandeccentricshaftlubrication
12
13
Oilductforexhaustcamshaftlubrication
14
15
Connectiontoexhaustturbochargerlubrication
16
Connectionforoilspraynozzles
17
Crankshaftbearing
18
Oilductforoilpressurecontrol
20
21
Oilductforvacuumpumplubrication
22
Vacuumpump
48
N55Engine.
7.Oilsupply
N55engine,oilducts
Index
Description
Intakepipe
Oilpump
Unfilteredoilduct
Oilfilter
Mainoilduct(filteredoilduct)
49
N55Engine.
7.Oilsupply
Index
Description
Chaintensioner
10
15
Connectiontoexhaustturbochargerlubrication
16
Connectionforoilspraynozzles
17
Crankshaftbearing
18
19
21
Oilductforvacuumpumplubrication
22
Vacuumpump
7.1.2.Oilreturn
Thefollowinggraphicsshowtheintegratedoildeflector.Itcombinesthefollowingcomponents:
Oildeflector
Intakesnorkel
Thegreatestpossiblepartitioningbetweentheoilsumpandcrankdriveisachievedbytheintegrated
oildeflector.Oilscraperedgesthatspecificallydirectthesprayoilfromthecrankdriveareadditionally
providedonthebedplate.
Theadaptationfortherequiredtypeofoilpancanbesimplymadebychangingtheintakesnorkel.
Theoilflowingbackfromthecylinderheadisdirectedundertheoildeflector.Inthisway,noreturning
oilcanreachthecrankshaftandcausechurninglossesevenunderhightransverseaccelerationconditions.
50
N55Engine.
7.Oilsupply
N55engine,bedplatewithoilpumpandoildeflector
Index
Description
Oilpump
Bedplate
Oildeflector
51
N55Engine.
7.Oilsupply
N55engine,returnducts
Index
Description
Coolingduct
Cylinderliner
Groove
7.1.3.Oilpumpandpressurecontrol
AmodifiedversionofthereciprocatingslideoilpumpknownfromtheN54engineisused.Forthefirst
timeaDuroplastreciprocatingslidevalveisused.Thevolumetricflowcontrolsystemknownfromthe
N53engineisalsoused.TheoperatingprincipleoftheoilpumpisdescribedintheProductInformationN63Engine.TheoperatingprincipleofthepressurecontrolsystemisdescribedintheProduct
InformationN53Engine.
52
N55Engine.
7.Oilsupply
N55engine,oilpumpandpressurecontrolvalve
Index
Description
Oilpump
N55engine,oilpump
53
N55Engine.
7.Oilsupply
Index
Description
Controloilchamber
Pressurelimitingvalve
Rotor
Vane
Reciprocatingslidevalve
Innerrotor
Housing
Holeforpressurecontrolvalve
Dampingoilchamber
10
Compressionspring(2x)
11
Axisofrotation
TheoilpumphasbeenredesignedtocaterforthefunctionalityanddurabilityoftheDuroplastreciprocatingslidevalve.
7.1.4.Oilfiltrationandoilcooling
TheoilfilterhousingismadefromDuroplast.Aseparateengineoilcoolerisalsousedforcoolingthe
engineoil.Dependingontheoiltemperature,athermostatontheoilfilterhousingreleasestheoilflow
totheoilcooler.
7.1.5.Oilspraynozzles
TheN55engineisequippedwithoilspraynozzlesforthepurposeofcoolingthepistoncrown.Aspecialtoolisrequiredforpositioningtheoilspraynozzles.
7.1.6.Oilmonitoring
Oilpressure
SincetheN55enginehasanoilpumpwithvolumetricflowcontrol,itisnecessarytoexactlymeasure
theoilpressure.Forthisreason,anewsensorsuppliedbythecompanySensataisfitted.TheN53/
N43enginewasequippedwithaHoneywellsensor.
Advantagesofthenewsensor:
Measurementofabsolutepressure(previouslyrelativepressure)
Characteristicmapcontrolpossibleinallspeedranges.
Oillevel
Theknownoilconditionsensorisusedforthepurposeofmeasuringtheoillevel.
54
N55Engine.
8.Airintakeandexhaustsystem
8.1.Airintakesystem
8.1.1.Overview
SeveralfunctionshavebeenoptimisedfortheN55engine:
Unfilteredairrouteduptotheintakesilencer(adoptedfromtheN54engine)
Filteredairductcompletelynewandsimplifiedtoaccommodatethenewexhaustturbocharger
Crankcaseventilation
Divertervalvesystemintegratedinexhaustturbocharger
Fueltankventilationcorrespondinglyadapted.
Ascanbeseenfromthegraphics,thedesignlayoutoftheairintakesystemhasbeensimplifiedasonlyoneturbochargerisused.
N55engine,airintakesystem
55
N55Engine.
Index
Description
Intakesnorkel
Unfilteredairline
Intakesilencer
Airintakesilencercover
Hot-filmairmassmeter
Crankcaseventilationconnection
Exhaustturbocharger
Charge-airpipe
10
Intercooler
11
Charge-airpipe
12
Boostpressure-temperaturesensor
13
Throttlevalve
14
Intakemanifold
56
N55Engine.
N55engine,airintakesystem
Index
Description
Unfilteredair
Purifiedair
Heatedchargeair
Cooledchargeair
Intakesnorkel
Unfilteredairline
Intakesilencer
57
N55Engine.
