N57TU_S_en

Technisches echnisches Training. rainin g. Produktinformation. N57TU super engine.

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General information Symbols used

The following symbol is used in this document to facilitate better comprehension or to draw attention to very important information:

Contains important safety information and information that needs to be observed strictly in order to guarantee the smooth operation of the system. Information status and national-market versions

BMW Group vehicles meet the requirements of the highest safety and quality standards. Changes in requirements for environmental protection, customer benefits and design render necessary continuous development of systems and components. Consequently, Consequently, there may be discrepancies between the contents of this document and the vehicles available available in the training course. This document basically relates to the European version of left-hand drive vehicles. Some operating elements or components are arranged differently in right-hand drive vehicles than shown in the graphics in this document. Further differences may arise as a result of the equipment specification in specific markets or countries. Additional sources of information

Further information on the individual topics can be found in the following: •

Owne Owner' r'ss Hand Handbo book ok

•

Integrat Integrated ed Service Service Technical echnical Applicati Application. on.

Contact: [email protected] ©2012 BMW AG, Munich, Germany Reprints of this publication or its parts require the written approval of BMW AG, Munich

The information contained in this document forms an integral part of the technical training of the BMW Group and is intended for the trainer and participants in the seminar. seminar. Refer to the latest relevant relevant information systems of the BMW Group for any changes/additions to the technical data. Contact

Gernot Nehmeyer Telephone +49 (0) 89 382 34059 [email protected]























N57TU super engine. Contents. 1.

Models......................... .................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... .................... ........ 5 ..................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ..................... ........ 5 1.1. History.........................

2.

Intr Introd oduc ucti tion on.......................... .................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ................ 8 .................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ........................ ......................... ...................... ......... 8 2.1. 2.1. Techn echnic ical al data data........................ .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ...................... .......... 10 2.2. 2.2. Engi Engine ne iden identi tifi fica cati tion on....................... ..................................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ................ .... 10 2.2. 2.2.1. 1. Engi Engine ne de desig signa nati tion on......................... ..................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ .............. 11 2.2.2. Engine identification........................ ................................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ............ 14 2.3. 2.3. Modif odific icat atio ions ns....................

3.

..................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ....................... ........... Engi Engine ne mech mechan anic ics. s.......................... ..................................... ......................... ............... ... ....................... .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ................ ... 3.1. Crankcase........................ ............................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ............ 3.2. 3.2. Cylind linder er head head................... ....................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ................. ..... 3.3. 3.3. Cylilind Cy nder er head head gask gasket et........................... .................................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ............ 3.4. 3.4. Cran Cranks ksha haft ft driv drive e....................... ..................................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ..................... ........ 3.4.1. Crankshaft........................ .................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ................ 3.4. 3.4.2. 2. Cran Cranks ksha haft ft be bear aring ingss........................ ........................................................ ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ................ .... 3.4.3. Piston........................................... ................................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ................ 3.4. 3.4.4. 4. Gud Gudge geon on pin pin....................... ................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ .................. ...... 3.4.5. Connecting rod....................... .................................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ............... ... 3.4.6. Connecting rod bearing........................ .................................... ........................ ................ .... ....................... ................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ................. ..... 3.5. Valve gear........................ ...................................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ............... ... 3.5.1. Timing......................................... .................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ....................... .......... 3.5.2. Valves........................ ..................................... ........................ ................... ....... ........................ .................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ................ .... 3.6. Oil sump......................... .................................... ......................... ................... ...... ........................ ..................................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ............... ... 3.7. Belt drive........................ ............................................. ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ................. .... 3.7.1. Overview................................. .................................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... .................. ...... 3.7. 3.7.2. 2. Torsi orsion onal al vibra vibrati tion on damper........................

15 15 18 18 20 20 20 21 23 23 24 24 24 25 26 27 27 28

4.

Oil Oil sup supply ply......................... ..................................... ......................... ........................ ........................ ............... ... ........................ .................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ............... ... .............................................. ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ............. 4.1. Overview................................. .................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ........................ ............ 4.1.1. Ducts at engine housing........................ ..................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ............ 4.2. 4.2. Oil Oil filt filter er modu module le........................ ..................................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ............ 4.2.1. Transmission oil cooling........................

