Product Information. N57 Engine. - Quality Service...

Product Information.N57 Engine.

Rear-mounted chain drive system

Vacuum pump in sump

Complies with EURO 5 and EURO 6

Notes on this Product Information

Symbols used

The following symbols are used in this Product Information to improveunderstanding and to highlight important information:

3 contains important safety guidance and information that is necessaryfor proper system functioning and which it is imperative to follow.

1 identifies the end of a note.

Information status and national variants

BMW vehicles satisfy the highest requirements of safety and quality.Changes in terms of environmental protection, customer benefits anddesign render necessary continuous development of systems andcomponents. Consequently, there may be differences between thedetails provided in this Product Information and the vehicles availableduring the training course.

This document essentially refers to left-hand-drive vehicles.On right-hand-drive vehicles, some controls and components arearranged differently from what is shown in the illustrations in this ProductInformation. There may also be other differences due to variations inequipment between individual countries or markets.

Additional sources of information

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

- the Owner's Handbook

- the Integrated Service Technical Application.

Contents.N57 Engine.

Objectives 1

Product Information and reference work forpractical purposes 1

Models 3

Engine variants 3

Introduction 11

System overview 21

Engine identification 21

System components 23

Engine mechanical system 23Oil system 61Air intake and exhaust system 74Fuel system 101Fuel conditioning system 110Cooling system 121Engine electrical system 131

Service information 175

System components 175

Summary 179

Points to remember 179

Test questions 183

Questions 183Answers to questions 188

2

Objectives.N57 Engine.

Product Information and reference work for practicalpurposes

General informationThis Product Information is intended toprovide you with information on the designand function of the N57 engine.

This Product Information is designed as aworking reference and complements thespecified content of the technical trainingcourse. The Product Information is alsosuitable for private study.

As preparation for the technical trainingcourse, this Product Information provides an

insight into the new N57 6-cylinder dieselengine. In conjunction with practical exercisescarried out in the training course, the ProductInformation will enable course participants tocarry out servicing work on the N57 engine.

Previous technical and practical knowledge ofthe current range of BMW diesel engines willmake it easier for you to understand thesystems described here and their functions.

Existing SIPs• Diesel Engine Basics.

Please remember to work throughthe SIP (Service InformationProgramme) on Diesel EngineBasics.The basic knowledge it provides willfacilitate understanding of thisProduct Information.

1

3

Models.N57 Engine.

Engine variants

Models with N57 engine as at autumn 2008.

HistoryFigures marked *, *1, etc. relate to the similarlymarked model series.

6-cylinder diesel engine

The list of models shows in whichvehicles which engine variants arecurrently used and have been usedin the past.