Index
Description
Filterelement
Airintakesilencercover
Hot-filmairmassmeter
Crankcaseventilationconnection
Exhaustturbocharger
Charge-airpipe
10
Intercooler
11
Charge-airpipe
12
Boostpressure-temperaturesensor
14
Intakeairmanifold
Thebasicfunctionofthedivertervalveremainsthesame.ThedifferencecomparedtotheN54engine
isthatthedivertervalveisnotoperatedpneumatically.ThedivertervalveontheN55engineisanelectricactuatorthatiscontrolleddirectlybytheDME.Thenumberofcomponentshasbeengreatlyreducedbypositioningthedivertervalveontheexhaustturbocharger.Thedivertervalvecanconnect
theintakesidetothepressureside.
AsontheN54engine,theundesirablepeaksintheboostpressurethatcanoccurwhenthethrottle
valveclosesfastarereduced.Thismeansthedivertervalveplaysanimportantroleintermsoftheengineacousticswhileprotectingthecomponentsoftheexhaustturbocharger.Thedetailedoperating
principleisdescribedintheProductInformationN54Engine.
8.1.2.Airintakesystem
Ascanbeseeninthefollowinggraphic,theenginecontrolunitismountedontheintakesystem.The
intakeairisalsousedtocooltheenginecontrolunit.
Thankstothisarrangement,theenginecanalreadybeassembledwiththecontrolunitandthesensorsandactuatorsconnectedtotheengineinproduction.
58
N55Engine.
N55engine,intakesystemwithDMEcontrolunit
Index
Description
Connectionflangeforenginecontrolunitcooling
Connectionflangeforthrottlevalve
Airintakesystem
Enginecontrolunit
Coolingfins
8.1.3.Fueltankventilationsystem
Thefuelvapoursarebufferedinacarboncanisterandthenfedviathefueltankventvalvetothecombustionprocess.Theturbochargingsystemmakesitnecessarytoalsoadaptthissystemtogivenconditions.
59
N55Engine.
N55engine,fueltankventilationsystem
Index
Description
Connectiontoventilationlinefromcarboncanister
Connectionupstreamofthrottlevalve
Fueltankventvalve
Connectiondownstreamofthrottlevalve
Connectionupstreamofexhaustturbocharger
8.2.Exhaustsystem
8.2.1.Overview
Withthetwinscrollexhaustturbocharger,thedesignoftheexhaustsystemislesscomplicatedthan
thatfortheN54enginewithtwoexhaustturbochargers.Inadditiontoanear-enginecatalyticconverter(3),theexhaustsystemalsofeaturesacentresilencer(4)andtworearsilencers(5+6).
60
N55Engine.
N55engine,exhaustsystemF07
Index
Description
Exhaustmanifold
Exhaustturbocharger
Catalyticconverter
Centresilencer
Rearsilencer,right
Rearsilencer,left
8.2.2.Exhaustmanifold
Theexhaustmanifoldisair-gapinsulatedanddesignedasasixintotwomanifold.Combiningthree
exhaustchannelseachintooneexhaustchannelisnecessaryinordertoensureoptimumflowtothe
twinscrollexhaustturbocharger.Theexhaustmanifoldandexhaustturbochargerareweldedtogether
toformonecomponent.
61
N55Engine.
N55engine,attachmentofexhaustturbochargertoengineblock
Index
Description
Exhaustmanifold
Vacuumunit
Connectiontointercooler
Oilfeedline
Divertervalve
Oilreturnline
Coolantinfeed
Coolantreturn
Shaft,wastegatevalve
10
Connectiontoexhaustsystem
62
N55Engine.
8.2.3.Exhaustturbocharger
TheN55engineisequippedwithatwinscrollexhaustturbochargerinsteadoftwoseparatesmallturbochargersasusedontheN54engine.Thefollowinggraphicshowstheoperatingprincipleofthe
twinscrollexhaustturbocharger.
Twinscrollexhaustturbocharger
Index
Description
Exhaustduct1(cylinders1-3)
Connectiontocatalyticconverter
Inletfromintakesilencer
Ringchannel
Outlettointercooler
Wastegatevalve
Leverarm,wastegatevalve
Vacuumunitforwastegatevalve
Divertervalve
63
N55Engine.
Index
Description
Turbinewheel
Coolingduct
10
Oilreturn
11
Coolantreturn
Index
Description
Ringchannel
Outlettointercooler
Wastegatevalve
64
N55Engine.
Index
Description
Divertervalve
10
Oilreturn
11
Coolantreturn
Index
Description
Ringchannel
Outlettointercooler
Wastegatevalve
Divertervalve
Bypass
65
N55Engine.
Index
Description
Turbinewheel
Compressorwheel
Coolingduct
Turbineshaft
Functionofthetwinscrollexhaustturbocharger
Aconstantexhaustgaspressureisappliedtotheexhaustturbochargeronlyrarely.Atlowengine
speeds,theexhaustreachestheexhaustturbineinpulsatingform.Duetothispulsation,ahigherpressureratioistemporarilyreachedintheexhaustturbine.Sincetheefficiencyincreasesasthepressure
rises,thepulsationalsoimprovestheboostpressureprogressionandthusthetorqueprogressionof
theengine.Thisisthecaseparticularlyatlowenginespeeds.
Toensuretheindividualcylindersdonotmutuallyinfluenceeachotherduringthecylindercharge
changeprocess,cylinders1-3(cylinderbank1)andcylinders4-6(cylinderbank2)areeachcombinedtoformoneexhaustchannel.Theflowofexhaustgasintheturbochargerisdirectedinscrolls
(spirals)totheexhaustturbineviatheexhaustchannels(1+2).Thisdesignlayoutmakesitpossibleto
optimallyusethepulsationsforgeneratingboostpressure.