30 30 32 33 33

5.

Cool Coolin ing g syste ystem. m........................ .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ....................... .......... 36























N57TU super engine. Contents. 6.2. 6.2.

6.3. 6.3.

.................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ...................... .......... Inta Intak ke air air syste ystem m....................... .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ................ 6.2.1. Overview iew....................... ................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ................... ....... 6.2. 6.2.2. 2. Inta Intak ke mani manifo fold ld....................... .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ................... ...... Exha Exhaus ustt emis emissi sion on syst system em....................... ..................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ................ 6.3. 6.3.1. 1. Char harger unit unit......................... .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ............ 6.3. 6.3.2. 2. Funct unctio ions ns....................... ..................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ............ 6.3. 6.3.3. 3. Swit Switch chin ing g poin points ts......................... ..................................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ....................... ........... 6.3. 6.3.4. 4. NOx NOx cata cataly lyst st stor storag age e......................... ..................................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ .................. ...... 6.3. 6.3.5. 5. Dies Diesel el part partic icula ulate te filte filterr......................... .................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ................ .... 6.3. 6.3.6. 6. H2S H2S cata cataly lytic tic conv conver erte terr........................

41 42 43 44 46 49 55 64 64 64

7.

Vacuu acuum m syst ystem......................... ..................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ....................... ........... 66 .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ...................... .......... 66 7.1. 7.1. Syst Sy stem em overv vervie iew w.......................

8.

Fuel Fuel prep prepar arat atio ion. n........................ .................................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... .................... ....... .................................... ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ................ .... 8.1. Rail........................ .................................... ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ..................... ......... 8.2. 8.2. High High-p -pre ress ssur ure e pump pump........................ .................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ................ ... 8.3. Injector........................ ..................................... ......................... ........................ ........................ ......................... ......................... ....................... ........... 8.3.1. 8.3 .1. Inject Injection ion quantit quantity y compen compensat sation ion........................ .................................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ........................ ............... ... 8.4. 8.4. Oil Oil leak leakag age e syste ystem m........................

75 76 76 76 76 77

9.

..................................... ........................ ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ........................ ................ Engine Engine electr electrica icall syst system. em.......................... .................................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ......................... ......................... ................ 9.1. 9.1. Prehe Preheat ating ing cont contro roll unit unit....................... ................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ............ 9.2. 9.2. New New sens sensor orss and and actu actuat ator orss....................... ................................... ......................... ......................... ........................ ......................... ......................... ........................ ........................ ......................... ......................... ........................ ....................... ........... 9.2. 9.2.1. 1. Glow low elem elemen entt.......................

79 83 83 83























N57TU super engine. 1. Models. 1.1. History The following tables provide an overview of the existing N57 engine versions. Engine

