BMW N62 Series Service Training Download

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New Generation N62 Engine

Chapter 3 P.22

Course Contents/Background Material

© BMW AG,

Service Training

- Alternator

Due to its high power capacity of 180 A, the alternator is cooled
by the engine's cooling system. This ensures constant and even
cooling.

The brushless alternator is supplied by Bosch, and is found in an
aluminium housing which is flanged to the engine block. The
exterior alternator walls are rinsed with engine coolant.

The function and design of the alternator are the same as that in
the M62, with only minor modifications.

The BSD interface (bit-serial data interface) for the DME control
unit is new.

Fig. 19: Alternator

Index

Description

Watertight housing

Rotor

Stator

Seal

KT-7321

Summary of Contents for N62 Series

Page 1: ...BMW Service Training New Generation N62 Engine Course Contents Background Material Information status April 2001...

Page 2: ...1 Engine management 1 VANOS 1 Valvetronic system 1 CHAP 3 N62 engine mechanics 1 Fresh air system 1 Air routing 1 Intake manifold 4 Crankcase venting system 13 Exhaust system 15 Structure 15 Exhaust...

Page 3: ...mper 78 Engine suspension 78 Lubrication system 79 Oil circuit 79 Oil check valve 80 Oil pressure switch 81 Oil pump 82 Oil filter 83 Pressure control 84 Oil cooling 85 Technical data 86 CHAP 4 N62 en...

Page 4: ...eral information 1 Injection valves 1 Fuel pressure regulator 2 Electric fuel pump EKP 2 EKP regulation 2 CHAP 6 E65 fuel systems 1 General information 1 Filling the tank 3 Tank ventilation 5 Fuel sup...

Page 5: ...ves a complete package of measures was introduced in the following areas Engine mechanics Valve timing Intake air guidance Subsequent treatment of exhaust emissions Engine management control The most...

Page 6: ...tio 10 2 10 0 Valves cylinders 4 4 Intake valve diameter mm 32 35 Exhaust valve diameter mm 29 29 Intake valve lift mm 0 3 9 85 0 3 9 85 Exhaust valve lift mm 9 7 9 7 Cams opening period crankshaft 28...

Page 7: ...ation N62 Engine Chapter 1 P 3 Course Contents Background Material BMW AG Service Training Full load graphs N62B36 Fig 1 Full load graphs comparison Broken lines M62B35 Output in kW Torque in Nm Speed...

Page 8: ...New Generation N62 Engine Chapter 1 P 4 Course Contents Background Material BMW AG Service Training N62B44 Fig 2 Full load graphs comparison Broken lines M62B44 Torque in Nm Output in kW Speed KT 8236...

Page 9: ...raining Views of the N62 engine N62B36 Fig 3 N62 engine front view Index Description 1 Valvetronic motors 2 Tank ventilation valve AKF valve 3 VANOS solenoid valve 4 Alternator 5 Pulley for the water...

Page 10: ...New Generation N62 Engine Chapter 1 P 6 Course Contents Background Material BMW AG Service Training Fig 4 N62 engine side view Index Description 1 Starter motor with heat protection KT 7682...

Page 11: ...ear view Index Description 1 Camshaft position sensor cylinder bank 5 8 2 Valvetronic eccentric shaft position sensor cylinder bank 5 8 3 Valvetronic eccentric shaft position sensor cylinder bank 1 4...

Page 12: ...the M44 for details of how the pressure control valve functions Alternator See the M57 EU for details of the principle Characteristic mapping thermostat See the M62 and DME M5 2 for details of how th...

Page 13: ...two cylinder head intake ducts In accordance with fording depth guidelines the air intake ducts are situated high in the engine compartment Fording depth is as follows 150 mm water depth at 30 km h 30...

Page 14: ...ntake paths ensure optimum volumetric efficiency in the lower to middle speed ranges This optimizes the torque curve and increases the torque In order to optimize the power increase in the upper speed...

Page 15: ...tle mode approximately 60 seconds after it is started up In cold conditions however the engine is started with the throttle valve fully opened since this has a positive effect on the starting characte...

Page 16: ...and often appear to be contrary to one another The most important requirements are High engine output High engine torque at favourable engine speeds Favourable torque curve Low pollutant emissions Sm...