Mo

de

l

Se

rie

s

En

gin

e

En

gin

e c

apac

ity

in c

m3

Str

ok

e/b

ore

in m

m

Po

we

r o

utp

ut

in k

W/b

hp

at

rpm

To

rqu

e in

Nm

at

rpm

330d E90 N57D30O0 2,993 90/84 180/2454,000

5201,750 - 3,000

330d E91 N57D30O0 2,993 90/84 180/2454,000

5201,750 - 3,000

330d E92 N57D30O0 2,993 90/84 180/2454,000

5201,750 - 3,000

730d F01 N57D30O0 2,993 90/84 180/2454,000

5402,000 - 2,750

Engine M21D24S

Series E28* E30

Models 324d 524d

Power output in kW/bhpat rpm

60/82 63/86*4,600

Torque in Nm at rpm 1522,500

Number of cylindersand configuration

In-line6

Engine capacity incm3

2,443

Stroke/bore in mm 81/80

Compression ratio 22 : 023 : 0*

Valves/cylinder 2

Period used 9/85 - 12/9009/86 - 12/87*

Engine management MechanicalDDE2

3

3

Engine M21D24T

Series E28 E30* E34

Models 324td 524td


85/1154,800

Torque in Nm at rpm 2102,400222*

1,750*


In-line6


2,443


Compression ratio 24 : 1*25 : 1

Valves/cylinder 2

Period used 9/83 - 9/91

Engine management MechanicalDDE1

Engine M51D25UL

Series E34 E36

Models 325td 525td


85/1154,800



In-line6


2,497

Stroke/bore in mm 82.8/80

Compression ratio 22 : 1

Valves/cylinder 2


Engine management DDE2DDE2.1

4

3

Engine M51D25OL

Series E34 E36

Models 325tds 525tds


105/1434,800



In-line6


2,497



Valves/cylinder 2


Engine management DDE2DDE2.1

Engine M51D25UL TU

Series E36* E39

Models 325td 525td


85/1154,800

Torque in Nm at rpm 222*/2301,900


In-line6


2,497



Valves/cylinder 2


Engine management DDE2.1DDE2.2

5

3

Engine M51D25OL TU

Series E36 E38 E39

Models 325tds 525tds*725tds*


105/1434,800/4,600*

Torque in Nm at rpm 260/280*2,200


In-line6


2,497



Valves/cylinder 2


Engine management DDE2.1DDE2.2

Engine M57D25O0

Series E39

Models 525d


120/1634,000

Torque in Nm at rpm 3502,000-3,000


In-line6


2,497


Compression ratio 17.5 : 1

Valves/cylinder 4


Engine management DDE4.0

6

3

Engine M57D30O0

Series E38 E39 E46/3E46/4 E53

Models 330d 530d730d*1*2

X5 3.0d*1


135/1844,000

Torque in Nm at rpm 390/1,750-3,200410/2,000-3,000*1

430/2,000-2,500*2


In-line6


2,926



Valves/cylinder 4


Engine management DDE4.0DDE4.1*1*2

Engine M57D25O1

Series E60 E61

Models 525d


130/1774,000



In-line6


2,497



Valves/cylinder 4

Period used 4/04-3/07

Engine management DDE5.0

7

3

Engine M57D30O1

Series E46/2 E46/3 E46/4E53 E60 E61 E65

E83

Models 330d 530d*1 730dX3 3.0d*X5 3.0d*


150/204160/218* *1

4,000

Torque in Nm at rpm 410/1,500-3,250500/2,000-2,750*

*1


In-line6


2,993



Valves/cylinder 4


Engine management DDE506DDE508*1

DDE509* *1

Engine M57D30U2

Series E60 E61 E90 E91E92 E93

Models 325d 525d


145/1974,000



In-line6


2,993



Valves/cylinder 4

Period used 9/06 to date

Engine management DDE606

8

3

Engine M57D30O2

Series E60 E61 E65 E66E70 E83 E90 E91

E92 E93

Models 330d 530d 630d730d*2 730Ld*2

X3 3.0d*X3 xDrive30d*

X5 3.0d*1

X5 xDrive30d*1


160/218*170/231*2

173/235*1

4,000

Torque in Nm at rpm 500/1,750-3,000*520/2,000-2,750*1.2


In-line6


2,993



Valves/cylinder 4



Engine M57D30T1

Series E60 E61

Models 535d


200/2724,400



In-line6


2993


Compression ratio 16.5 : 1

Valves/cylinder 4



9

3

Engine M57D30T2

Series E60 E61 E63 E64E83 E70 E90 E91

E92

Models 335d 535d 635dX3 3.0sd

X3 xDrive35dX5 3.0sd

X5 xDrive35d


210/2864,400



In-line6


2,993



Valves/cylinder 4



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4

Introduction.N57 Engine.

Highlights

The N57 is a logical development from theN47 engine. For instance, the N47 alreadyfeatured rear-mounted chain drive systemdesigned to satisfy future pedestrian impactseverity reduction requirements and a vacuumpump relocated inside the sump.

Another modification was the repositioning ofthe auxiliary units on the left-hand side of theengine. By having the auxiliary units all on oneside, space is created on the right-hand side ofthe engine for locating exhaust treatmentcomponents close to the engine. There is alsosufficient space for the Top modelturbocharger assembly (N47 Top engine).

It has also been possible to reduce the heightof the cylinder head by 29 mm compared withthe predecessor model. The inlet ports nowrun parallel and the intake system with integralswirl flaps is an ultra-compact design.

Below the sound insulation cover on the F01,sufficient space is allowed at the rear for an airintake muffler and the engine-mountedunfiltered and filtered air ducting. Theindividual power options vary in this regardonly in terms of the size of the filter element.

In order to minimize the complexity ofapplication adaptations, instead of the engine-mounted air intake muffler, the E9x models

use the unfiltered air ducting and the vehicle-mounted air intake muffler from theM57D30T2 engine.

The 3rd-generation common-rail system withan injection pressure of up to 1,800 bar, a newCP4.2 high-pressure pump and piezo-electricfuel injectors complete the fuel-systemmodifications.

As on the N47 engine, the exhaust system hasan electric EGR valve flange-mounted on the"hot" side and a bypass in the EGR cooler sothat the EURO 5 emission limits can bereliably complied with. Thus on volumeproduction launch, the N57 engine will alreadymeet the EURO 5 emission requirements notdue to come into force until 01/01/2011.