Theknownwastegatevalveisusedforthepurposeoflimitingtheboostpressure.
8.2.4.Catalyticconverter
Twoceramicmonolithsarecontainedinthecatalyticconverterhousing.Thecatalyticconverterhasa
volumeof2.7litres.Dependingonthetypeofvehicletheceramicmonolithshavedifferentcoatings.
Ceramicmonolith1hasavolumeof1.2litres,adiameterof125mmandcontains600cells.
Ceramicmonolith2hasavolumeof1.5litres,adiameterof125mmandcontains400cells.
66
N55Engine.
N55engine,catalyticconverter
Index
Description
Oxygensensorupstreamofcatalyticconverter
Connectionatexhaustturbocharger
Ceramicmonolith1
Catalyticconverteroutletfunnel
Ceramicmonolith2
Oxygensensorafterceramicmonolith1
67
N55Engine.
9.Vacuumsystem.
9.1.Design
TheN55engineisequippedwithavacuumpumpforgeneratingthevacuumrequiredbythebrake
boosterandtheauxiliaryload.ThisauxiliaryloadontheF07isthewastegatevalve.Avacuumaccumulatorisusedtoensurethereissufficientvacuumforthewastegatevalveatalltimes.
N55engine,vacuumsystem
Index
Description
Vacuumpump
Non-returnvalve
Non-returnvalve
Brakeservounit
Non-returnvalve
Vacuumaccumulator
Electropneumaticpressureconverter
Vacuumunit,wastegatevalve
9.1.1.Vacuumpump
ThevacuumpumpissimilartothatusedontheN63engine.Itisatwo-stagepumpandthereforehas
twoconnections.Thefirststageisforthebrakeboosterandthesecondfortheauxiliaryload.
68
N55Engine.
9.Vacuumsystem.
N55engine,vacuumpump
Index
Description
Non-returnvalveforbrakebooster
Non-returnvalveforauxiliaryload
Connectionopeningforauxiliaryload
Vacuumpumphousing
Vane
Connectionopeningforbrakebooster
Thelargestpartofthespaceexpansion(evacuation)isusedforthefirststage,ensuringvacuumis
builtupatarapidrateforthebrakebooster.Onlyinthelastsectionistheopeningfortheauxiliaryload
released,i.e.thesecondstagecutsin.Itthereforetakeslongertobuildupthevacuumhere,asshown
inthefollowingdiagram.
69
N55Engine.
9.Vacuumsystem.
N55engine,deliveryrateofthetwo-stagevacuumpump
Index
Description
Vacuum
Time
Deliveryrateforauxiliaryload
Deliveryrateforbrakebooster
Thissolutiontakesintoaccountthedifferentrequirementsforthebrakeboosterandtheauxiliaryload.
70
N55Engine.
10.Fuelpreparation.
10.1.Overview
Thehighpressurefuelinjectionsystem(HDE)isusedontheN55engine.Incontrasttohighprecision
injection(HPI)solenoidfuelinjectorswithmulti-holenozzlesareused.
Thefollowingoverviewshowsthecompletefuelpreparationsystem.Thefuelpreparationsystemused
ontheN55engineissimilartothefuelpreparationsystemoftheN54engine.Forinstance,thesame
highpressurepumpisused.Thehighpressurefuelinjectionvalvesarenew.Boschhighpressurefuel
injectionvalveswiththedesignationHDEV5.2areused.
N55engine,overviewofhighpressurefuelinjectionsystem
71
N55Engine.
10.Fuelpreparation.
Index
Description
Highpressureline
Rail
Highpressureline
Fuelrailpressuresensor
Solenoidvalvefuelinjector
10.1.1.Fuelpressuresensor
Thefuelisconveyedataprimarypressureof5barbytheelectricfuelpumpfromthefueltankviathe
supplylinetothehighpressurepump.Theprimarypressureismonitoredbythefuelpressuresensor.
Thefuelisdeliveredbytheelectricfuelpumpcorrespondingtorequirements.ThefuelpressuresensorknownfromtheN54,N53andN63engineisused.
Intheeventofthefuelpressuresensorfailing,theelectricfuelpumpcontinuesoperationat100%deliveryrateasfromterminal15ON.
N55Engine
72
N55Engine.
10.Fuelpreparation.
Index
Description
Non-returnvalveforbrakebooster
Non-returnvalveforauxiliaryload
Knocksensor
Connection,highpressurelinetofuelrail
Fuelpressuresensor
Fuelsupplyline
Oilpressuresensor
Quantitycontrolvalve
Highpressurepump
10
Vacuumpump
10.1.2.Highpressurepump
Thefuelispressurisedinthepermanentlydriventhree-pistonhighpressurepumpanddeliveredto
thefuelrailviathehighpressureline.Thefuelstoredunderpressureinthefuelrailisdistributedvia
thehighpressurelinestothehighpressurefuelinjectionvalves.Therequiredfuelpressureisdeterminedbytheenginemanagementasafunctionoftheengineloadandenginespeed.Thepressure
levelisregisteredbytherailpressuresensorandsenttotheenginecontrolunit.Thefuelisregulated
bythequantitycontrolvalvebasedonatarget/actualvaluecomparisonoftherailpressure.ThepressurelevelisconfiguressuchtoachievethebestpossiblefuelconsumptionandsmoothrunningpropertiesoftheN55engine.Apressureof200barisonlyrequiredathighloadandlowenginespeed.The
highpressurepumpisofthesamedesignasthehighpressurepumpusedontheN53andN54engines.
N55engine,fuelpressurediagram
73
N55Engine.