Deve De velo lopm pmen entt seri series es Models

N57D30U0

E90, E90, E91, E91, E92, E92, E93, F10*, F11* 325d, 525d

Power in kW (HP) at

150 (204) rpm 3750

Torque in Nm at

430/450* rpm 1750

Design and number of cylinders

In-line 6

Displacement in cm³

2993

Bore hole/Stroke in mm

84/90

Compression ratio

16.5 : 1

Valves per cylinder

4

Deplo eploy yment ment peri period od

sinc since e 03/2 3/2010 010

Engine control

DDE7.3

Engine

N57D30O0

Series

E90, E91, E92, E93, E70, E71, F01, F02, F07, F10, F11

Models

330d*, 530d, 730d, X5 xDrive30d, X6 xDrive 30d

Power in kW (HP) at

180 (245) rpm 4000

Torque in Nm at

520*/540 rpm 1750 – 3000


In-line 6


2993

Bore hole/Stroke in

84/90























N57TU super engine. 1. Models. Engine

N57D30T0

Series

E70, E71, F01, F02, F07, F10, F11

Models

535d*, 740d, X5 xDrive40d, X6 xDrive40d

Power in kW (HP) at Torque in Nm at

220* (300)/225 (306) rpm 4400 600 rpm 1500 – 2500


In-line 6


2993


84/90

Compression ratio

16.5 : 1

Valves per cylinder

4

Depl eploymen ymentt peri period od

sinc since e 9/20 /2009

Engine control

DDE7.3* DDE7.31

Engine

N57D30O1

Series

F10, F11, F25

Models

530d (530d manual gearbox*), X3 xDrive30d

Power in kW (HP) at

190 (258) rpm 4000

Torque in Nm at

560 (540*) rpm 1500 – 3000


In-line 6


2993


84/90

Compression ratio

16.5 : 1

























N57TU super engine. 1. Models. Engine

N57D30T1

Series

F10, F11, F12, F13, F25

Models

535d, 640d, xDrive30d

Power in kW (HP) at Torque in Nm at

630 rpm 1500 – 2500


In-line 6


2993


84/90

Compression ratio

16.5 : 1

Valves per cylinder

4

Deployment perio riod

09/2011 on

Engine control * = related.

230 (313) rpm 4400

DDE7.31























N57TU super engine. 2. Introduction. The M550d xDrive marks the start of a new model category - the BMW M Performance models - and gives BMW a unique competitive edge. In its overall design aligned to driving dynamics, this model category is only surpassed by the high-performance sports cars of BMW M GmbH. This model is aimed specifically at customers who want to experience more feeling and power but who do not want to go without the comfort of their vehicle and its suitability for daily use. The N57TU super engine complements the diesel range in the upper performance class. The new engine sets standards for example in dynamics, low consumption and power, power, which are exceptional exceptional for a displacement of 3 litres. The N57TU engine, which is already on the market in the N57D30O1 and N57D30T1, serves as the basis. Adaptations have been made and new features added which were necessary for the enormous performance data and the high torque. The following table provides an overview of the models in which the new engine is used. Model

Exhaust emissions legislation

Series

Engine

Market introduction

M550d xDrive

EURO 6

F10

N57D30S1

3/2012

M550d xDrive

EURO 6

F11

N57D30S1

3/2012

X5 M50d

EURO 5

E70

N57D30S1

4/2012

X6 M50d

EURO 5

E71

N57D30S1

4/2012

750d xDrive

EURO 6

F01

N57D30S1

7/2012

750Ld xDrive

EURO 6

F02

N57D30S1

7/2012

2.1. Technical data The following table compares the N57TU top engine to the N57TU super engine.























N57TU super engine. 2. Introduction.























N57TU super engine. 2. Introduction. Unit

N57D30T1 F10/535d xDrive

Valves per cylinder Fuel consumption complying with EU

N57D30S1 F10/M550d xDrive

4 [l/100 km]

5.7

6 .3

[g/km]

149

165

Digital Engine Electronics (DME)

DDE7.31

DDE7.31

Exhaust emissions legislation

EURO 5

EURO 6

[km/h]

250

250

Acceleration 0–100 km/h

[s ]

5.5

4 .7

Vehicle kerb weight DIN/EU

[kg]

1795/1870

1895/1970

CO2 emissions

Maximum speed

2.2. Engine identification 2.2.1. Engine designation In the technical documentation, the engine designation is used to ensure unambiguous identification of the engine. Frequently, Frequently, however, however, only a short designation is used. This short form is used so an engine can be identified as belonging to a specific engine family. family. Therefore, the N57 engine family is often mentioned which is made up of numerous engines such as the N57D30T0, N57D30O0 and the N57D30U0. For the first redesign the family is then called N57TU engine, which currently comprises the N57D30T1 and N57D30O1 engine, and is now supplemented with the N57D30S1. Position

Meaning

Index

Explanation

1

Engine developer

M, N P S

BMW Group BMW M Sport BMW M GmbH























N57TU super engine. 2. Introduction. Position

Meaning

Index

Explanation

5+6

Displacement in 1/10 litre

30

3.0 litre itress disp displa lac cemen ementt

7

Performance class

K U M O T S

Lowest Lower Middle Upper Top Super

8

Revision relevant to approval

0 1–9

New development Redesign

Breakdown of N57D30S1 engine designation Index

Explanation

N

BMW Group Development

5

6-cylinder in-line engine

7

Direct fuel injection and exhaust turbocharger

D

Diesel engine longitudinal installation

30

3.0 litres displacement

S

Super performance class

1

1. Revision

2.2.2. Engine identification The engines have an identification mark on the crankcase to ensure unambiguous identification and classification. The engine identification is also required for approval by the authorities. With the N57 top engine, this identification has been developed further with the number of digits it contains being reduced from eight to seven. The engine number can be found on the engine above the

