Page 17: ...eeded at low engine speeds the engine was fitted with a long intake pipe The consequence was a poorly running engine with insufficient end output If the emphasis is on a lively high capacity engine a...

Page 18: ...ine cylinders the intake pressure in front of the intake valve should ideally be high This means that good airflow high gas molecule density in front of the intake valve is necessary This is only poss...

Page 19: ...o the cylinder This means that suction waves form in the intake pipe which move at sonic speed 333 m s in the opposite direction to the intake air These suction waves are reflected in the intake manif...

Page 20: ...ed air flow to the cylinders once more This process is described as recharge effect The opening angle of the intake valve remains unchanged as the engine speed increases The opening time however is re...

Page 21: ...manifold is located in the V of the engine and is mounted on the cylinder head intake ducts The variable intake manifold housing is made from a magnesium alloy Index Description 1 Drive unit 2 Thread...

Page 22: ...3 The rotors are supported by one shaft 4 per cylinder bank The second shaft from which the rotor for the opposite cylinder bank is adjusted is turned by spur gears 5 in the opposite direction from th...

Page 23: ...gine Chapter 3 P 11 Course Contents Background Material BMW AG Service Training Setting the intake manifold Fig 11 Intake manifold set to short intake path Fig 12 Intake manifold set to longer intake...

Page 24: ...that the intake air must cover a longer path to reach the cylinders When an engine speed of 6 200 rpm is reached the rotor is adjusted to the shorter intake path position The intake path to the cylind...

Page 25: ...ng droplets of oil were to be fed into the engine combustion zone there would be the following consequences Higher oil consumption An effect on pollutant emissions Blue smoke In order to avoid this th...

Page 26: ...m there flows back to the sump The remaining gases are passed back to the engine for combustion via the pressure control valve 5 in the intake manifold One labyrinth separator with pressure control va...

Page 27: ...and is identical in each engine It has been optimized in terms of cylinder filling and scavenging the acoustic system and rapid catalytic converter light off Index Description Index Description 1 Man...

Page 28: ...encer An absorption type 1 8 l capacity front silencer has been fitted for each cylinder bank An absorption type 5 8 l centre silencer is fitted downstream of the two front silencers The rear silencer...

Page 29: ...l secondary combustion which in turns results in a reduction of the non combusted hydrocarbons HC and carbon monoxide CO contained in the exhaust vapours The energy generated during this process heats...

Page 30: ...air valves Once the engine has been started the SLP is supplied with on board voltage by the DME via the secondary air pump relay It remains switched on until the engine has taken in a certain amount...

Page 31: ...back of the cylinder heads see also Engine views in the Intro duction section for the N62 The SLV is opened by the pressure generated by the secondary air pump The secondary air is led through a pipe...

Page 32: ...llary components and belt drive Belt drive Fig 17 Belt drive Index Description Index Description 1 Air conditioning compressor 6 Alternator 2 4 V belt 7 Deflection pulley 3 Crankshaft pulley 8 Power s...

Page 33: ...lley A 4 V belt is used for the air conditioning belt drive and a 6 V belt is used for the main drive Each belt drive has a tensioning unit with tensioning pulley and torsioner The belt drive needs no...

Page 34: ...he brushless alternator is supplied by Bosch and is found in an aluminium housing which is flanged to the engine block The exterior alternator walls are rinsed with engine coolant The function and des...

Page 35: ...ystem to adapt its calulations and specifications to the type of alternator fitted The DME takes on the following functions Activation deactivation of the alternator using specified DME values Informi...

Page 36: ...t changed in comparison with the alternators used until now Regulating the alternator torque particularly when activating Valvetronic operating motors could cause headlamp power fluctuations to occur...

Page 37: ...ator voltage is influenced by the DME BSD interface The battery terminal charge voltage can therefore be up to 15 5 V depending on the battery temperature If therefore the after sales service measure...

Page 38: ...ssor is a 7 cylinder swash plate compressor The compressor s displacement can be reduced to less than 3 This means that no refrigerant is supplied to the coolant circuit There is an internal compresso...

Page 39: ...d is a compact planetary drive starter with a 1 8 kW output Fig 22 N62 engine Power steering pump The power steering pump is a tandem radial piston pump and is driven by the 6 V belt A vane pump is fi...