10.Fuelpreparation.
Index
Description
Engineload
Enginespeed
Pressure
Warninginformationforworkingonthehighpressuresystem
10.1.3.Fuelinjectors
ThehighpressurefuelinjectionvalveHDEV5.2fromBoschisasolenoidvalvefuelinjector.Incontrast
tothepiezo-injectorusedonthecurrentBMWengines,thesolenoidvalvefuelinjectorisdesignedas
aninward-openingmulti-holevalvewithhighlyvariablejetangleandjetform.Thesolenoidvalvefuel
injectorisdesignedforasystempressureofupto200bar.
Workshouldonlybecarriedoutonthefuelsystemaftertheenginehascooleddown.Thecoolant
temperaturemustnotbemorethan40C.Theserequirementsmustbeobservedotherwisetheresidualpressureinthehighpressurefuelsystemcouldcausefueltosprayout.
Itisessentialtoobservetheutmostcleanlinesswhenworkingonthehighpressurefuelsystemand
followtheworkingproceduresdescribedintherepairinstructions.Evenminutesoilinganddamageat
thescrewconnectionsofthehighpressurelinescouldcauseleaks.
ParticularcaremustbetakenwhenworkingonthefuelsystemoftheN55enginetoensurethatthe
ignitioncoilsarenotsoiledwithfuel.Theresistanceofthesiliconematerialisgreatlyreducedbycontactwithfuel.Thiscouldresultinsparkoveratthetopofthesparkplugandmisfiring.
74
Beforeworkingonthefuelsystem,removetheignitioncoilsandusearagtopreventfuelenteringthesparkplugwell.
Theignitioncoilsmustberemovedbeforeinstallingnewsolenoidvalvefuelinjectorsandutmostcleanlinessmustbeobserved.
Ignitioncoilsthathavebeenheavilysoiledwithfuelmustbereplaced.
N55Engine.
11.Coolingsystem.
11.1.Overview
ThecoolingsystemoftheN55engineconsistsofacoolantcoolingsystemandanoilcoolingsystem.
Dependingontheversion,differenttypesofoilcoolingsystemareused.Inthehotclimatevariant,
heattransferfromtheengineoiltothecoolantareaoftheengineisavoidedbydecouplingtheoilcoolerfromthecoolantcircuit.
N55engine,coolingsystem
75
N55Engine.
11.Coolingsystem.
Index
Description
Radiator
Engineoilcooler(hotclimateversion)
Heatercoil
Characteristicmapthermostat
Electriccoolantpump
Exhaustturbocharger
Heatingheatexchanger
Coolantvalve
Oil-to-coolantheatexchanger(Europeversion)
10
Coolanttemperaturesensor
11
Engineoilthermostat(hotclimateversion)
12
Expansiontank
13
Coolantlevelswitch
14
Equalisationline
15
Auxiliaryradiator(Europeversion)
16
Electricfan
ThecomponentshighlightedinredinthefollowinggraphicareonlyfittedintheEuropeversion.The
Europeversionhasanauxiliaryradiator(A)ontheleft-handsideofthevehicle.Theengineoiliscooled
bymeansofanoil-to-coolantheatexchanger(C).
76
N55Engine.
11.Coolingsystem.
N55engine,coolingsystem
Index
Description
Auxiliaryradiator
Coolantfeedlinetoauxiliaryradiator
Oil-to-coolantheatexchangers
Coolantfeedlinetooil-to-coolantheatexchanger
Coolantreturnlinefromauxiliaryradiator
Zone1feedline,heatingheatexchanger
Zone2feedline,heatingheatexchanger
Coolantvalve
Expansiontank
Equalisationline
Radiator
Bypasslineforsmallcoolingcircuit
Thermostat
Electriccoolantpump
10
Exhaustturbochargersupplyline
11
Thermostatfortransmissionoilcooling
77
N55Engine.
11.Coolingsystem.
Index
Description
12
Coolantfeedlinetoengineblock
13
Transmissionoil-to-coolantheatexchanger
14
Connection,transmissionoilline
15
Connection,transmissionoilline
16
Return,heatingheatexchanger
17
Heatingheatexchanger
Thefollowinggraphicshowstheconnectionoftheauxiliaryradiatortothecoolingsystem.Theauxiliaryradiatorisconnectedtotheradiatorbymeansofparallelcoolantlines,thusincreasingthecooling
surfacearea.
N55engine,auxiliaryradiator
Index
Description
Radiator
Auxiliaryradiator
Feedconnectiontoauxiliaryradiator
Feedconnectionatauxiliaryradiator
Returnconnectionatauxiliaryradiator
Returnconnectionfromauxiliaryradiator
Aseparateengineoilheatexchangerisusedforthehotclimatevariant.
78
N55Engine.
11.Coolingsystem.
N55engine,engineoilcooling,hotclimate
Index
Description
Oilfiltermodule
Thermostat
Oilcoolerlines
Engineoilcooler
11.1.1.Coolantducts
Thecoolantductsinthecylinderheadarenowalsousedforindirectcoolingofthefuelinjectors.The
followinggraphicclearlyshowsthatthecoolantflowsoverthevalvesandthefuelinjectors,thusreducingtheheattransfertothecomponentstoaminimum.
79
N55Engine.
11.Coolingsystem.
N55engine,coolantductsincylinderhead
Index
Description
Channel,intakevalves
Channel,fuelinjectors
Channel,exhaustvalves
Connection,coolanthosetothermostat(smallcoolingcircuit)
Connection,coolanthosetoradiator(largecoolingcircuit)
Thecastironcylinderlinersarecastinthealuminiumdiecasting.Thewebsbetweenthecylindershavegroovestooptimisecooling.Coolantcanflowalongthesegroovesfromonesideofthe
crankcasetotheother,thuscoolingthewebs.