N57TU super engine. 2. Introduction. Position

Meaning

Index

Explanation

1

Engine developer

M, N P S W

BMW Group BMW M Sport BMW M GmbH Bought-in engines

2

Engine type

1 2 4 5 6 7 8

4-cylinder in-line engine (e.g. N18) 4-cylinder in-line engine (e.g. N20) 4-cylinder in-line engine (e.g. N47) 6-cylinder in-line engine (e.g. N57) V8 engine (e.g. N63) V12 engine (e.g. N74) V10 engine (e.g. S85)

3

Change to the basic engine concept

0 1–9

Basic engine Changes, e.g. combustion process

4

Working method or fuel type and possibly installation position

A B C D H

Petrol engine transversal installation Petrol engine longitudinal installation Diesel engine transversal transversal installation Diesel engine longitudinal installation Hydrogen internal combustion engine longitudinal installation

5+6

Displacement in 1/10 litre

30

3.0 litr itres disp displlace acement ment























N57TU super engine. 2. Introduction.

N57TU super engine, engine identification and engine number























N57TU super engine. 2. Introduction. 2.3. Modifications System

Engine mechanics

Comment

•

New crankca crankcase se with screw screw connection connection of the cylinder cylinder head and the crankshaft bearing via a threaded bolt (tiebolt principle)

•

Redesign Redesigned ed cooling cooling circuit circuit in the cylinder cylinder head with coolant ducts in the cylinder head gasket

•

Redesign Redesigned ed cylinder cylinder head with larger larger valve valve diameter diameter and new manufacturing procedure

•

New piston piston with with bronze bronze bushin bushing g

•

Gudgeo Gudgeon n pin with with DL DLC C coatin coating g

Belt drive

•

New vibration vibration absorber absorber in connection connection with the 8-gear 8-gear transmission

Oil supply

•

Redes Redesign igned ed and adapte adapted d oil supply supply

Intake air system

•

Newly develope developed d intake intake air sys system tem with three three exhaust exhaust turbochargers and new flaps for the control of the charging pressure in all operating conditions

Exhaust emission























N57TU super engine. 3. Engine mechanics. 3.1. Crankcase The aluminium crankcase of the N57TU super engine is a new design and is based on the crankcase of the N57TU engine. This new design was necessary as the engine support required additional connection points, the oil pressure switch needed to be repositioned and a new medium ducting system (oil and cooling ducts) for the oil filter module supply was required. In addition, the increase in performance of the N57TU super engine caused higher loads for the crankcase. This has been taken into account by making changes to details and geometry to optimise its strength. As can be seen in the following graphic, the engine block has two bridge bore holes ( 6) and a bore hole for the cooling jacket in order to be better able to dissipate heat from the bridge area. Another new feature is the screw connection of the cylinder head and the crankshaft bearing. The bolts are not secured directly in the engine block but in a threaded bolt installed in the engine block at the side. The reason for this is the high tensile load which the aluminium of the engine block would not withstand. Now the cylinder head and the main bearing cap are screwed on together. together. The main bearing caps are also now more stable and sintered.























N57TU super engine. 3. Engine mechanics.

























N57TU super engine. 3. Engine mechanics. Index

Explanation

6

Coolant duct in the crankcase

7

Coolant jacket in the crankcase

8

Sealing cap

9

Threaded bolt

Further changes were made to the crankcase. The ducts for the different media have been optimised and redesigned. The following graphic provides an overview of the various ducts in the crankcase.
























