BMW Advanced Diesel with BluePerformance Product Information

Technical Training ­Product Information.
Advanced Diesel with BluePerformance.
BMW Service
The information contained in the Product Information and the Workbook form an integral part of the training literature of BMW Technical Training.
Refer to the latest relevant BMW Service information for any changes/supplements to the Technical Data.
Information status: June 2008
Contact: conceptinfo@bmw.de
© 2008 BMW AG München, Germany Reprints of this publication or its parts require the written approval of BMW AG, München VH-23, International Technical Training
Product Information.
Advanced Diesel.
Diesel engine for North America
Selective Catalytic Reduction (SCR)
Low pressure exhaust gas recirculation (LP EGR)

Notes on this Product Information

Symbols used
The following symbols are used in this Product Information to improve understanding and to highlight important information:
3 contains important safety information as well as information that is
necessary to ensure smooth system operation and must be adhered to.
1 identifies the end of a note.
Information status and national variants
BMW vehicles conform to the highest safety and quality standards. Changes in terms of environmental protection, customer benefits and design render necessary continuous development of systems and components. Consequently, there may be discrepancies between this Product Information and the vehicles available in the training course.
This documentation describes left-hand drive vehicles. In right-hand drive vehicles, the arrangement of some controls or components may differ from the illustrations in this Product Information. Further differences may arise as the result of the equipment variants used in specific markets or countries.
Additional sources of information
Further information on the individual topics can be found in the following:
- Owner's Handbook
- Integrated Service Technical Application.
Contents.
Advanced Diesel.
Objectives
Product information and working reference for practical applications.
Models 3
Engine variants 3
Introduction 7
System components 23
Engine mechanical system 23 Air intake and exhaust system 25 Cooling system 38 Fuel preparation system 41 Overview of fuel supply system 43 Functions of the fuel supply system 47 Components of the fuel supply system 51 Overview of selective catalytic reduction 60 Functions of selective catalytic reduction system Components of the selective catalytic reduction system Engine electrical system 110 Automatic transmission 119
72
95
1
1
6

Objectives.

Advanced Diesel.

Product information and working reference for practical applications.

This Product Information provides information on the design and function of the M57D30T2 US engine.
This Product Information is structured as a working reference and complements the subject material of the BMW Aftersales Training seminar. The Product Information is also suitable for self-study.
As a preparation for the technical training program, this Product Information provides an
insight into the diesel engine for the US market. In conjunction with practical exercises carried out in the training course, its aim is to enable course participants to carry out servicing work on the M57D30T2 US engine.
Technical and practical background knowledge of the current BMW diesel engines will simplify your understanding ofthesystems described here and their functions.
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6
2
7

Models.

Advanced Diesel.

Engine variants

Models with the M57D30T2 US engine at the time of market launch in Autumn 2008.
1 - BMW 335d 2 - BMW X5 xDrive35d
3
Model
335d E90 M57D30T2 2993 90/84
X5 xDrive35d E70 M57D30T2 2993 90/84
Model series
Engine
Cylinder capacity in cm
Bore/stroke
in mm
Power in
kW/bhp at rpm
200/265
4200
200/265
4200
Torque in
Nm at rpm
580
1750
580
1750
Market launch
11/08
11/08
3
7