80
N55Engine.
11.Coolingsystem.
N55engine,coolantductsandwebcoolinginengineblock
Index
Description
Coolingduct
Cylinderliner
Groove
81
N55Engine.
12.Engineelectricalsystem.
12.1.Connectiontovehicleelectricalsystem
12.1.1.Overview
Forthefirsttime,anengine-mountedDigitalMotorElectronics(DME)moduleisused.TheDMEis
flangedtotheintakemanifoldandiscooledbytheintakeair.Thenear-engineDMEhasthefollowing
advantages:
Enginewiringharnessdividedintosixindividualmodules
AllelectricalcomponentsontheenginesupplieddirectlyviatheDME
NoE-box
211pinsareavailable,theplug-inconnectionsarewater-tight
N55engine,wiringharnessrouting
82
N55Engine.
12.1.2.Systemcircuitdiagrams
Circuitdiagram,connectiontovehicleelectricalsystem
N55engine,circuitdiagram,connectiontovehicleelectricalsystem
83
N55Engine.
Index
Description
Electricairflapcontrol
Mechanicalairflapcontrol
Electricfan
Starter
A/Ccompressor
Frontpowerdistributionbox
Junctionboxelectronics
Junctionbox
10
IntegratedChassisManagement
11
Fueltankleakdiagnosticmodule(onlyUSandSouthKorea)
12
Electronicfuelpumpcontroller
13
Rearpowerdistributionbox
14
Intelligentbatterysensor
15
Batterypowerdistributionbox
16
Exhaustflapchangeovervalve
17
Diagnosissocket(enginespeedsignal)
18
Acceleratorpedalmodule
19
Instrumentcluster
20
CarAccessSystem
21
CentralGatewayModule
22
Dynamicstabilitycontrol
84
N55Engine.
Systemcircuitdiagram,enginecooling
N55engine,circuitdiagram,enginecooling
85
N55Engine.
Index
Description
Instrumentcluster
CentralGatewayModule
Coolantlevelswitch
Coolanttemperaturesensor
Electricfan
Mechanicalairflapcontrol
Electricairflapcontrol
Frontpowerdistributionbox
10
Junctionboxelectronics
11
Junctionbox
12
Electricfanrelay
13
Rearpowerdistributionbox
14
Electricfanrelay(onlyfor850Wattand1000Wattelectricfan)
15
Batterypowerdistributionbox
86
N55Engine.
SystemcircuitdiagramMEVD17.2
N55engine,circuitdiagramMEVD17.2
87
N55Engine.
Index
Description
EngineelectronicsValvetronic,directinjection17.2MEVD17.2
Ambientpressuresensor
Temperaturesensor
Brakelightswitch
Starter
CarAccessSystemCAS
Clutchmodule
ElectronicfuelpumpcontrolEKPS
Electricfuelpump
10
Terminal15Nrelay
11
A/Ccompressor
12
Coolantpump
13
Valvetronicrelay
14
JunctionboxelectronicsJBE
15
Refrigerantpressuresensor
16
Relay,ignitionandinjection
17
Terminal30Brelay
18
FueltankleakdiagnosismoduleDMTL
19
Electricfanrelay
20
Electricfan
21
Characteristicmapthermostat
22
Divertervalve
23
Fueltankventvalve
24
VANOSsolenoidvalve,intakecamshaft
25
VANOSsolenoidvalve,exhaustcamshaft
26
27
ElectropneumaticpressureconverterEPDWforwastegatevalve
28
Quantitycontrolvalve
29-34
Fuelinjectors
35-40
Ignitioncoils
41
Enginebreatherheater
42
Groundconnections
43
Oxygensensoraftercatalyticconverter
44
Oxygensensorbeforecatalyticconverter
45
Diagnosticsocket
88
N55Engine.
Index
Description
46
Low-pressurefuelsensor
47
Intakemanifoldpressuresensorafterthrottlevalve
48
Fuelrailpressuresensor
49
Chargeairtemperatureandpressuresensor
50
Knocksensor,cylinders1-3
51
Knocksensor,cylinders4-6
52
Hot-filmairmassmeter(HFM)
53
Intakecamshaftsensor
54
Exhaustcamshaftsensor
55
Crankshaftsensor
56
AcceleratorpedalmoduleFPM
57
ThrottlevalveMDK
58
Coolanttemperaturesensoratengineoutlet
59
Oilpressuresensor
60
Oiltemperaturesensor
61
62
Oilconditionsensor
63
Alternator
64
Activecoolingairflapcontrol
65
IntelligentbatterysensorIBS
66
DynamicstabilitycontrolDSC
67
CentralGatewayModuleZGM
68
IntegratedChassisManagementICM
12.1.3.Enginecontrolunit
TheN55engineisequippedwiththeBoschenginemanagementMEVD17.2.TheMEVD17.2isintegratedintheintakesystemandiscooledbytheintakeair.TheMEVD17.2isFlexRay-compatibleand
directlysuppliesvoltagetothesensorsandactuators.
ThetopsideoftheDMEhousingalsoservesasthebottomsectionoftheintakesystem.Thehousing
iscontouredintheareaoftheintakemanifoldtoensureoptimumflowthroughtheintakesystem.
TheplugconnectionsbetweenthewiringharnessandDMEarewater-tight.
89
N55Engine.