Explanation

8

Oil hole, is sealed by the cylinder head gasket

9

Cooling jacket

10

Cool Coolan antt duct duct from from the the oiloil-to to-w -wat ater er heat heat exchan change gerr retu return rn to the the cyli cylind nder er head head

11

Coolant duct from the cylinder head to the cool oolant pump

12

Oil Oil duct duct for the HVA eleme lemen nts and and for the the lubr lubric icat atio ion n of the cam camshaf shaftt

13

Oil Oil retur eturn n duc duct from the the crank ankcase ase venti entillati ation to the the oil oil sum sump

3.2. Cylinder head
























Explanation

1

Coating

2

Non-stick coating

3

Upper spring steel layer

4

Middle spring steel layer

5

Welded stopper seat

6

Lower spring steel layer

7

Non-stick coating

On examination of the cylinder head gasket between the spring steel layers, one striking point is the integration of the coolant ducts in the middle distance layer
























Explanation

1

Cylinder head gasket

2

Spring steel layer

3

Middle spring steel layer

4

Coolant ducts

5

Non-stick coating

6

Middle spring steel layer with size marking by bore holes

3.4. Crankshaft drive








































































Explanation

5

Minute ring

6

Oil

i

ih

i l

d














































N57TU super engine. 3. Engine mechanics. Intake N57TU

Exhaust N57TU Super

N57TU

N57TU Super






















































































































































































































































































































































































































































































































































































































































N57TU super engine. 6. Intake air/exhaust emission syst. Operating range 4 Speed of rotation

Flap position

from approx. 2600 rpm

•

Low-press Low-pressure ure stage bypass bypass plate plate is closed closed

•

Recircu Recirculate lated d air flap, high-pres high-pressure sure stage 2, is closed closed

•

Compressor Compressor flap, high-press high-pressure ure stage 2, is opened opened

•

Turbine urbine control control flap, high-pres high-pressure sure stage stage 2, is opened opened

•

Wast Wastega egate te valv valve e is closed closed

•

Charging Charging pressure pressure actuator actuator,, high-press high-pressure ure stage 1, is controlled

•

Charging Charging pressure pressure actuator actuator,, high-press high-pressure ure stage 2, is controlled.

Descri Des cripti ption on of the chargi charging ng

The low-pr low-press essure ure stage stage pre-co pre-compr mpress esses es the charge charge air and makes this available to the two high-pressure stages. Both high-pressure stages now increase the charging pressure and convey this via the charge air heat exchanger to the intake system and into the combustion chamber. The engine is now charged in two stages by the low-pressure stage and the two high-pressure stages.

Operating characteristics characteristics of the exhaust turbocharger

The high-pressure stage 1 arrives at the control limit and over the low-pressure stage and the wastegate valve valve is controlled by the charging pressure. The turbine control flap, highpressure stage 2, is now opened and the high-pressure stage 2 assumes its role. The wastegate valve is closed in combination with the turbine control flap, high-pressure stage 2 and the charging pressure controlled via the two high-pressure stages. Both high-pressure stages restrict the maximum charging pressure and ensure the supply of sufficient charge air until the maximum engine speed is reached. The low-pressure stage reaches its maximum performance.

Diagram























N57TU super engine. 6. Intake air/exhaust emission syst. Operating range 5 Speed of rotation

Flap position

From approx. 4000 rpm

•

Low-pres Low-pressure sure stage bypass bypass plate plate is closed closed

•

Recircu Recirculate lated d air flap, flap, high-press high-pressure ure stage stage 2, is closed closed

•

Compressor Compressor flap, high-press high-pressure ure stage 2, is opened opened

•

Turbine urbine control control flap, high-press high-pressure ure stage 2, is opened opened

•

Waste Wastegat gate e valv valve e is contro controlle lled d

•

Charging Charging pressure pressure actuator actuator,, high-press high-pressure ure stage 1, is controlled

•

Charging Charging pressure pressure actuator actuator,, high-press high-pressure ure stage 2, is controlled.

Descri Des cripti ption on of the chargi charging ng

The low-pr low-press essure ure stage stage pre-co pre-compr mpress esses es the charge charge air and makes this available to the two high-pressure stages. Both high-pressure stages now increase the charging pressure and convey this via the charge air heat exchanger to the intake system and into the combustion chamber. The engine is charged in two stages by the low-pressure stage and the two high-pressure stages.

