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BMW N55, Manual, Page: 59 / 100

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59

N55 Engine

Intake Manifold

The engine control unit is mounted on the intake manifold. The intake air is used to cool

the engine control unit.
Thanks to this arrangement, the engine comes down the assembly line completely

assembled with the control unit, the sensors, and actuators already connected.

N55, intake system with DME control unit

Index

Explanation

Index

Explanation

1

Mounting flange for engine control unit cooling

4

Engine control unit

2

Mounting flange for throttle valve

5

Cooling fins

3

Air intake system

Summary of Contents for N55

Page 1: ...and Bedplate 14 Crankshaft 17 Crankshaft Main Bearings 17 Pistons and Rings 18 Connecting Rod and Bearings 19 Oil Pan 22 Electrionic Volume controlled Oil Pump 23 Oil Pump and Pressure Control 24 Oil...

Page 2: ...lation System 60 Exhaust Manifold 61 Turbocharger 62 Function of the twin scroll turbocharger 65 Diverter valve 65 Catalytic Converter 66 Exhaust System 67 Vacuum System 68 Vacuum Pump 69 Fuel Injecti...

Page 3: ...Ignition Coil 94 Oil Pressure Sensor 95 Oxygen Sensors 95 Oxygen sensor before catalytic converter 96 Oxygen sensor after catalytic converter 96 Hot film air mass meter 97 High Pressure Fuel Injector...

Page 4: ...ble to Describe the features of the N55B30M0 engine Describe the specifications of the N55 engine Identify the internal and external components of the N55 engine Understand the function of the crankca...

Page 5: ...Re engineering and modifications have made it possible to now use only one exhaust turbocharger Against the backdrop of reduced costs and improved quality the technical data have remained virtually th...

Page 6: ...s are machined to work in conjuction with the Valvetronic III system with regard to promoting air turbulence and mixture formation Crankcase ventilation In contrast to the N54 the N55 crankcase ventil...

Page 7: ...se of a single turbo The intercooler is an air to air type mounted in the lower area of the front bumper cover The exhaust system uses no underbody catalytic converter Vacuum system The N55 engine has...

Page 8: ...at engine speed Nm rpm 400 1300 5000 400 1200 5000 Compression ratio 10 2 10 2 Valves cylinder 4 4 Fuel consumption EU combined l 100 km 10 9 8 9 CO2 emission g km 262 209 Digital Motor Electronics M...

Page 9: ...to its predecessor the N55 engine is characterized by lower fuel consumption with the same power output and torque data Full load diagram E90 335i with N54B30O0 engine compared to the F07 535i with N5...

Page 10: ...ft lbs 1400 5000 335i US E90 E92 E93 2979 89 6 84 0 300 SAE hp 5800 6250 407 300 ft lbs 1400 5000 335i xDrive US E90 E92 2979 89 6 84 0 300 SAE hp 5800 6250 407 300 ft lbs 1400 5000 335is US E92 E93 2...

Page 11: ...BMW Motorsport S BMW M mbH W Non BMW engines 2 Engine type 1 R4 e g N12 4 R4 e g N43 5 R6 e g N55 6 V8 e g N63 7 V12 e g N73 8 V10 e g S85 3 Change to the basic engine concept 0 basic engine 1 9 chan...

Page 12: ...h direct injection Valvetronic and exhaust turbocharger B Gasoline engine longitudinal 30 3 0 liter capacity M Medium performance class 0 New development Item Meaning Index explanation 1 Engine develo...

Page 13: ...number N Engine developer BMW Group 5 Engine type straight 6 5 Change to basic engine concept turbocharging Valvetronic direct fuel injection B Operating principle or fuel supply and installation posi...

Page 14: ...case to the other thus enhancing cooling of this area Five oil return ducts on the exhaust side 4 now permit oil to return from the cylinder head into the oil pan These oil return channels extend into...

Page 15: ...N55 crankcase with web cooling Index Explanation 1 Cooling duct 2 Cylinder liner 3 Grooved cooling passage 4 Oil return ducts exhaust side 5 Oil return ducts intake side 15 N55 Engine...