N55engine,enginemanagementMEVD17.2
Index
Description
Module100,sensors2
Module200,sensors1
Module300,vehiclewiringharnessconnection
Module400,Valvetronic
Module500,powersupplymodule
Module600,injectionandignition
12.2.Functions
12.2.1.Fuelsupplysystem
Thefuelpressuresensorsendsavoltagesignal,correspondingtothesystempressureappliedbetweenthefuelpumpandthehighpressurepump,totheenginecontrolunit(DMEcontrolunit).The
systempressure(fuelpressure)isdeterminedwiththefuelpressuresensorupstreamofthehighpressurepump.ThetargetpressureisconstantlycomparedtotheactualpressureintheDMEcontrolunit.
90
N55Engine.
Ifthetargetpressuredeviatesfromtheactualpressure,theenginecontrolunitincreasesordecreases
thevoltagefortheelectricfuelpump.ThisvoltageissentintheformofamessageviathePT-CANto
theEKPcontrolunit.
Theelectricfuelpump(EKP)controlunitconvertsthemessageintoanoutputvoltagefortheelectric
fuelpump,thusregulatingtherequireddeliverypressurefortheengine(orhighpressurepump).The
electricfuelpumpispilot-controlledintheeventofsignalfailure(fuelpressuresensor).Shouldthe
CANbusfailtheEKPcontrolunitoperatestheelectricfuelpumpwiththeappliedsystemvoltage.The
highpressurepumpincreasesthefuelpressureto50and200bar.Thefuelflowsviathehighpressure
linetothefuelrail.Thefuelisbufferedinthefuelrailanddistributedtothefuelinjectors.
Fuelquantitycontrol
Therailpressuresensormeasuresthecurrentfuelpressureintherail.Theexcessfuelisreturnedto
theinlettothehighpressurepumpwhenthequantitycontrolvalveinthehighpressurepumpopens.
Restrictedvehicleoperationispossibleintheeventofthehighpressurepumpfailing.
Thequantitycontrolvalvecontrolsthefuelpressureintherail.Theenginemanagementactuatesthe
quantitycontrolvalvewithapulsewidth-modulatedsignal.Dependingonthepulsewidth,avariable
throttlecrosssectionisreleased,thusprovidingthequantityoffuelrequiredforthecurrentloadstatus
oftheengine.Itisadditionallypossibletoreducethepressureintherail.
12.2.2.Boostpressurecontrol
Theenginemanagementcontrolstheboostpressurewiththewastegatevalveattheexhaustturbocharger.Anelectropneumaticpressureconverterwhichconvertsthesignalsfromtheenginemanagementanddefinedvacuumisusedtoadjustthewastegatevalveinfinitelyvariablewithvacuum.
Adivertervalveisflangedtotheexhaustturbocharger.Thisdivertervalvecancontroltheenginemanagementdirectly,thusestablishingaconnectionbetweentheintakesideandthepressureside.The
divertervalvecaneliminateundesirablepeaksintheboostpressurethatcanoccurwhenthethrottlevalveisclosedquickly.Thedivertervalvethereforehasadecisiveinfluenceontheengineacousticswhileprotectingthecomponentsoftheexhaustturbocharger.Apressurewaveisbuiltupfromthe
throttlevalvetotheexhaustturbochargerwhenthethrottlevalveisclosed.Thispressurewavecomes
upagainsttheturbinebladesintheexhaustturbochargerandpressesthemagainstthebearings.The
divertervalvesubstantiallyreducesthispressurewaveandthustheloadontheexhaustturbocharger.
12.2.3.Enginecooling
Theadvantagesoftheconventionalcoolingsystemareutilisedforthecoolingsystemwithelectriccoolantpump.Theheatmanagementdeterminesthecurrentcoolingrequirementandcontrols
thecoolingsystemaccordingly.Undercertaincircumstances,thecoolantpumpcanbecompletely
switchedoff,e.g.torapidlyheatupthecoolantduringthewarm-upphase.Thecoolantpumpcontinuestooperatewhenthehotengineisshutdown.Thecoolantcapacitycanthereforebevariedirrespectiveoftheenginespeed.Inadditiontothecharacteristicmapthermostat,theheatmanagement
makesitpossibletousevariouscharacteristicmapsforcontrollingthecoolantpump.Inthiswaythe
enginecontrolunitcanadapttheenginetemperaturetothedrivingconditions.
Theenginecontrolunitregulatesthefollowingtemperatureranges:
91
N55Engine.
108C=Economymode
104C=Normalmode
95C=Highmode
90C=Highmodeandcontrolwithcharacteristicmapthermostat
Theenginemanagementsetsahighertemperature(108C)when,basedonvehicleoperation,the
enginecontrolunitdetectsEconomymode.Theengineisoperatedwithrelativelylowfuelrequirementsinthistemperaturerange.Theinternalenginefrictionisreducedathighertemperatures.The
increaseintemperaturethereforerealiseslowfuelconsumptioninthelowloadrange.ThedriverwishestoutilisetheoptimumpowerdevelopedbytheengineinHighandcontrolwithcharacteristicmap
thermostatmode.Forthispurpose,thetemperatureinthecylinderheadisreducedto90C.This
temperaturereductionpromotesimprovedvolumetricefficiency,thusresultinginanincreasedengine
torque.Adaptedtotherelevantdrivingsituation,theenginecontrolunitcannowregulateadefined
operatingrange.Inthiswayitispossibletoinfluencethefuelconsumptionandpoweroutputthrough
thecoolingsystem.
12.2.4.Systemprotection
Ifthecoolantorengineoiloverheatduringengineoperation,certainvehiclefunctionsareinfluencedto
theeffectthatmoreenergyisavailabletotheenginecoolingsystem.