Operating characteristics characteristics of the exhaust turbocharger

The low-pressure stage always delivers more charge air and charging pressure at increasing engine speed. The charging pressure is restricted to the maximum value via the two high-pressure stages. So that the charging pressure can be restricted, the charging pressure actuators are activated and the cross-section of the turbine guide vanes enlarged. As this guide vane adjustment reaches the stop here and a further reduction in the charging pressure is no longer possible, the wastegate valve is also activated by the low-pressure stage and thus the charging pressure controlled.

Diagram























N57TU super engine. 6. Intake air/exhaust emission syst. Emergency operation

If the vacuum system fails, spring force moves the turbocharge group to the following fail-safe position: •

Low-press Low-pressure ure stage bypass bypass plate plate is closed closed

•

Recircu Recirculate lated d air flap, high-pres high-pressure sure stage stage 2, is closed closed

•

Compressor Compressor flap, high-press high-pressure ure stage 2, is closed closed

•

Turbine urbine control control flap, flap, high-pres high-pressure sure stage stage 2, is opened opened

•

Wast Wastega egate te valv valve e is closed closed

•

Charging Charging pressure pressure actuator actuator,, high-p high-pressu ressure re stage 1, is controlled controlled

•

Charging Charging pressure pressure actuator actuator,, high-p high-pressu ressure re stage 2, is controlled controlled..

This corresponds to the position for the middle engine speed range (1500 to 3000 rpm), i.e. the range in which a diesel engine is normally operated. Although this contradicts the BMW strategy of establishing the conditions for maximum power output during emergency operation, it makes good sense in this case, as the vehicle remains in a state in which it is much easier to drive. At high engine speeds and load conditions, the bypass plate may be pushed open in the direction of flow by the charging pressure of the high-pressure stage 2 in the event of a failure of the vacuum system. This prevents direct damage to the components. Protection against any damage resulting from the closed wastegate valve is ensured as the electronic engine control monitors the charging pressure and reduces engine power by a non-critical amount in the event of excessive excessive pressures.

6.3.4. NOx catalyst storage In the M550d xDrive a NO x catalyst storage is used. The NO x catalyst storage is attached before the diesel particulate filter.

The operating principle of the NO x catalyst storage is described in the information bulletin "N57 engine".

6.3.5. Diesel particulate filter In the M550d xDrive the familiar diesel particulate filter is used. The diesel particulate filter is positioned immediately after the low-pressure stage.

The operating principle of the diesel particulate filter is described in the information bulletin "N57 engine".























N57TU super engine. 6. Intake air/exhaust emission syst. The operating principle of the H 2S catalytic converter is described in the information bulletin "N57 engine".























N57TU super engine. 7. Vacuum system The vacuum system of the N57TU super engine is very complex. A total of five vacuum-controlled components are used for the control of the exhaust gas charging. In addition, further components are required for the exhaust-gas exhaust-gas recirculation and the control of o f the connectible engine mount. The vacuum system system in the N57TU super engine poses new challenges to laying lines and contacting. The following graphics provide an overview of how the vacuum lines are contacted with each other and what components are responsible for this.

7.1. System overview

N57TU super engine, system overview of vacuum system

Index

Explanation

























N57TU super engine. 7. Vacuum system Index

Explanation

5

Elec lectric tric chan change geo over valv alve, bypass pass fla flap, exhau xhausst-ga -gas recir ecircu cullati ation

6

Vacuum unit, bypass flap, exhaust-gas recirculation

7

Vacuum reservoir

8

Electric changeover valve for low-pressure bypass plate

9

Vacuum unit low-pressure stage bypass plate

10

Elec Electr tric ic chan change geov over er valv alve, turb turbin ine e cont contro roll flap flap,, high high-p -pre ress ssur ure e stag stage e2

11

Vacuum unit, turbine control flap, high-pressure stage 2

12

Pressure converter, wastegate valve

13

Vacuum unit, wastegate valve

14

Elec Electr tric ic chan change geov over er valv alve, comp compre ress ssor or swit switch chin ing g flap flap,, high high-p -pre ress ssur ure e stag stage e2