History of the M57 engine

The M57 engine is by far one of the most successful engines at BMW. It is fitted in numerous models right across the vehicle range. It plays the part of the extremely powerful top-of-the-range engine, for example in the 3 Series just as effectively as the well­balanced entry class engine in the 7 Series.
10 years have already passed since its introduction and many improvements have been made during this period. In particular the re-engineering that took place in 2002 and again in 2005 ensure that the M57 engine is still state-of-the-art.
The following table shows an overview of the individual models equipped with the M57 engine.
Engine
M57D30O0 530d E39 2926 135/184 390 DDE4.0 9/98 3/00 M57D30O0 730d E38 2926 135/184 410 DDE4.1 9/98 3/00 M57D30O0 330d E46 2926 135/184 390 DDE4.0 9/99 3/03 M57D25O0 525d E39 2497 120/163 350 DDE4.0 3/00 2/04 M57D30O0 530d E39 2926 142/193 390 DDE4.0 3/00 5/04 M57D30O0 730d E38 2926 142/193 430 DDE4.1 3/00 7/01 M57D30O0 X5 3.0d E53 2926 135/184 410 DDE4.0 4/01 9/03 M57D30O1 730d E65 2993 160/218 500 DDE506 9/02 3/05 M57D30O1 330d E46 2993 150/204 410 DDE506 3/03 9/06 M57D30O1 530d E60 2993 160/218 500 DDE508 3/03 4/04 M57D30O1 X3 3.0d E83 2993 150/204 410 DDE506 9/03 9/05 M57D30O1 X5 3.0d E53 2993 160/218 500 DDE506 9/03 9/06 M57D25O1 525d E60 2497 130/177 400 DDE509 4/04 3/07 M57D25O1 525d E61 2497 130/177 400 DDE509 4/04 3/07 M57D30O1 530d E60 2993 160/218 500 DDE509 4/04 9/05 M57D30O1 530d E61 2993 160/218 500 DDE509 4/04 9/05 M57D30T1 535d E90 2993 200/272 560 DDE606 9/04 3/07 M57D30T1 535d E61 2993 200/272 560 DDE606 9/04 3/07
Model
Model series
Cylinder capacity
in cm3Power output
in (kW/bhp)
Torque
in Nm
Engine
management
First used
Last used
4
7
Engine
M57D30O2 730d E65 2993 170/231 520 DDE626 3/05 9/08 M57D30O2 330d E90 2993 170/231 500 DDE626 9/05 9/08 M57D30O2 330d E91 2993 170/231 500 DDE626 9/05 9/08 M57D30O2 530d E61 2993 170/231 500 DDE626 9/05 in production M57D30O2 530d E61 2993 170/231 500 DDE626 9/05 in production M57D30O2 730Ld E66 2993 170/231 520 DDE626 9/05 9/08 M57D30O2 X3 3.0d E53 2993 160/218 500 DDE626 9/05 in production M57D30U2 325d E90 2497 145/197 400 DDE606 9/06 in production M57D30U2 325d E91 2497 145/197 400 DDE606 9/06 in production M57D30O2 330d E92 2993 170/231 500 DDE626 9/06 in production M57D30T2 335d E90 2993 210/286 580 DDE626 9/06 in production M57D30T2 335d E91 2993 210/286 580 DDE626 9/06 in production M57D30T2 335d E92 2993 210/286 580 DDE626 9/06 in production M57D30T2 X3 3.0sd E83 2993 210/286 580 DDE626 9/06 in production M57D30U2 325d E92 2497 145/197 400 DDE606 3/07 in production M57D30U2 525d E60 2497 145/197 400 DDE606 3/07 in production M57D30U2 525d E61 2497 145/197 400 DDE606 3/07 in production M57D30O2 330d E93 2993 170/231 500 DDE626 3/07 in production M57D30O2 X5 3.0d E70 2993 173/235 520 DDE626 3/07 in production M57D30T2 535d E60 2993 210/286 580 DDE626 3/07 in production M57D30T2 535d E61 2993 210/286 580 DDE626 3/07 in production M57D30U2 325d E93 2497 145/197 400 DDE606 9/07 in production M57D30T2 635d E63 2993 210/286 580 DDE626 9/07 in production M57D30T2 635d E64 2993 210/286 580 DDE626 9/07 in production M57D30T2 X5 3.0sd E70 2993 210/286 580 DDE626 9/07 in production M57D30O2 X6
M57D30T2 X6
Model
xDrive30d
xDrive35d
Model series
Cylinder capacity
in cm3Power output
E71 2993 173/235 520 DDE626 5/08 in production
E71 2993 210/286 580 DDE626 5/08 in production
in (kW/bhp)
Torque
in Nm
Engine
management
First used
Last used
5
7
6
8

Introduction.

Advanced Diesel.