Page 40: ...st vapour treatment are integrated in the cylinder heads The cylinder heads are cooled according to the cross flow principle The inlet camshaft and the Valvetronic eccentric shaft are jointly guided b...

Page 41: ...over 1 to cover the ignition coil cabling The covers 1 are fixed by connecting them to rubber grommets on the cylinder head covers The engine is additionally fitted with a sound absorption cover 2 whi...

Page 42: ...d covers are made from plastic The sleeves for threading the ignition coil rods are inserted into the cylinder head through the cylinder head cover nos 1 4 Index Description 1 4 Apertures for the igni...

Page 43: ...Fig 25 Plastic sleeves for threading the ignition coil rods through the cylinder head cover to the spark plugs Note The plastic sleeves have moulded on gaskets The sleeves must be completely replaced...

Page 44: ...head for cylinder bank 1 4 7 Hole for VANOS intake solenoid valve 2 Cylinder head for cylinder bank 5 8 8 Hole for VANOS outlet solenoid valve 3 Upper timing chain guide with oil jet 9 Oil pressure sw...

Page 45: ...ion N62 Engine Chapter 3 P 33 Course Contents Background Material BMW AG Service Training Fig 27 Cylinder head cylinder bank 1 4 seen from below Cylinder head gaskets Fig 28 Cylinder head gaskets KT 7...

Page 46: ...d with gaskets of a different thickness The cylinder head gaskets on the B36 and the B44 have different hole diameters Once fitted it is possible to tell the cylinder head gaskets apart This is becaus...

Page 47: ...fts Fig 29 Camshafts The camshafts are made from chilled cast iron and are hollowed to reduce their weight The camshafts are fitted with balancing weights for equalising imbalances in the valve gear I...

Page 48: ...valve is only opened slightly in these ranges The throttle valve prevents the engine from aspirating freely The consequences are poor cylinder filling poor torque and increased fuel consumption The t...

Page 49: ...a During the valve opening phase the engine aspirates more freely via the valves even with small valve lifts than via a throttle valve which is continuously blocked In the cylinder filling and scaveng...

Page 50: ...These features currently represent the best in the field of petrol engine construction The main benefits of these features are Improved cylinder filling with fuel air mixture Improved mixture control...

Page 51: ...s improves cylinder filling still further and reduces fuel consumption The Valvetronic system is based on the one used in the N42 engine and has been brought into line with the geometrics of the N62 e...

Page 52: ...haft thrust bearing is mounted on the cylinder head independently of the bridge support Index Description Index Description 1 Eccentric shaft 7 Chain tensioner mount 2 Valvetronic motor mount 8 Exhaus...

Page 53: ...of the Valvetronic system is the same as that of the N42 engine and has already been described in this documentation Note The cylinder heads are precision mounted together work side to ensure precise...

Page 54: ...Material BMW AG Service Training Valvetronic motor The two Valvetronic motors are located towards the inside in the engine s V Fig 32 Valvetronic motor Index Description 1 Cylinder head cover cylinder...

Page 55: ...rm gear could otherwise be damaged when separating the worm shaft and the worm wheel as the eccentric shaft springs back due to the torque compensation spring If it is not possible to remove the motor...

Page 56: ...are fitted with the new adjustable VANOS vane cells The camshaft adjustment rate is 60 crankshaft 300 ms The VANOS units are labelled In Out The VANOS function is the same as that of the N42 engine VA...

Page 57: ...Service Training The VANOS unit gear teeth have been brought into line with the new toothed chain The VANOS unit for the cylinders 1 4 outlet shaft has a mounting for the vacuum pump drive A spring pl...

Page 58: ...al BMW AG Service Training VANOS oil supply Fig 34 Camshaft with VANOS oil supply holes Fig 35 Cross section of a camshaft Index Description 1 2 Rear oil duct with four holes 3 4 Front oil duct with f...

Page 59: ...on the left and right of the thrust bearing Depending on the individual VANOS adjustment direction the VANOS is supplied with oil via either the rear oil ducts 1 2 or the front oil ducts 3 4 The oils...

Page 60: ...pendently of the VANOS unit on the opposite side of the camshaft The sensor wheels are made from a sintered material The following diagram shows the VANOS unit camshaft adjustment possibilities Fig 36...

Page 61: ...being driven which means that insufficient intake pipe vacuum pressure is created The N62 vacuum pump has a larger internal volume than the N42 vacuum pump for greater evacuation capacity A second vac...