15

Vacuu acuum m uni unit compr ompres esso sorr swi switchin ching g flap, lap, highigh-pr pre essur ssure e stag tage 2

16

Elec Electr tric ic chan change geov over er valv alve, reci recirc rcul ulat ated ed air air flap flap,, high high-p -pre ress ssur ure e stag stage e2

17

Vacuu acuum m uni unit recir ecirc culat ulate ed air air flap lap, highigh-p press ressur ure e stage tage 2

18

Electric changeover valve, engine mount

19

Adjustable engine mount, right

20

Adjustable engine mount, left

The vacuum lines are shown in different colours for better identification. All colours shown in the following graphic are black in reality.























N57TU super engine. 7. Vacuum system

N57TU super engine, vacuum reservoir with vacuum supply

Index

Explanation

A

Vacu acuum conne onnect ctiion for elec electtric ric chan hangeo geover valv alve, engi engine ne mount ount Ø 0.5 mm

B

Vacuum connection for vacuum reservoir Ø 0.5 mm

C

Vacuum connection for vacuum reservoir Ø 0.5 mm

D

Vacuu acuum m conn connec ecti tion on for for elec electr tric ic chan change geov over er valve alve,, bypa bypass ss flap flap,, exhau xhaust st-g -gas as
























N57TU super engine, vacuum reservoir with vacuum supply

Index

Explanation

1

Electric changeover valve for low-pressure bypass plate

2

Elec lectric tric chan change geo over valv alve, bypass pass fla flap, exhau xhausst-ga -gas recir ecircu cullati ation
























N57TU super engine, vacuum line laying

Index

Explanation

1

Elec Electr tric ic chan change geov over er valv alve, bypa bypass ss valv alve, low low-pre -press ssur ure e stag stage, e, vacuu acuum m line line,, black (shown here in green for better identification)
























N57TU super engine, vacuum system


























Explanation

7

Vacuu acuum m unit unit,, bypa bypass ss flap flap,, lowlow-pr pres essu sure re stag stage, e, vacuu acuum m line line,, blac black k (sho (shown wn here here in green for better identification)

8

Vacu acuum line ine, whi white, from from the the pres pressu sure re con converte rter, wast waste egat gate valv alve

9

Vacu acuum unit nit, bypas ypasss flap flap,, exha xhaust ust-gas -gas recir ecirc culat ulatio ion, n, vacuu acuum m line line red

10

Vacuum line connector

11

Vacu acuum line ine, blac black k (sho (shown wn her here in oran orange ge for bet better iden identi tifi fica cattion) ion)

12

Vacuu acuum m unit unit,, wast wasteg egat ate e valve alve,, vacuu acuum m line line,, blac black k (sho (shown wn here here in oran orange ge for for better identification)

13

Vacuu acuum m unit unit,, reci recirc rcul ulat ated ed air air flap flap,, high high-p -pre ress ssur ure e stag stage e 2, vacuu acuum m line line,, blue blue

14

Vacuu acuum m unit unit,, turb turbin ine e cont contro roll flap flap,, high high-p -pre ress ssur ure e stag stage e 2, vacuu acuum m line line,, blac black k

15

Vacuu acuum m unit unit,, comp compre ress ssor or swit switch chin ing g flap flap,, high high-p -pre ress ssur ure e stag stage e 2, vacuu acuum m line line,, red

The following graphic is created from photographs and provides a real overview of the laying of the vacuum lines.















































Explanation

1.1 1.1

Elec Electr tric ic cha changeo ngeovver valv alve for low low-pr -pressu essurre bypas ypasss pla plate

1.2

Vacuum line, black

1.3

Vacuum unit low-pressure stage bypass plate

2.1 2.1

Elec Electr tric ic chan change geov over er valv alve, bypa bypass ss flap flap,, exhau xhaust st-g -gas as reci recirc rcul ulat atio ion n

2.2

Vacuum line, red

2.3 2.3

Vacu acuum unit nit, bypas ypasss flap flap,, exha xhaust ust-gas -gas recir ecirc culat ulatio ion n

3.1 3.1

Elec Electr tric ic chan change geov over er valv alve, turb turbin ine e cont contro roll flap flap,, high high-p -pre ress ssur ure e stag stage e2