A diesel engine for North America

Impressive power and performance as well as exemplary efficiency have contributed to making BMW diesel engines an attractive as well as future-oriented drive technology. This technology is now being made available to drivers in North America.
BMW is introducing this diesel technology to the USA and Canada under the name "BMW Advanced Diesel". The introduction is an integral part of the EfficientDynamics

History

In 1892, Rudolf Diesel applied for a patent for his first self-igniting combustion engine. Initially, this large, slow-running engine was intended for stationary operation only. The intricate engine structure and complicated injection system meant production costs were high. The first simple diesel engines were not particularly comfortable and powerful-revving machines. It was not possible to mistake the distinctive sound of the harsh combustion process in the diesel engine when cold (diesel knock). Compared to thesparkignition engine, it offered a poorer power/weight ratio, acceleration characteristics and lower specific output.
"Miniaturization" could be realized only by improving materials and the manufacturing process during the course of commercial vehicle production. Although the first diesel vehicle was presented as early as 1936, it was not before the 1970s that the diesel engine became accepted as a viable drive source. The breakthrough came in the 1980s when the diesel engine was finally refined enough to be a real alternative to the spark ignition engine. At this time, in view of the improved dynamics and acoustics the decision was
development strategy, which has become a synonym for extremely low CO2 emissions ­not surprising when considering its extremely low fuel consumption. EfficientDynamics is not solely an instrument for reducing fuel consumption but rather it is designed as an intelligent entity with increased dynamics. Not without good reason theM57D30T2 engine is referred to as the world's most agile diesel engine.
made to introduce the diesel engine in series production vehicles at BMW.
1 - Rudolf Diesel and his engine
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8
1983
The M21D24 engine introduced for the first time in the E28 as the 524td featured an exhaust turbocharger and had a displacement of 2.4 litres. It was derived from the M20 6­cylinder petrol engine and developed 85 kW/ 115 bhp. Both engines could therefore be built on the same production facilities.
At that time, the performance with a top speed of 180 km/h and acceleration from 0 to 100 km/h in 13.5 seconds set new standards in the dynamics of diesel motor vehicles. The 524td was therefore given the nickname "Sport diesel".
This was thefirst diesel engine at BMWand, at the same time, the last for a long time in the US market.
2 - BMW 524td with M21 engine
1985
The M21 was also built as a naturally­aspirated diesel engine as from September 1985, making it possible to offer a cost­effective "entry-level engine". This engine made a name for itself in the 324d (E30) as the smoothest running auto-ignition engine on the market.
1987
As the world's first carmaker to do so, BMW introduced the electronic engine management system, the so-called Digital Diesel Electronics (DDE). Faster and more exact than a mechanical control system, the electronics effectively controls:
• Exhaust emission characteristics
• Fuel consumption characteristics
• Noise emission
• Engine running refinement.
8
8
1991
1991 saw the debut of the newly developed M51D25 engine which, with intercooling and an output of 105 kW/143 bhp was the most powerful diesel engine in its class throughout the world. It replaced the M21 engine and was
3 - BMW 525tds with M51 engine
fitted with a crankcase based on a completely new design.
The engine was offered in the output variants 115 bhp and 143 bhp. Exhaust emission and full load smoke were reduced by a V-shaped main combustion chamber in the piston.
1994
The M41 engine was the first4-cylinder diesel engine to beused at BMW. It was derived from the M51D25 engine and shared 56 % of its components. New features included the
hollow-cast camshaft mounted in 5 bearings as well as a cylinder head cover the isolated structure-borne noise.
This engine was fitted in various models of the E36 series.
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8
1998
In 1998 BMW built the most powerful 4­cylinder diesel engine - the M47 with direct fuel injection.
4 - BMW 320d with M47 engine
Motor sport provided the best proof of the efficiency and reliability of the new diesel technology. BMW celebrated a historic success on the Nürburg Ring.
With 100 kW developed from 2 litre displacement, a performance level was achieved which up until then was the reserve only of petrol engines. This corresponds to a specific output of 50 kW or 68 bhp.
With the 320d, a diesel engine won a 24 hour race for the first time in motor sports history in
1998. This victory came not only due to the fact that it needed fewer pit stops for refuelling but also because the BMW drove the fastest lap times.
10
5 - BMW 320d touring car with M47 engine
8
1999
The first V8 diesel engine, the M67D40 engine, with 4 litre displacement was presented in the E38 which developed an output of 175 kW. BMW proved its technical authority with the, at that time, world's most powerful passenger vehicle diesel engine with
6 - BMW 740d with M67 engine
common rail fuel injection and 2 exhaust turbochargers.
The engine is fitted with a crankcase made from high-strength cast iron with vermicular graphite (GGV), an aluminium cylinder head and a two-piece oil sump.
2001
The M47TU with the second generation common rail injection system and DDE5 boosted the power output to 110 kW/150 bhp.
The M57D30 engine is a further development of the M51D25 engine. It has a cast iron casing fitted with a light alloy cylinder head with 4-valve technology. The M57 engine is the world's first 6-cylinder in-line diesel engine in a passenger vehicle that is equipped with
future-oriented common rail injection technology.
This new, highly complex electronically controlled fuel injection system perfectly satisfies the demands for high and constant injection pressure over the entire injection period. The engine offers substantially lower fuel consumption compared to swirl-chamber engines, superior performance and smooth engine operation under extreme conditions.
11
8
7 - BMW 530d with M57 engine
2004
The M57TU TOP engine with 2-stage turbocharging is introduced as the most powerful diesel engine (E60 and E61). One small and one large turbocharger is usedin the 2-stage turbocharging system. The diesel engine in the 535d develops 40 kW/54 bhp more than at the same displacement (3.0 litres) in the 530d.
The power output is 200 kW/272 bhp. The maximum torque of 560 Nm is reached at 2000 rpm. With this extraordinary engine, Luc Alphand won not only the diesel classification of the Paris-Dakar Rally, but also came fourth in the overall rankings.
12
8 - BMW X5 3.0d with M57TU TOP engine
8
2005
The M57TU2 engine is fitted in the E65. In addition to the increase in output and torque, it boasts the following technical features:
• Reduced weight through aluminium crankcase
• 3rd generation common rail system with piezo-injector and a fuel rail pressure of 1600 bar
• Compliance with the exhaust emission regulation EURO 4 and diesel particulate filter as standard
• Optimized electric boost pressure actuator for the turbocharger with variable turbine geometry.
9 - BMW 730d with M57TU2 engine
2005
The M67 engine in the E65 was comprehensively reengineered in the same year. The aim was to achieve a distinct boost in dynamics by increasing power output and reducing weight. In the case of the M67 specifically this aim is reflected in an increase
in power output of 16 % while simultaneously reducing the engine weight by 14 % - and achieved without increasing fuel consumption.
This was mainly achieved through a new, lightweight aluminium crankcase and by increasing the displacement to 4.4 litres.
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8
10 - BMW 745d with M67TU engine
2006
In 2006, the M57TU TOP engine was re­engineered and equipped with the same technical details as the M57TU2, such as an aluminium crankcase and piezo-fuel injectors. This engine was given the designation M57D30T2. It was introduced simultaneously into the 3 Series as the 335d and in the X3 as
the 3.0sd. This re-engineering resulted in further-improved power characteristics, enhanced smooth operation and a significant reduction in fuel consumption. This engine forms the basis for re-introducing diesel technology into the USA after more than 20 years.
14
11 - X3 3.0sd with M57TU2 TOP engine
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Legislation