Thesemeasuresaredividedovertwooperatingmodes:
Componentprotection
Coolanttemperaturebetween117Cand124C
Engineoiltemperaturebetween150Cand157C
Result:theoutputoftheairconditioningsystem(upto100%)andoftheengineisreduced
Emergency
Coolanttemperaturebetween125Cand129C
Engineoiltemperaturebetween158Cand163C
Result:thepoweroutputoftheengineisreduced(uptoapprox.90%).
12.3.Sensors
12.3.1.Crankshaftsensor
Thefunctionofthenewintegratedcrankshaftsensorisidenticaltothatofthecrankshaftsensorsused
fortheautomaticenginestart-stopfunction(MSA).Theenginereversaldetectionisrequiredforthe
MSAfunction.ThesensorandfunctionaredescribedintheProductInformationN47Engine.
92
N55Engine.
N55engine,locationofcrankshaftsensor
Index
Description
Directionofviewtowardscrankshaft
Sameviewwithoutstarter
Connector
Dustseal
Sensor
Multipolewheel
93
N55Engine.
N55engine,crankshaftsensorwithmultipolesensorwheel
Index
Description
Connector
Dustseal
Sensor
12.3.2.Ignitioncoilandsparkplug
Ignitioncoil
AnewignitioncoilhasbeendevelopedfortheN55engine.Theignitioncoilprovidesahigherignition
voltage,improvedelectromagneticcompatibilityandissturdier.
TheignitionvoltageofthesecondarycoilontheN43andN53enginesisreversed.Thisisachievedby
reverseactuationandadiodeinthesecondarycircuit.Thepositivepolarisationextendssparkpropagation,thusimprovingtheflammabilityofthemixture.Thisfeatureisonlyrequiredinstratifiedcharge
mode.Sincetheair/fuelmixtureishomogeneousontheN55engine,thenormalignitioncoilisused.
Sparkplug
TheN55engineisequippedwiththesparkplugthatisacommonpartwiththeN63engineandN74
engine.Thestrengthhasbeenimprovedandthevoltagestrengthincreasedbyimprovedceramics.
12.3.3.Oilpressuresensor
Thenewoilpressuresensorcannowdeterminetheabsolutepressure.Thisisrequiredformoreaccurateoilpressurecontrol.Thesensordesignisidenticaltothatofthefuelpressuresensor.
94
N55Engine.
TheDMEsuppliesavoltageof5Volttotheoilpressuresensor.
N55engine,oilpressuresensor
12.3.4.Oxygensensors
N55engine,catalyticconverterandparticulatefilter
Index
Description
Oxygensensorupstreamofcatalyticconverter
Connectionatexhaustturbocharger
Ceramicmonolith1
Catalyticconverter
Ceramicmonolith2
Anewconnectorisusedfortheoxygensensors.Thenewconnectorsystemprovidesgreatlyimprovedcontactingpropertiesandeliminatesbackgroundnoisecausedbycontactingproblems.The
vibration-freecontactpointrepresentsafurtherimprovement.
95
N55Engine.
Oxygensensorbeforecatalyticconverter
TheBoschoxygensensorLSUADVisusedasthecontrolsensorbeforethecatalyticconverter.The
functioniscomparablewiththatoftheoxygensensorLSU4.9andisthereforenotdescribedindetail
here.ThisoxygensensorisalreadyusedontheN63engine.TheabbreviationLSUstandsfor'LambdasondeUniversal'andADVforAdvanced.
Theoxygensensorbeforecatalyticconverter(LSUADV)offersthefollowingadvantages:
Highsignalstabilityspeciallyduringturbochargedoperationthankstolowdynamicpressure
dependence
Increaseddurabilityduetoreducedpumpvoltage
Increasedaccuracy(byafactorof1.7comparedtoLSU4.9)
Readyforoperationfaster<5seconds
Greatertemperaturecompatibility
Improvedsystemconnectorwithmoreeffectivecontactingproperties
TheLSUADVhasanextendedmeasuringrange,makingitpossibletomeasurepreciselyfromlambda
0.65.Thenewoxygensensorisreadyforoperationfastersothatexactmeasuredvaluesarealready
availableafter5seconds.
Themeasuringdynamicsofthesensorarehigher,makingitpossibletodetermineandthereforealso
controlthefuel-airratioseparatelyineachcylinder.Consequently,theflowofexhaustgasishomogeneous,theemissionvaluescanbereducedandthelong-termemissionscharacteristicsoptimised.
Theoxygensensoraftercatalyticconverterisalsoknownasthemonitoringsensor.TheknownBosch
LSF4.2minitoringsensorisused.
12.3.5.Hot-filmairmassmeter
TheSiemensSIMAFGT2hot-filmairmassmeterisused.TheSiemensSIMAFGT2airmassmeteris
equippedwithplanarmetalresistorsonglass.ThistechnologyhasbeenusedintheSIMAFGT1for
morethan15years.Basedonthistriedandtestedsensortechnology,theSIMAFGT2representsa
consistentfurther-developmentandoptimisationwithhighervibrationresistance,improvedaccuracy
atalloperatingtemperaturesandlowersensitivitytowaterandpulsations.
96
N55Engine.
N55engine,HFM
12.4.Actuators
12.4.1.Valvetronicservomotor
Abrushlessdirectcurrentmotor(BLDCmotor)isusedastheValvetronicservomotor.Thankstothe
contactlessenergytransfersystem,theBLCDmotorismaintenance-freeandverypowerful.Theuse
ofintegratedelectronicmodulesensuresprecisioncontrol.