Page 16: ...cillating air columns that are created in the crankcase by the up and down movement of the pistons This enhances power by relieving the unwanted pressure that acts against the downward movement of the...

Page 17: ...kshaft The timing chains are mounted by means of an M18 central bolt N55 Crankshaft Crankshaft Main Bearings As on the N54 engine the main bearings on the crankshaft are designed as two component bear...

Page 18: ...ed Napier type ring The oil scrape ring is designed as a steel band ring with spring that is also known as VF system N55 piston with piston rings Index Explanation 1 Plain rectangular compression ring...

Page 19: ...his formed hole is machined wider on the lower edges of the wrist pin bushing bore This design evenly distributes the force acting on the wrist pin over the entire surface of the rod bushing and reduc...

Page 20: ...without the formed hole Due to combustion pressure the force exerted by the piston via the wrist pin is mainly transmitted to the edges of the rod bushing N54 connecting rod small end without formed h...

Page 21: ...s reduced considerably N55 connecting rod small with formed hole Lead free bearing shells are used on the large connecting rod end The material G 488 is used on the connecting rod side and the materia...

Page 22: ...the oil deflector Consequently the oil return ducts end in the oil sump Ducts are provided for the oil supply to the vacuum pump as it is now lubricated by filtered oil and not by unfiltered oil as o...

Page 23: ...down the oil aging process The pump is designed as a slide valve type vane pump In delivery mode the pump shaft is positioned off center in the housing and the vanes are displaced radially during rota...

Page 24: ...ssure control valve which affects the oil pressure at the slide valve control mechanism within the oil pump altering the pump output This has the advantage of avoiding power losses by running the oil...

Page 25: ...e is set to the default control setting The pump compression springs are allowed to expand moving the slide valve to its maximum oil pressure position Hydraulic diagram of the N53 engine oil circuit w...

Page 26: ...26 N55 Engine N55 oil pump and pressure control valve Index Explanation 1 Oil pressure control valve 2 Oil pump 3 Oil pressure sensor 3...

Page 27: ...ng graphics show an overview of the oil circuit of the N55 Compared to the N54 engine there are considerably fewer oil ducts in the cylinder head This is mainly due to the use of the new VANOS solenoi...

Page 28: ...0 VANOS adjustment unit exhaust side 11 Oil duct for intake camshaft and eccentric shaft lubrication 12 Hydraulic valve lash adjustment 13 Oil duct for exhaust camshaft lubrication 14 Hydraulic valve...

Page 29: ...29 N55 Engine N55 oil passages front view...

Page 30: ...ion 1 Intake pipe 2 Oil pump 3 Unfiltered oil duct 4 Oil filter 5 Main oil duct filtered oil duct 6 Chain tensioner 7 VANOS solenoid valve exhaust side 8 VANOS solenoid valve intake side 9 VANOS adjus...

Page 31: ...ges Oil Level The oil quality sensor is used for measuring the oil level as on previous BMW engines Oil Return The following graphics show the integrated oil deflector It combines the following compon...

Page 32: ...pact design and is equipped with third generation Valvetronic The combination is referred to as Turbo Valvetronic Direct Injection TVDI This system reduces CO2 emission and fuel consumption by 3 6 The...

Page 33: ...equipped with a vacuum controlled crankcase ventilation system therefore a regulated negative pressure of approximately 38 mbar is maintained N55 cylinder head cover with crankcase ventilation Index E...

Page 34: ...is drained via a return flow duct into the oil pan Naturally Aspirated Mode The standard function can only be used as long as a vacuum prevails in the intake air manifold i e in naturally aspirated e...

Page 35: ...35 N55 Engine N55 crankcase ventilation naturally aspirated mode...

Page 36: ...ir creates a vacuum in the clean air pipe between the turbocharger and intake silencer This vacuum is sufficient to open the non return valve 12 and draw the blow by gasses via the pressure control va...

Page 37: ...N55 crankcase ventilation turbocharged boost mode 37 N55 Engine...

Page 38: ...ould be checked Index Explanation A Excess pressure B Vacuum C Exhaust gas D Oil E Blow by gas 1 Air cleaner 2 Intake manifold 3 Impact plates 4 Oil return channel 5 Crankcase 6 Oil sump 7 Oil return...