Since the first exhaust emission legislation for petrol engines came into force in the mid­1960s in California, the permissible limits for a range of pollutants have been further and further reduced. In the meantime, all industrial nations have introduced exhaust emission legislation that defines the emission limits for petrol and diesel engines as well as the test methods.
Essentially, the following exhaust emission legislation applies:
• CARB legislation (California Air Resources Board), California
• EPA legislation (Environmental Protection Agency), USA
• EU legislation (European Union) and corresponding ECE regulations (UN Economic Commission for Europe), Europe
• Japan legislation.
This legislation has lead to the development of different requirements with regard to the
limitation of various components in the exhaust gas. Essentially, the following exhaust gas constituents are evaluated:
• Carbon monoxide (CO)
• Nitrogen oxides (NOx)
• Hydrocarbons (HC)
• Particulates (PM)
It can generally be said that traditionally more emphasis is placed on low nitrogen oxide emissions in US legislation while in Europe the focus tends to be more on carbon monoxide.
The following graphic compares the standard applicable to BMW diesel vehicles with the current standards in Europe. A direct comparison, however, is not possible as
• different measuring cycles are used and
• different values are measured for hydrocarbons.
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8
12 - Comparison of exhaust
emission legislation
Standard Valid from CO
[mg/km]
EURO 4 01.01.2005 500 250 300 - 25 EURO 5 01.09.2009 500 180 230 - 5 EURO 6 01.09.2014 500 80 170 - 5 LEV II MY 2005 2110 31 - 47 6 * In Europe, the sum of nitrogen oxide and hydrocarbons is evaluated, i.e. the higher the HC
emissions, the lower the NOx must be and vice versa.
** In the USA, only the methane-free hydrocarbons are evaluated, i.e. all hydrocarbons with no methane
Although the European and US standards cannot be compared 1:1 it is clear that requirements relating to nitrogen oxide emissions are considerably more demanding.
Diesel engines generally have higher nitrogen oxide emission levels than petrol engines as
NO
[mg/km]
HC + NOx*
x
diesel engines are normally operated with an air surplus.
For this reason, the challenge of achieving approval in all 50 states of the USA had to be met with a series of new technological developments.
[mg/km]
NMHC**
[mg/km]PM[mg/km]
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Overview of innovations, modifications and special features