Page 62: ...ter 3 P 50 Course Contents Background Material BMW AG Service Training Chain drive Fig 37 Chain drive The camshafts are driven by a toothed chain one for each cylinder bank The oil pump is driven by a...

Page 63: ...r bank 5 8 4 Sensor wheels for the camshaft position sensor cylinder bank 5 8 5 Upper timing chain guide with integrated oil jet 6 Guide rail 7 Sprocket for oil pump drive 8 Timing case lower section...

Page 64: ...n The camshafts are driven by the crankshaft using newly developed no maintenance toothed chains The relevant toothed chain gear wheels are located on the crankshaft and on the VANOS unit Use of the n...

Page 65: ...r the oil pump drive chain Note The sprocket will also be fitted to a 12 cylinder engine variant which will be available in the future Please observe the instal lation instructions and the relevant la...

Page 66: ...the cylinder head for each camshaft drive chain There is a guide ball in the chain tensioner The guide ball moves in an arched groove at the tensioning rail The chain tensioner seal must be replaced e...

Page 67: ...sioning rail cylinder bank 1 4 is hollowed There is a ball valve in the bearing pin The valve closes at an oil pressure of 1 5 bar and allows engine oil to flow to the tensioning rail via a hole 1 Ind...

Page 68: ...2 Chain tensioner cylinder bank 5 8 An oil jet has been fitted to lubricate the right hand drive chain cylinder bank 5 8 There is a valve in the oil jet which opens at a pressure of 1 5 bar and suppli...

Page 69: ...d An immobile guide rail is screwed to the cylinder head to guide the drive chain to the cylinder head There is a small hole in the guide rail through which the cylinder head area of the drive chain i...

Page 70: ...New Generation N62 Engine Chapter 3 P 58 Course Contents Background Material BMW AG Service Training Cooling system Coolant circuit Fig 44 N62 coolant circuit KT 7960...

Page 71: ...ng delivery line 6 Cylinder head ventilation line 7 Holes for crankcase venting system 8 Transmission oil lines 9 Oil water heat exchanger for automatic transmission 10 Thermostat for transmission oil...

Page 72: ...en improved and is carried out via ventilation ducts in the cylinder heads and in the radiator see the overview of the coolant circuit The air in the cooling system accumulates in the expansion tank W...

Page 73: ...ylinder heads blue arrows The coolant then flows from the cylinder heads in the engine block V red arrows and through the connection 3 to the thermostat The still cold coolant flows from the thermosta...

Page 74: ...ice Training Fig 46 Coolant flow to the rear of the engine block From the rear of the engine block the coolant flows through the side apertures to the cylinder walls and from there it flows to the cyl...

Page 75: ...ase lower section Index Description 1 Map controlled thermostat radiator return flow 2 Electrical connection for map controlled thermostat heating element 3 Thermostat mixing chamber in water pump 4 T...

Page 76: ...ing ring seal usually accumulates here and evaporates through a hold in the leakage chamber evaporation area If the sliding ring seal is faulty the leakage chamber fills completely with coolant Slidin...

Page 77: ...eal leakage which is necessary for water pump operation resulted in evaporation residues being left on the external walls of the water pump The leakage restraint system has the advantage that the cool...

Page 78: ...ents Background Material BMW AG Service Training Fig 50 Timing chain lower section Index Description 1 Coolant to engine 2 Water pump housing in lower section of timing chain 3 Threaded connection for...

Page 79: ...tat The map controlled thermostat allows the engine to be cooled in accordance with the relevant operating conditions This reduces fuel consumption by around 1 6 The electrical connections the design...

Page 80: ...m components Cooling radiator Air conditioning condenser Transmission oil water heat exchanger WT with control unit Hydraulic fluid radiator Engine oil radiator Main electric fan Fan shroud for viscou...

Page 81: ...ed Some of the coolant flows through an opening in the radiator partition wall to the high temperature section then on to the low temperature section where it is cooled further The coolant then flows...

Page 82: ...o heat up as quickly as possible From an WT thermostat return flow water temperature of 82 C the WT thermostat switches the transmission oil water heat exchanger to the low temperature coolant radiato...