Page 39: ...hows the design of the cylinder head on the N55 engine with Valvetronic III and direct fuel injection N55 overview of valvetrain Note Notice the hollow lightweight design of the camshafts 7 and the bl...

Page 40: ...reinforced Valve Springs The valve springs are different for the intake side and exhaust side Index Explanation 1 VANOS unit intake camshaft 2 VANOS unit exhaust camshaft 3 Injector well 4 Spark plug...

Page 41: ...used on the N55 engine The lightweight camshafts for the N55 are manufactured in an internal high pressure forming process called hydroforming The exhaust camshaft features bearing races and is encap...

Page 42: ...ve mm 28 28 Maximum valve lift intake valve exhaust valve mm 9 7 9 7 9 9 9 7 Intake camshaft spread VANOS adjustment range crankshaft 55 70 Exhaust camshaft spread VANOS adjustment range crankshaft 45...

Page 43: ...ex Explanation 1 Main oil duct 2 VANOS solenoid valve intake side 3 VANOS solenoid valve exhaust side 4 Chain tensioner 5 Non return valve exhaust side 6 Non return valve intake side 7 VANOS adjustmen...

Page 44: ...ring the N54 VANOS system with the N55 VANOS that fewer oil passages are required and that the non return valves are no longer on the cylinder head but rather incorporated into the solenoid valves on...

Page 45: ...in the cylinder head The screen filters on the VANOS solenoid valve ensure trouble free operation and reliably prevent the VANOS solenoid valve from sticking due to dirt particles Cam Sensor Wheels T...

Page 46: ...ting mode The quench areas also contribute to mixture formation Phasing Phasing results in a lift difference between both intake valves of up to 1 8 mm in the lower partial load range Consequently the...

Page 47: ...47 N55 Engine N55 Top of the combustion chamber Index Explanation 1 Quench area 2 Exhaust valves 3 Spark plug 4 Fuel injector 5 Intake valve 6 Masking 7 Quench area...

Page 48: ...III direct injection and tur bocharging The response up to naturally aspirated full load is shortened on a naturally aspirated engine with Valvetronic as there is now no need wait for the intake air...

Page 49: ...s not used but rather a Bosch solenoid valve fuel injector with multi hole nozzle The fuel injection is specially adapted to the combination of Valvetronic III and tur bocharging For better illustrati...

Page 50: ...ic III Another new feature is that the eccentric shaft sensor is no longer mounted on the eccentric shaft but has been integrated into the servomotor N55 valve lift adjustment Index Explanation 1 Valv...

Page 51: ...shaft mechanism N55 design of valve lift adjustment Index Explanation Index Explanation 1 Oil spray nozzle 10 Intake valve 2 Eccentric shaft 11 Valvetronic servomotor 3 Return spring 12 Exhaust valve...

Page 52: ...the integrated sensor system Power consumption is reduced by about 50 Higher actuating dynamics e g cylinder selective adjustment idle speed control etc Lightweight design is approximately 600 grams...

Page 53: ...lection pulleys and one double ribbed belt N55 Belt drive Index Explanation Index Explanation 1 Belt pulley alternator 5 Deflection pulley 2 Deflection pulley 6 Vibration absorber with belt pulley 3 B...

Page 54: ...design layout additionally reduces the belt load as the vulcanization decouples the belt pulley with flywheel mass from the crankshaft N54 vibration damper Index Explanation A Vibration damper N55 en...

Page 55: ...55 N55 Engine N55 vibration damper Index Explanation 1 Secondary belt pulley with flywheel mass 2 Flange 3 Vulcanization...

Page 56: ...been integrated into the compressor housing of the turbocharger The fuel tank ventilation has been correspondingly adapted The design layout of the air intake system has been simplified compared to t...

Page 57: ...N55 Air Intake and Exhaust System 57 N55 Engine...

Page 58: ...orkel 2 Unfiltered air pipe 3 Intake silencer 4 Filter element 5 Air intake silencer cover 6 Hot film air mass meter 7 Crankcase ventilation connection 8 Exhaust turbocharger 9 Charge air pipe 10 Inte...