3.2

Vacuum line, black

3.3 3.3

Vacu acuum unit nit, turb turbin ine e contr ontrol ol flap, lap, high high-p -prress essure ure stage tage 2

4.1 4.1

Elec Electr tric ic chan change geov over er valv alve, reci recirc rcul ulat ated ed air air flap flap,, high high-p -pre ress ssur ure e stag stage e2

4.2

Vacuum line, blue

4.3 4.3

Vacu acuum unit nit reci ecircul culated ated air air flap, lap, high high-p -prress essure ure stage tage 2

5.1 5.1

Elec Electr tric ic chan change geov over er valv alve, comp compre ress ssor or swit switch chin ing g flap flap,, high high-p -pre ress ssur ure e stag stage e2

5.2

Vacuum line, red

5.3 5.3

Vacu acuum unit nit com compres presso sorr swit switc ching hing flap flap,, high high-p -prressu essure re stage tage 2

6.1

Pressure converter, wastegate valve























N57TU super engine. 8. Fuel preparation. The fuel preparation has been redesigned and adapted to the requirements of the N57TU super engine. The injection pressure has been raised to 2200 bar in o rder to be able to inject the fuel at full load and increased maximum engine speed in sufficient quantity and atomisation quality. quality. The main changes are: •

Rail

•

High High-p -pre ress ssur ure e pump pump

•

Injectors ors.























N57TU super engine. 8. Fuel preparation. 8.1. Rail The rail was adapted to the higher pressures and is hot forged. The designation from Bosch is HFR-22; this designation stands for "Hot Forged Rail" and the 22 for 2200 bar pressure. In addition to the rail, the rail pressure sensor and the rail pressure regulating valve have also been adapted to the high pressure of up to 2200 bar.

8.2. High-pressure pump The high pressure pump has also been adapted to the high pressures. The designation from Bosch CP4-22/2 stands for "Common Rail Pump" and the 22 for the maximum operating pressure of 2200 bar and the last digit 2 for the number of pump pistons.

8.3. Injector Injectors from Bosch CRI3–22 are used. The injector is aligned to the required pressure and injection quantities. The designation CRI3–22 means "Common Rail Injector", 3rd generation with 2200 bar injection pressure. The maximum injection pressure is at 2200 bar and is for the new injectors. So that the injectors work reliably for a long period, the structure has been optimised and the valve seat load reduced by the pressure-balanced changeover valve. The injector, however, has a permanent leak due to the changeover valve adaptations, which causes a larger leak in the leakage oil line. The injectors only function in a defined return pressure range if a pressure-retaining valve has been

























N57TU super engine. 8. Fuel preparation.























N57TU super engine. 8. Fuel preparation.























N57TU super engine. 9. Engine electrical system. system. The engine electrical system has been slightly redesigned. Some new sensors and actuators are used, but these correspond to the function and operating principle of the sensors and actuators in the N57TU top engine. The following system overview overview shows the components of the EURO 5 version. The DDE7.31 assumes the function of activating and evaluating evaluating the sensors and actuators.























N57TU super engine. 9. Engine electrical system. system.























N57TU super engine. 9. Engine electrical system. system. Index

Explanation

1

Digital Diesel Electronics DDE

2

Temperature sensor in the DDE control unit

3

Ambient pressure sensor in the DDE control unit

4

Starter motor

5

Car Access System

6

A/C compressor

7

Refrigerant pressure sensor

8

Junction box

9

Relay, terminal 30B

























N57TU super engine. 9. Engine electrical system. system. Index

Explanation

33

Electric fuel pump

34

Glow elements























N57TU super engine. 9. Engine electrical system. system. 9.1. Preheating control unit The preheating control unit is secured to the crankcase for reasons of space and is located near the high pressure pump.























N57TU super engine. 9. Engine electrical system. system. The service function ensures that the correct data record for the installed glow elements is activated in the preheating control unit. An incorrect data record may possibly remain active if glow element identification is not performed. This may result if functional restrictions during glowing or damage to the glow elements.













































N57TU_S_en

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