Page 83: ...ntents Background Material BMW AG Service Training Engine block Oil sump Fig 53 Oil sump Index Description 1 Upper section of the oil sump 2 Oil pump 3 Oil condition sensor 4 Lower section of the oil...

Page 84: ...d to the crankcase with a rubber coated sheet steel gasket The double skinned lower section of the oil sump is flanged to the upper section of the oil sump The upper section of the oil sump is sealed...

Page 85: ...re honing Exposure honing involves treating the cylinders with a special soft strip This flushes the aluminium from the cylinders and the hard silicone particles remain on the cylinder walls The crank...

Page 86: ...ly hardened For reasons of weight the crankshaft has been hollowed around bearings 2 3 and 4 The crankshaft has five bearings The fifth bearing is also the axial guide bearing The crankshaft lift is 8...

Page 87: ...tion N62 Engine Chapter 3 P 75 Course Contents Background Material BMW AG Service Training Fig 56 Crankshaft thrust bearing A locating bearing is fitted transmission side as a crankshaft thrust bearin...

Page 88: ...connecting rod The cast piston is a weight optimized box piston with integrated valve pockets in the piston crown The pistons are made from high temperature aluminium alloy and are equipped with three...

Page 89: ...connecting rod eye is split at 30 it is possible to carry out the cranking in a very compact space The pistons are cooled by oil jets on the exhaust side of the piston crown The pistons for the B36 an...

Page 90: ...ng detection are riveted directly on the drive disc while warm The flywheel diameter is 320 mm Vibration damper The vibration damper is a torsional vibration absorber in an axial non interacting desig...

Page 91: ...ts in the crankcase and cylinder head are supplied with engine oil Crankcase Crankshaft bearing Oil jets for cooling the piston crowns Oil jets for the chain drive on cylinder bank 5 8 Tensioning rail...

Page 92: ...o each cylinder head from the outside This prevents the engine oil from flowing back out of the cylinder head and the VANOS units As the check valves are accessible from the outside there is no need t...

Page 93: ...nd Material BMW AG Service Training Fig 60 Oil check valves Note The oil check valves are identical in design which means that they cannot be mixed up Oil pressure switch The oil pressure switch is lo...

Page 94: ...le and is driven by the crankshaft using a roller chain The oil pump is a two level gear oil pump with two parallel switched gear clusters The oil pump function is the same as that of the N42 engine I...

Page 95: ...e oil sump The support for the oil filter element is integrated in the rear oil pump cover The oil filter cover is screwed to the rear oil pump cover through an opening in the oil sump An oil drain pl...

Page 96: ...the VANOS units even at high oil temperatures and low speeds The oil pump s power consumption is reduced by switching off the second level 2 It monitors the required oil pressure for the engine The p...

Page 97: ...tion on the generator support The generator support has an oil thermostat A wax element in the oil thermostat continuously opens the inflow to the oil cooler when the oil temperature is between 100 C...

Page 98: ...roduction plant 9 7 l Total capacity when first filled at the production plant engines with oil cooler 8 l After sales service oil filter change capacity 1 5 l Capacity between min max mark in the oil...

Page 99: ...t and the IVM integrated supply module The DME controls an electronic equipment compartment fan to cool the electronics system The control unit connector has a modular structure and has a 5 connector...

Page 100: ...New Generation N62 Engine Chapter 4 P 2 Course Contents Background Material BMW AG Service Training ME 9 2 overview ME 9 2 section 1 Fig 62 ME 9 2 block diagram section 1 KT 7075...

Page 101: ...New Generation N62 Engine Chapter 4 P 3 Course Contents Background Material BMW AG Service Training ME 9 2 section 2 Fig 63 ME 9 2 block diagram section 2 KT 7029...

Page 102: ...ders 5 6 KS 7 8 Knock sensor cylinders 7 8 KWG Crankshaft sensor L1 Electronic fan L2 Electronic equipment compartment fan LSH 1 Oxygen sensor downstream of catalytic converter 1 LSH 2 Oxygen sensor d...

Page 103: ...sensor signal ground Oxygen sensor 1 upstream of catalytic converter 2 08 G Oxygen sensor ground Oxygen sensor 2 downstream of catalytic converter 2 09 G Oxygen sensor signal ground Oxygen sensor 2 u...