Page 59: ...arrangement the engine comes down the assembly line completely assembled with the control unit the sensors and actuators already connected N55 intake system with DME control unit Index Explanation Ind...

Page 60: ...process It was also necessary to adapt this system to all the given conditions related to turbocharging N55 fuel tank ventilation system Index Explanation 1 Connection to ventilation line from charcoa...

Page 61: ...ee cylinders 1 3 feed one scroll duct 1 of the turbo while the last three 4 6 feed the second scroll duct 2 The exhaust manifold and turbocharger are welded together to form one component N55 attachme...

Page 62: ...scroll turbocharger Twin scroll turbocharger rear view Index Explanation Index Explanation A Exhaust duct 1 cylinders 1 3 2 Lever arm wastegate valve B Exhaust duct 2 cylinders 4 6 3 Vacuum unit for w...

Page 63: ...haust duct 1 cylinders 1 3 1 Wastegate valve B Exhaust duct 2 cylinders 4 6 2 Lever arm wastegate valve C Connection to catalytic converter 3 Vacuum unit for wastegate valve D Inlet from intake silenc...

Page 64: ...Vacuum unit for wastegate valve B Exhaust duct 2 cylinders 4 6 4 Diverter valve C Connection to catalytic converter 5 By pass D Inlet from intake silencer 6 Turbine wheel E Ring channel 7 Compressor...

Page 65: ...pressure based on the firing order of the engine This improves engine efficiency by enhancing throttle response and limiting unwanted turbo lag The wastegate valve is used for the purpose of limiting...

Page 66: ...Ceramic structure 1 has a volume of 1 2 liters a diameter of 125 mm and contains 600 cells Ceramic structure 2 has a volume of 1 5 liters a diameter of 125 mm and contains 400 cells Index Explanation...

Page 67: ...ine catalytic converter design the exhaust system also features a center silencer and two rear silencers N55 exhaust system F07 Note Due to the high efficiency of the near engine three way catalytic c...

Page 68: ...built into the cylinder head cover is used to ensure there is sufficient vacuum for the wastegate valve at all times N55 vacuum system Index Explanation Index Explanation 1 Vacuum pump 5 Non return v...

Page 69: ...is used for the first stage ensuring vacuum is built up at a rapid rate for the brake booster The last section is the opening stage for the auxiliary consumers It therefore takes longer to build up th...

Page 70: ...account the different requirements for the brake booster and the auxiliary consumers N55 delivery rate of the two stage vacuum pump Index Explanation 1 Vacuum 2 Time 3 Delivery rate for auxiliary cons...

Page 71: ...stem The system is similar to the N54 fuel injection Although the same high pressure pump pressure sensor and fuel rail are used the high pressure fuel injection valves are new The HDE system uses Bos...

Page 72: ...uirements The fuel pressure sensor known from the N54 and N63 is used In the event of the fuel pressure sensor failing the electric fuel pump continues operation at 100 delivery rate as from terminal...

Page 73: ...load and engine speed The pressure level is registered by the rail pressure sensor and sent to the engine control unit The fuel is regulated by the quantity control valve based on a target actual valu...

Page 74: ...proper working procedures described in the repair instructions Even minute soiling or damage at the thread connections of the high pressure lines could cause leaks Note Special tool 13 0 270 must be u...

Page 75: ...e hot climate version heat transfer from the engine oil to the engine coolant is avoided by separating the oil cooler from the engine coolant circuit The other version uses an auxiliary radiator in co...

Page 76: ...stic map thermostat 5 Electric coolant pump 6 Exhaust turbocharger 7 Heating heat exchanger 8 Coolant valve 9 Oil to coolant heat exchanger 10 Coolant temperature sensor 11 Engine oil thermostat hot c...

Page 77: ...l to coolant heat exchanger 10 Exhaust turbocharger supply line E Coolant return line from auxiliary radiator 11 Thermostat for transmission oil cooling 1 Zone 1 feed line heating heat exchanger 12 Co...

Page 78: ...the oil filter housing See component C in the previous graphic N55 auxiliary radiator Note If a separate oil to air cooler is not installed an auxiliary radiator in conjuction with an oil to coolant...