For compliance with the EURO 6 emissionlimits, additional use of an active exhausttreatment system will be necessary.Depending on flywheel weight class (vehicleweight) and resistance to motion, either anNOx-accumulator catalytic converter or anSCR (selective catalytic reduction) systemsupplemented by low-pressure exhaustrecirculation will be used. Those two systemsare explained in the "M57D30T2 US Engine"documentation and, therefore, are notdescribed in further detail at this point.

Objectives• Increased power and torque

• Ability to derive performance versions

• Reduction of CO2 emissions

• Compliance with EURO 5 and upgradabilityto EURO 6 and LEVII/Bin5 (USA)

• Reduction of weight and dimensions with aview to compliance with futurerequirements regarding exhaust treatmentand pedestrian impact severity reduction

• Modular design and use of identicalcomponents from the N47 models.

Following on from the 4-cylinderdiesel engine, a new 6-cylinderdiesel engine has now also beenintroduced. After 10 years and twomajor upgrades, the 6-cylinderdiesel engine is now being replacedby an entirely new design, the N57.The N57 engine has manycomponents that have already beenused in volume production on theN47 engine.With even more power and torquecombined with lower fuelconsumption and lighter weight, it isideally equipped to continue thesuccess story.

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Technical data

Designation

Model

M57D30O2

330d

M57D30O2

730d 730Ld

M57D30O2

X5 xDrive30d

Configuration 6 inline 6 inline 6 inline

Displacement [cm3] 2,993 2,993 2,993

Stroke/bore [mm] 90/84 90/84 90/84

Power output [kW/bhp]at [rpm]

170/2314,000

170/2314,000

173/2354,000

Torque [Nm]at [rpm]

5001,750-3,000

5202,000-2,750

5202,000-2,750

Engine speed limit [rpm] 4,600 4,600 4,600

Power output per litre[kW/l] 56.8 56.8 57.8

Compression ratio ε 17.0 : 1 17.0 : 1 17.0 : 1

Cylinder spacing [mm] 91 91 91

Valves/cylinder 4 4 4

Inlet-valve dia. [mm] 25.9 25.9 25.9

Exhaust-valve dia. [mm] 25.9 25.9 25.9

Crankshaft main bearingjournal dia. [mm] 60 60 60

Crankshaft big-endbearing dia. [mm] 45 45 45

Engine management DDE626 DDE626 DDE626

Emissions standard EURO 4 EURO 4 EURO 4

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Designation

Model

N57D30O0

330d

N57D30O0

730d

N57D30O0

330d

Configuration 6 inline 6 inline 6 inline

Displacement [cm3] 2,993 2,993 2,993

Stroke/bore [mm] 90/84 90/84 90/84

Power output [kW/bhp]at [rpm]

180/2454,000

180/2454,000

180/2454,000

Torque [Nm]at [rpm]

5201,750 - 3,000

5401,750 - 3,000

5201,750 - 3,000

Engine speed limit [rpm] 5,000 5,000 5,000

Power output per litre[kW/l] 60.1 60.1 60.1

Compression ratio ε 16.5 : 1 16.5 : 1 16.5 : 1

Cylinder spacing [mm] 91 91 91

Valves/cylinder 4 4 4

Inlet-valve dia. [mm] 27.2 27.2 27.2

Exhaust-valve dia. [mm] 24.6 24.6 24.6

Crankshaft main bearingjournal dia. [mm] 55 55 55

Crankshaft big-endbearing dia. [mm] 50 50 50

Engine management DDE7.3 DDE7.3 DDE7.3

Emissions standard EURO 5 EURO 5 EURO 6

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Performance graphCompared with its predecessor, the N57engine is distinguished by an increase in

overall performance and a more musculartorque curve.

330d

1 - Performance graph for330d E90 withN57D30O0 enginecompared with 330d E90with M57D30O2 engine

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4

730d

2 - Performance graph for730d F01 withN57D30O0 enginecompared with 730d E65with M57D30O2 engine

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Summary of design features

Variant structure

The basic concept means that the enginecasing components can be developed andproduced according to the same standardsboth for the 4-cylinder and the 6-cylinderdiesel engines.

Differentiation is achieved by way ofturbocharging, fuel injection and exhausttreatment systems.

Thus the N47 engines and the N57 engineshare the following features:

• Standardized combustion chamber

• Same cylinder spacing

• Same engine height

• Same attachment arrangements (e.g.gearbox)

• Standardized auxiliary units.

The table below summarizes the changesimplemented on the N57 engine. Distinctionsare made in various categories.

• "New development" denotes a technologythat was not used on the predecessorengine.

• "Identical component" denotes acomponent that was designed for the N47engine and is also used on the N57 engine.