The following table provides an overview of the special features of the M57D30T2 US engine. They are divided into various categories.
• New development signifies a technology that has not previously been used on BMW engines.
• Modification signifies a component that was specifically designed for the
M57D30T2 US engine but does not represent a technical innovation.
• Adopted describes a component that has already been used in other BMW engines.
This Product Information describes only the main modifications to the M57D30T2 engine compared to the Europe version as well as fundamental vehicle systemsspecificto diesel engines.
Component
Engine mechanical system 7 Very few modifications have been made to
Air intake and exhaust system
Cooling system 7 In principle, the cooling system corresponds
Fuel preparation system 7 The functional principle of the fuel
New development
Modification
7 The most extensive changes were made to
Remarks
Adopted
the basic engine. The modifications that have been made focus mainly on ensuring smooth engine operation.
A significant feature, however, is the OBD monitoring of the crankcase breather.
the air intake and exhaust system. For instance, low pressure exhaust gas recirculation (low pressure EGR) is used for the first time at BMW on the E70.
In addition to other minor adaptations, there are substantial differences in the sensor and actuator systems.
to that of the Europe versions, however, it has been adapted to hot climate requirements.
preparation system does not differ from that of the Europe version, however, individual components have been adapted to the different fuel specification.
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Component
Fuel supply system 7 The fuel supply system is vehicle-specific
SCR system (Selective Catalytic Reduction)
Engine electrical system 7 The engine is equipped with the new DDE7
Automatic transmission 7 The automatic transmission corresponds to
New development
Modification
7 The SCR system is used for the first time at
Remarks
Adopted
and corresponds to the Europe version. There are, however, significantdifferencesto petrol engine vehicles.
BMW. Nitrogen oxide emissions are drastically reduced by the use of a reducing agent that isinjected into the exhaustsystem upstream of a special SCR catalytic converter. Since the reducing agent is carried in the vehicle, a supply facility, made up of two reservoirs, is part of this system.
(digital diesel electronics)control unit that will be used in thenext generation diesel engines (N47, N57).
The preheater system also corresponds to the N47/N57 engines.
that in the ECE variant of the X5 xDrive35d. The gearbox itself has already been used in the US version of the X5 4.8i, however, a different torque converter is used for the diesel model.
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Technical data