Page 79: ...hot climate Note Most current US vehicles use a separate engine oil to air heat exchanger to cool the engine oil hot climate version Index Explanation 1 Oil filter module 2 Thermostat 3 Oil cooler lin...

Page 80: ...ant flows over the valves and the fuel injectors thus reducing the heat transfer to the components to a minimum N55 casting of the coolant passages in cylinder head Index Explanation 1 Channel intake...

Page 81: ...oolant passages Coolant can flow along these grooves from one side of the block to the other thus cooling the deck area between the cylinders N55 coolant passages and web cooling of the engine block I...

Page 82: ...anifold and is cooled by the intake air The engine mounted DME has the following advantages Engine wiring harness is divided into six individual modules All electrical components on the engine are sup...

Page 83: ...83 N55 Engine Circuit Diagram N55 circuit diagram connection to vehicle electrical system...

Page 84: ...box electronics 9 Junction box 10 Integrated Chassis Management 11 Fuel tank leak diagnostic module 12 Electronic fuel pump controller 14 Rear power distribution box 15 Intelligent battery sensor 16...

Page 85: ...85 N55 Engine Engine Cooling Circuit Diagram N55 circuit diagram engine cooling...

Page 86: ...mperature sensor 5 Electric fan 6 Mechanical air flap control 7 Electric air flap control 8 Digital Motor Electronics 9 Front power distribution box 10 Junction box electronics 11 Junction box 12 Elec...

Page 87: ...e manifold The housing is contoured in the area of the intake manifold to ensure optimum air flow An O ring type seal is installed between the DME housing and the intake The plug connections between t...

Page 88: ...88 N55 Engine Digital Motor Electronics Circuit Diagram N55 MEVD17 2 Circuit Diagram...

Page 89: ...lm air mass meter HFM 14 Junction Box Electronics JBE 53 Intake camshaft sensor 15 Refrigerant pressure sensor 54 Exhaust camshaft sensor 16 Relay ignition and injection 55 Crankshaft sensor 17 Termin...

Page 90: ...mp with the applied system voltage The fuel flows via the high pressure line to the fuel rail The fuel is buffered in the fuel rail and distributed to the fuel injectors Fuel quantity control The rail...

Page 91: ...he coolant pump continues to operate when the hot engine is shut down The coolant capacity can therefore be varied regardless of the engine speed In addition to the characteristic map thermostat the h...

Page 92: ...n 150 C 300 F and 157 C 314 F Result The output of the air conditioning system up to 100 and of the engine is reduced Emergency Coolant temperature between 125 C 257 F and 129 C 264 F Engine oil tempe...

Page 93: ...93 N55 Engine N55 location of crankshaft sensor Index Explanation A Direction of view towards crankshaft B Same view without starter 1 Connector 2 Dust seal 3 Sensor 4 Multi pole trigger wheel...

Page 94: ...has been rein forced with silicone and a metal collar shielding compared to the coils used on previous engines See the Service Information section of this training material for more details Always re...

Page 95: ...The DME supplies a voltage of 5 Volt to the oil pressure sensor Oxygen Sensors A new connector is used for the oxygen sensors The new connector system provides greatly improved contacting properties...

Page 96: ...actor of 1 7 compared to LSU 4 9 Ready for operation in 5 seconds Greater temperature compatibility Improved connector with more effective contacting properties The LSU ADV has an extended measuring r...

Page 97: ...e Opening of the HDEV5 2 is initiated in the booster phase by a high booster voltage from the DME The booster phase ends on reaching approximately 10 amps The high current is achieved by a voltage of...

Page 98: ...Function N55 actuation phases of the HDEV5 2 Index Explanation Index Explanation A DME actuation signal 1 Booster phase B Current flow HDEV5 2 2 Energizing phase C Voltage at HDEV5 2 3 Hold phase 4 Sw...

Page 99: ...air pipe after the introduction of the blow by gasses then the entire engine should be checked for leaks Defective gaskets or crankshaft seals may be the cause of excessively high blow by gas output...

Page 100: ...N55 have been redesigned for better rigidity and durability Particular care must be taken when working on the fuel system to ensure that the ignition coils are not wet with fuel The resistance of the...

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