Page 104: ...onic Control 3 19 D Alternator and oil quality 3 20 O VANOS valve signal Exhaust camshaft 1 3 21 O TEV Tank ventilation 3 22 Blank 3 23 O VANOS valve signal Exhaust camshaft 2 3 24 O Negative activati...

Page 105: ...position sensor Accelerator pedal sensor 4 08 I Signal pedal position sensor Accelerator pedal sensor 4 09 O Supply pedal position sensor Accelerator pedal sensor 4 10 Blank 4 11 Blank 4 12 G Ground...

Page 106: ...et temperature sensor 4 40 O Automatic start X6005 9 pin black Plug connector DME module 5 5 01 O Signal terminal 1 Ignition coil cylinder 3 5 02 O Signal terminal 1 Ignition coil cylinder 4 5 03 O Si...

Page 107: ...catalytic converter 2 LSV2 Coolant outlet temperature sensor NTC1 Water temperature sensor NTC2 Exhaust camshaft sensor 1 NWGA1 Exhaust camshaft sensor 2 NWGA2 Inlet camshaft sensor 1 NWGE1 Inlet cams...

Page 108: ...ining Switch Starter switch A1 Relay DME relay K1 Starter motor relay K2 Secondary air pump relay K3 Valvetronic relay K4 Power supply relay to ignition coils 1 8 K5 Interfaces Car CAN bus high CAN F...

Page 109: ...g Fig 64 Engine wiring harness Index Description 1 Plug connector to electronic equipment compartment 2 Plug connector to injection valves 3 Valvetronic sensor plug connector 4 Camshaft angle sensor p...

Page 110: ...t system via the ZGM and ISIS integrated safety and information system using the airbag control unit in the SBSR right hand side satellite B pillar This enables the fuel pump to be switched off in the...

Page 111: ...eam of each of the two primary catalytic converters There is a secondary catalytic converter sensor for each cylinder bank positioned downstream of the main catalytic converter volatile characteristic...

Page 112: ...built in the engine s oil sump to record the exact engine oil level oil temperature and the condition of the engine oil Recording the engine oil level protects the engine from having an oil level whi...

Page 113: ...l tubes 2 3 which act as capacitor electrodes are located inside the sensor The engine oil 4 dielectric is located between the electrodes The electrical material properties of the engine oil change in...

Page 114: ...of the sensor 5 This part of the sensor is located on the top of the oil level in the oil sump As the oil level lowers dielectric the capacitance of the capacitor also changes The sensor electronics...

Page 115: ...current position The driver may notice this in the form of loss of power or reduced elasticity Idle speed control The Valvetronic system controls the engine speed and the idle speed Reduced valve lift...

Page 116: ...ents Background Material BMW AG Service Training Note If the idle speed control is faulty the engine must be checked for leaks because leaking air has an immediate effect on idling This also becomes n...

Page 117: ...control system was extended for the N62 engine by adding two Valvetronic motors and two Valvetronic sensors Index Description DME Digital motor electronics K1 DME main relay K2 Additional relay M1 Val...

Page 118: ...1 2 2 02 O Sensor power supply Cylinder bank 1 2 03 O Guide sensor signal chip select Cylinder bank 1 2 04 I Guide sensor signal data Cylinder bank 1 2 05 O Clock signal for data transfer from the gu...

Page 119: ...trol unit reduce the voltage supply to the control unit electronics system and the sensors to 5 volts The electronics system carries out a pre drive check The additional relay electronics are switched...

Page 120: ...y running lead There is another interface between the DME control unit and the Valvetronic control unit which is known as the emergency running wire It is operated by the DME control unit and the Valv...

Page 121: ...oad control is now operated via the throttle valve Valvetronic control unit The Valvetronic control unit can be fitted in both the N42 and the N62 engine The control unit is assigned to the appropriat...

Page 122: ...fts For adjustments they are operated by a frequency of 16 kHz for reasons of acoustics and in order to make exact adjustments In order to position the engine exactly the polarity is briefly reversed...

Page 123: ...eference sensor is opposite to that of the guide sensor The Valvetronic control unit supplies the guide and reference sensors with 5 volts and the earth connection using common wires Each of the two s...

Page 124: ...ervice Training The data telegram from the guide sensor is then issued on the DAT line giving the exact position of the eccentric shaft The reference sensor works in exactly the same way but does not...