• "Identical concept" denotes a componentthat is based on the same design concepton the N47 and the N57 engines but whichhas been adapted for the N57 engine.

Component Ne

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nt

Ide

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N4

7 e

ng

ine

and

N5

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ine

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cep

t o

nN

47

en

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e a

nd

N5

7 e

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ine

Remarks

Pistons and connectingrods

7 7 Optimized for new generation of dieselengines

Main and big-end bearings 7 7 Dimensioned for the various performanceratings (e.g. N47TOP)

Valvegear components 7 7 Use of reduced-friction and weight-optimized components

Fuel pump 7 7 The fuel pump is a regulated-pressuredesign

Fuel filter heater 7 7 The fuel filter heater is controlled by thedigital diesel engine management

Fuel injectors and high-pressure fuel lines

7 7 New generation of fuel injectors adapted forthe high injection pressures. The higher-performance and the "Top" line models havepiezo-electric injectors.

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4

Glow plugs 7 7 Use of ceramic glowplugs with temperaturesup to 1,300 °C.

Chain sprockets and guides 7 7 The crankshaft has integral sprockets fordriving the timing chain and the oil pump.The guides are identical on the N47 and N57engines.

Auxiliary unit mountingbracket

7 7 All auxiliary units are positioned on the intakeside of the engine. The auxiliary unitmounting bracket is identical on all E9xmodels. On the F01 a new mounting bracketwith sliding bushes is used.

Auxiliary units 7 7 The auxiliary units are adapted to the vehicleconcerned.

Drive belts, belt tensionerand guide pulleys

7 7 Different belt tensioners are used accordingto vehicle model. A two-sided belt is used.

Throttle body and exhaustrecirculation valve (EGRvalve)

7 7 New-design components are used for bothengine casing assemblies (N47 and N57engines). On the N47 engine, a bypass valveis fitted in some cases dependent ongearbox version and performance rating. TheN57 engine always has a bypass valve.

Sensor system 7 7 The same, new-design sensor system isused both on the N47 engine and the N57engine.

Crankcase 7 7 The crankcase is an entirely new design andemploys an identical concept for bothengines. Rigidity has been increased so as tobe able to meet future requirements as well.A reinforcing plate further increasesstrength. The aluminium crankcase hasthermally joined cast iron cylinder liners. Thecrankshaft main bearing caps are providedwith a raised profile on the joint face.

Crankshaft drive system 7 7 The crankshaft drive system has beenadapted to the higher engine power output.At the same time, however, great emphasiswas placed on lightweight design.

Component Ne

w d

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Ide

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N4

7 e

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ine

and

N5

7 e

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ine

Ide

nti

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cep

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47

en

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N5

7 e

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ine

Remarks

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Cylinder head 7 7 For the first time, the cylinder head is a two-piece design.

Valvegear 7 7 For the first time, the valves are parallel withthe cylinder axes.

Chain drive system 7 7 The chain drive system on the N47 enginehas been moved to the flywheel-end to makespace for pedestrian impact severityreduction.

Combined oil and vacuumpump

7 7 By combining the oil and vacuum pumps, ithas been possible to reduce the componentheight in the pedestrian impact severityreduction zone.

Camshafts 7 7 The composite camshafts run on bearingsmounted in a separate carrier plate and aremanufactured using the Presta process.

Rotational vibration damper 7 7 The rotational vibration damper is adapted tothe particular requirements of the engine.

Cylinder head cover 7 7 The cylinder head cover incorporates thepressure-controlled crankcase ventingsystem and spring-plate separator.

Intake manifold 7 7 The intake system is an ultra-compactdesign and incorporates the electricallyoperated and monitored swirl flaps.

Oil module 7 7 The oil module is made of plastic andincorporates the oil/coolant heat exchanger.The number of plates in the oil/coolant heatexchanger is dependent on the requiredcooling capacity.

High-pressure pump 7 7 The model used is the CP4.1 or 4.2. TheCP4.1 is a single-piston HP pump, the CP4.2a twin-piston HP pump. The high-pressurepumps can generate injection pressures upto 2,000 bar.

High-pressure accumulator 7 7 The high-pressure accumulator is designedfor the high fuel pressures.

Control unit 7 7 The latest-generation engine managementis used.

Component Ne

w d

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N4

7 e

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and

N5

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cep

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47

en

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N5

7 e

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Remarks

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Wiring loom 7 7 The wiring loom is optimized and identical forthe different transmission variants. Thus asupplementary wiring loom is usedaccording to transmission variant.

Exhaust manifold 7 7 The exhaust manifold has been given anextra connection for a temperature sensorand is an air-gap insulated pressed-steeldesign.