The following table compares the M57D30T2 US engine with petrol engines that are offered for the same models.
Designation N52B30O1 N54B30O0 N62B48O1 M57D30T2
Type Straight 6 Straight 6 V8 Straight 6 Displacement [cm3] 2996 2979 4799 2993 Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-4-8-6-3-7-2 1-5-3-6-2-4 Stroke/bore [mm] 88.0/85 88.9/84 88.3/93 90.0/84 Output
at engine speed Torque
at engine speed Governed engine
speed limit Power output per
litre Compression ratio ε 10.7 10.2 10.5 16.5 Cylinder spacing [mm] 91 91 98 91 Valves/cylinder 4 4 4 4 Intake valve [mm] 34.2 31.4 35.0 27.4 Exhaust valve [mm] 29.0 28.0 29.0 25.9 Main bearing
journal on crankshaft
Big-end bearing journal on crankshaft
Fuel specification [RON] 98 98 98 Fuel [RON] 91-98 91-98 91-98 Diesel Engine
management Exhaust emission
standard US * SAE-hp
[kW/hp*]
[rpm]
[Nm/lbft]
[rpm]
[rpm] 7000 7000 6500 4800
[hp/l] 86.7 100 72.9 89.3
[mm] 56 56 70 60
[mm] 50 50 54 45
193/260
6600
305/225
2500
MSV80 MSD80 ME9.2.3 DDE7.3
ULEVII ULEVII
225/300
5800
407/300
1400
261/350
6250
475/350
3500
ULEVII
200/265
4200
580/428
1750
LEVII
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8

Full load diagrams

To get an idea of the performance of the M57D30T2 US engine, it is compared to
various petrol engines in the following full load diagrams.
By comparing these two 3 litre engines it can be clearly seen that, despite virtually identical
13 - M57D30T2 US engine
compared to N52B30O1 engine
power output, the maximum torque of the diesel is almost double as high.
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8
This enormous difference in maximum torque is also apparent when comparing the
14 - M57D30T2 US engine
compared to N54B30O0 engine
turbocharged 3 litre petrol engine that has a considerably higher nominal power output.
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8
Even the 4.8 litre V8 engine cannot achieve the maximum torque of the 3 litre diesel engine.
However, the decisive factor is the low engine speeds at which the diesel engine develops
15 - M57D30T2 US engine
compared to N62B48O1 engine
this high torque. This means that more power is available in this range. In terms of power output, the diesel engine is superior to any of these petrol engines up to an engine speed of 4000 rpm.
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9

System components.

Advanced Diesel.

Engine mechanical system

Only slight modifications have been made to the engine mechanical system compared to the Europe version.

Crankshaft and big-end bearings

Only lead-free crankcase and big-end bearings are used in the M57D30T2 US engine. This conforms to requirements

Crankcase

In contrast to the Europe version, the M57D30T2 US engine has a larger reinforcement panel on the underside of the crankcase.
The reinforcement panel now covers four of the main bearing blocks for the crankshaft.

Pistons

The piston pin has a greater offset than in the Europe version. The offset of the piston pin means that the piston pin is slightly off centre. This provides acoustic advantages during
The modifications include:
• Crankcase
• Crankshaft and big-end bearings
• Pistons
• Crankcase breather.
relating to environmental protection and the disposal of end-of-life vehicles.
In principle, the reinforcement panel serves to enhance the stability of the crankcase. However, the enlargement was realized solely for acoustic reasons.
3 Never drive the vehicle without the
reinforcement panel. 1
changes in piston contact. The acoustic advantages of increasing the offset are further developed particularly at idle speed.
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Crankcase breather

The crankcase breather in the US version is generally heated. In addition, operation of the crankcase breather is OBD monitored (On Board Diagnosis). This is because a leaking system would produce emissions.
The only probable reason for a leak in the system would be that the blow-by pipe is not connected to the cylinder head cover. To facilitate protection of this situation by the OBD, the heating line isrouted via a connector to the cylinder head cover (2). Essentially, this connector serves only as a bridge so that actuation of the heating system is looped through. The plug connection is designed in such a way that correct contact is made only when the blow-by pipe has been connected correctly to the cylinder head cover, i.e. the contact for the heating system is not closed if the blow-by pipe is not connected to the cylinder head cover. OBD recognizes this situation as a fault.
1 - Blow-by pipe
Index Explanation
1 Cylinder head cover 2 Blow-by heater connector for OBD
monitoring
3 Blow-by heater connector at wiring
harness 4 Filtered air pipe 5 Intake air from intake silencer 6 Blow-by heater connector at blow-
by pipe 7 Intake air to exhaust turbocharger 8 Blow-by pipe
3 If the blow-by pipe is not connected to the
cylinder head correctly, the OBD will activate the MIL (Malfunction Indicator Lamp). 1
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