Page 125: ...jection valves Fig 68 Fuel distributor block with injection valves The injection valves have been positioned closer to the intake valves This means that larger injection angles can be covered by the i...

Page 126: ...ps in the intake air pipe behind the mass air flow sensor Electric fuel pump EKP The fuel pump is a two part in tank gear pump The first part is for the pre delivery stage It feeds the in tank gear pu...

Page 127: ...ulation is integrated in the SBSR right hand side satellite B pillar The SBSR controls the front right belt force limiter and the fuel pump The SBSR controls the EKP via a PWM signal in accordance wit...

Page 128: ...ng Possible malfunctions consequences If the fuel quantity requirement from the DME and EKP rotation speed signal in the SBSR fails the fuel pump will continue to operate with the greatest delivery ra...

Page 129: ...New Generation N62 Engine Chapter 6 P 1 Course Contents Background Material BMW AG Service Training E65 fuel systems General information Fig 70 E65 US design fuel system KT 8112...

Page 130: ...rbon canister 10 Fuel tank leak diagnostic module 11 Roll over valve 12 Dust filter 13 Service ventilation 14 Pressure test lead 15 Fuel tank cap 16 Service vent valve float valve 17 Anti spitback fla...

Page 131: ...es This means that fuel from the left half of the tank must be channelled into the right half of the tank to enter the fuel pump Filling the tank There must be no escape of fuel vapours when the tank...

Page 132: ...f the fuel filler cap has been opened The filler neck is designed so that the incoming fuel functions like a venturi tube during refuelling and also draws external air into the tank so that no fuel va...

Page 133: ...in the fuel expansion tank 11 28 A service vent hose 13 An activated carbon filter with hoses 9 A dust and spider filter 12 Tank ventilation components Service vent 16 The service vent valve 16 on th...

Page 134: ...inlet and outlet openings and prevents fuel from escaping Dust and spider filter 12 The dust and spider filter prevents dust and small insects from entering the activated carbon filter which would thu...

Page 135: ...ere The layout of the tank ventilation is designed such that trouble free refuelling can take place If the fuel level reaches the ventilation valve 30 the ball floats and closes the ventilation pipe T...

Page 136: ...uel tank 22 Surge chamber 18 Fuel pump 19 Two suction jet pumps 21 Outlet protection valve 23 Pressure relief valve 20 Internal tank fuel lines Fuel filter with fuel pressure regulator 25 26 Fuel dist...

Page 137: ...uction jet pump acts like a venturi tube which draws the returning fuel from the left half of the tank into the right half The other amount of diverted fuel flows via the second internal fuel supply d...

Page 138: ...cated by the MIL malfunction indicator lamp Function The fuel tank leak diagnostic module generates excess pressure of 20 30 mbar in the fuel tank using an electrically operated air pump vane pump The...

Page 139: ...reference hole Finally the actual leak test is carried out The time taken for the measurement is 60 220 seconds if the system has no leaks 200 360 seconds if there is a leak measuring 0 5 mm 30 80 se...

Page 140: ...Training Fig 72 Diagnostic procedure 1st Flushing the activated carbon filter Index Description A Throttle valve B To the engine C Fresh air 1 Tank ventilation valve TEV 2 Activated carbon filter AKF...

Page 141: ...ervice Training Fig 73 Diagnostic procedure 2nd Reference measurement Index Description A Throttle valve B To the engine C Fresh air 1 Tank ventilation valve TEV 2 Activated carbon filter AKF 3 Fuel t...

Page 142: ...G Service Training Fig 74 Diagnostic procedure 3rd Tank measurement Index Description A Throttle valve B To the engine C Fresh air 1 Tank ventilation valve TEV 2 Activated carbon filter AKF 3 Fuel tan...

Page 143: ...cond time the main start conditions are fulfilled The main start conditions are usually fulfilled twice daily for example if the driver drives to work in the morning and drives home in the evening Sta...

Page 144: ...is opened and the subsequent pressure increase when the tank is filled In this case the leakage diagnosis is interrupted the solenoid valve in the DMTL module is switched off and the tank pressure es...

Page 145: ...geometry intake manifold EKP Electronic fuel pump FGR Cruise control HVA Hydraulic valve clearance adjustment HFM Hot film air mass meter ISIS Intelligent Safety Integration System MIL Malfunction In...

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