Turbocharger 7 7 The VNT turbocharger is operated by anelectrically actuated charge-pressureadjuster. A Step3 turbocharger is used.

Oxidation catalyticconverter and diesel particlefilter

7 7 The oxidation catalytic converter and thediesel particulate filter are located in a sharedhousing close to the engine. Thesecomponents vary according to engine modelbut are identical across vehicle models.

Oil level indication 7 The oil level is measured by an oil conditionsensor.

Component Ne

w d

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me

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Ide

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N4

7 e

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N5

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47

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N5

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Remarks

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System overview.N57 Engine.

Engine identification

Engine designationIn the technical documentation, the enginedesignation is used for unique identification ofthe engine.

The following version of the N57 engine isdescribed:

• N57D30O0.

In the technical documentation you will alsofind the abbreviated engine designation, i.e.N57, that only indicates the engine type.

This means:

Engine identification code and serial numberThe engines are marked on the crankcasewith an engine identification code for uniqueidentification. This engine identifier is alsorequired for approval by the authorities. Thedefinitive part of the code is the first sevencharacters.

With the N47 engine, the engine identifier has,for diesel engines too, been changed so as tocomply with the new standard whereby thefirst six positions are the same as the engine

designation. That new standard also applies tothe N57 engine.

The engine serial number is a consecutivenumber that permits unique identification ofevery single engine.

The engine identification code and serialnumber are marked on the crankcase on thebracket for the high-pressure fuel pump.

For the purposes of uniqueidentification there is an engineidentification code marked on thecrankcase. In the documentationand descriptions of the engine, theengine designation is used, whichdiffers from the identification codeby its last 2 characters.

Index Explanation

N BMW Group "New Generation"

5 6-cylinder engine

7 Direct diesel injection

D Diesel engine

30 3.0-litre capacity

O Upper power output stage

0 New development

1 - Engine identification code and serial number on the N57 engine

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System components.N57 Engine.

Engine mechanical system

OverviewThe engine mechanicals can be subdividedinto three major systems:

• Engine casing components

Functions of the engine casingcomponents:

– Containing the forces generated byoperation of the engine

– Sealing functions for the combustionchamber, engine oil and coolant

– Holding the crankshaft drive system,valvegear and other components.

By reducing the height and length, spacehas been created under the bonnet for thepurposes of pedestrian impact severityreduction.

• Crankshaft drive system

The crankshaft drive system, also known asthe power unit, is a function group thatconverts the combustion chamberpressure into kinetic energy. In the process,the crankshaft converts the linear motion ofthe pistons into a rotary motion. Thecrankshaft drive system represents theoptimum in terms of work utilization,efficiency and technical practicability for thetask in question.

Nevertheless, the following technicallimitations and design challenges have tobe dealt with:

– Engine speed limitation due to inertialforces

– Uneven power delivery over the courseof an operating cycle

– Generation of torsional vibrations thatplace stresses on the crankshaft anddrive train

– Interaction of the various frictionalsurfaces.

• Valvegear

The valvegear is made up of the followingcomponents:

– Camshafts

– Transmitting elements (roller camfollowers)

– Valves (complete valve assemblies)

– Hydraulic valve clearance adjustment(HVA).

Like all current BMW diesel engines, theN57 engine has a DOHC valvegear layout.

This stands for "double overheadcamshaft" and means that the engine hasoverhead valves with two camshaftslocated above the cylinders. One camshaftis used for the intake valves, the other forthe exhaust valves.

On the N57 engine, as on all current BMWdiesel engines, the action of the cams istransferred from the camshaft to the valvesby roller lever tappets.

In order that the correct amount of play ismaintained between camshaft cam and thecam follower (roller lever tappet), the N57 isequipped with hydraulic valve clearanceadjusters (HVA).

Those three systems are in a state of constantinteraction with one another. That interactionhas a very significant effect on enginecharacteristics.

Firing order:1-5-3-6-2-4

The engine mechanical systems canessentially be divided into the threesubassemblies, engine casingcomponents, crankshaft drivesystem and valvegear. Those threesubassemblies are closelyinterlinked and have to be matchedto one another.

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Engine casing components

1 - N57 engine casingcomponents

Index Explanation Index Explanation

1 Cylinder head cover 6 Sprocket cover gasket

2 Camshaft carrier plate 7 Sprocket cover

3 Cylinder head 8 Sump gasket

4 Cylinder head gasket 9 Sump

5 Crankcase

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Crankshaft drive system

2 - Crankshaft drive system, N57 engine

Index Explanation Index Explanation

1 Connecting rod 3 Crankshaft

2 Piston

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