Function
ActuationoftheValvetronicservomotorislimitedtomaximum40amps.Amaximumof20ampsis
availableoveraperiodof>200milliseconds.TheValvetronicservomotorisactuatedbyapulsewidthmodulatedsignal.Thedutycycleisbetween5%and98%.
97
N55Engine.
N55engine,Valvetronicservomotor
Index
Description
Socket
Wormshaft
Needlebearing
Bearingcover
Magneticsensorwheel
Rotorwithfourmagnets
Sensor
Stator
Housing
10
Bearing
98
N55Engine.
TheDMEsuppliesthesensorwithavoltageof5Volt.TheDMEreceivessignalsviafiveHallelements
andevaluatesthem.ThreeofthefiveHallsensorsareusedforroughdivisionandtwoforfinesubdivision.Inthisway,theangleofrotationoftheservomotorcanbedeterminedto<7.5.Togetherwiththe
step-upratioofthewormdrive,veryaccurateandfastliftadjustmentofthevalvecanbeachievedin
thisway.
12.4.2.Highpressurefuelinjectionvalve
TheHDEV5.2usedontheN55engineisanewdevelopmentbasedontheHDEV5.1highpressurefuelinjectionvalveusedontheN14engine.Thefunctionisthesame.
Function
TheHDEV5.2isactuatedinfourphasesasshowninthefollowinggraphic.
99
N55Engine.
N55engine,actuationphasesoftheHDEV5.2
100
N55Engine.
Index
Description
DMEactuationsignal
CurrentflowHDEV5.2
VoltageatHDEV5.2
Boosterphase
Energisationphase
Holdphase
Switchoffphase
Boosterphase:OpeningoftheHDEV5.2isinitiatedintheboosterphasebyahighboostervoltagefromtheDME.Theboosterphaseendsonreachingapprox.10amps.Thehighcurrentis
achievedbyavoltageofuptoapprox.65Volt.
Energisationphase:Intheenergisationphase,theHDEV5.2iscompletelyopenedbycontrollingthecurrenttoapprox.6.2amps.Attheendoftheenergisationphase,thecurrentisreduced
fromtheenergisationtotheholdingcurrentlevelofapprox.2.5amps.
Holdphase:TheenergisedHDEV5.2iskeptopenbycontrollingthecurrentatapprox.2.5amps
intheholdphase.
Switchoffphase:Thecurrentisswitchedoffattheendoftheinjectiontimeintheswitchoff
phase.Atleast2millisecondselapsebetweentwoinjectioncycles.
101
N55Engine.
13.Serviceinformation.
13.1.Enginemechanicalsystem
13.1.1.Enginecasingcomponents
Cylinderhead
Thecombinationofexhaustturbocharger,ValvetronicanddirectfuelinjectionsisreferredtoasTurbo-Valvetronic-Direct-Injection(TVDI).
Cylinderheadcover
Ifacustomercomplainsabouthighoilconsumptionandatthesametimetheexhaustturbochargerisfoundtobeoiledup,itshouldnotbeimmediatelyassumedthattheexhaustturbochargerisdefective.Iftheoilingalreadyexistsaftertheintroductionoftheblow-bygassesthentheentireengine
shouldbecheckedforleaks.Defectivegasketsordefectivecrankshaftsealsmaybethecauseofexcessivelyhighblow-bygasthroughput.Leakingcrankshaftsealscancauseanoilconsumptionofup
to3l/1000km.
13.2.Fuelconditioningsystem
13.2.1.Overview
Fuelinjectors
Workshouldonlybecarriedoutonthefuelsystemaftertheenginehascooleddown.Thecoolant
temperaturemustnotbemorethan40C.Theserequirementsmustbeobservedotherwisetheresidualpressureinthehighpressurefuelsystemcouldcausefueltosprayout.
Itisessentialtoobservetheutmostcleanlinesswhenworkingonthehighpressurefuelsystemand
followtheworkingproceduresdescribedintherepairinstructions.Evenminutesoilinganddamageat
thescrewconnectionsofthehighpressurelinescouldcauseleaks.
ParticularcaremustbetakenwhenworkingonthefuelsystemoftheN55enginetoensurethatthe
ignitioncoilsarenotsoiledwithfuel.Theresistanceofthesiliconematerialisgreatlyreducedbycontactwithfuel.Thiscouldresultinsparkoveratthetopofthesparkplugandmisfiring.
102
N55Engine.
13.Serviceinformation.
Beforeworkingonthefuelsystem,removetheignitioncoilsandusearagtopreventfuelenteringthesparkplugwell.
Theignitioncoilsmustberemovedbeforeinstallingnewsolenoidvalvefuelinjectorsandutmostcleanlinessmustbeobserved.
Ignitioncoilsthathavebeenheavilysoiledwithfuelmustbereplaced.
13.3.Engineelectricalsystem
13.3.1.Ignitioncoilandsparkplug
Ignitioncoil
TheignitionvoltageofthesecondarycoilontheN43andN53enginesisreversed.Thisisachievedby
reverseactuationandadiodeinthesecondarycircuit.Thepositivepolarisationextendssparkpropagation,thusimprovingtheflammabilityofthemixture.Thisfeatureisonlyrequiredinstratifiedcharge
mode.Sincetheair/fuelmixtureishomogeneousontheN55engine,thenormalignitioncoilisused.
103
BayerischeMotorenwerkeAktiengesellschaft
HndlerqualifizierungundTraining
Rntgenstrae7
85716Unterschleiheim,Germany

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