oil pressure BMW 545i 2002 E60 N62B44 Engine Workshop Manual
[x] Cancel search | Manufacturer: BMW, Model Year: 2002, Model line: 545i, Model: BMW 545i 2002 E60Pages: 55, PDF Size: 1.05 MB
Page 2 of 55
Downloaded from www.Manualslib.com manuals search engine SubjectPage
Components
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
- Coolant Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
- Map-Controlled Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
- Cooling Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
- Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Expansion Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
- Transmission Oil/Water Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . .44
- Electrically-Operated Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Viscous Coupling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Engine block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
- Connecting Rods and Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
- Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Vibration Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
- Oil Jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
- Oil Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
- Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
- Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
- Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
- Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Review Questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Page 3 of 55
Downloaded from www.Manualslib.com manuals search engine 1
N62 Engine
N62 ENGINE
Model: E65 - 745i / E66 - 745Li
Engine: N62B44
Production Date: 11/2001 - E65, 01/2002 - E66
Objectives of The Module
After Completing this module, you will be able to:
• Describe the two stage oil supply.
• Distinguish the difference between the left and right drive chain tensioning assem-
blies.
• Explain the Bi-VANOS operation.
• Understand the function of the Variable intake manifold.
• Explain the cooling circuit flow.
• List what chamber A and chamber B is used for in the Bi-VANOS system.
• Identify the Secondary air components.
• Explain how the initial VANOS position is retained when oil pressure is not present.
• List the proper drive belt removal procedure.
• Describe the throttle valve functions.
• Identify the N62B44 designation.
Page 14 of 55
Downloaded from www.Manualslib.com manuals search engine Crankcase Venting System
The crankcase vapors (a result of combustion blow-by gasses) are led out of the crank-
case and back into the combustion chamber via the intake manifold. The blow-by gasses
contain droplets of oil which must be separated. The oil is returned to the sump while the
blow-by gasses are led into the intake pipe for combustion.
The engine performance is affected by the introduction of crankcase vapors into the com-
bustion process, particularly in idle speed ranges. This influence is monitored by lambda
regulation.
The crankcase vapors are carried from the crankcase and into the cylinder head covers
through labyrinth separators (one per cylinder head). The oil which accumulates on the
walls of the labyrinth separators flows into the cylinder head via a siphon and from there
back to the sump.
The remaining vapors are passed to the engine for combustion via the pressure control
valve (5) in the intake manifold. One labyrinth separator with a pressure control valve is inte-
grated in each of the two cylinder head covers.
The throttle valve is controlled so that there is always a 50 mbar vacuum in the intake man-
ifold. The pressure control valve regulates the crankcase pressure to a low 0-30 mbar.
12
N62 Engine
43-02-12 Cylinder Head Cover
1-4. Opening for Spark Plugs
5. Pressure Control Valve
6. Opening Valvetronic Motor
7. Opening Valvetronic Sensor
Connector
8. Camshaft Sensor
Page 22 of 55
Downloaded from www.Manualslib.com manuals search engine Cylinder Heads
The two N62 cylinder heads are a new development from BMW. They are fitted with the
Valvetronic system. The secondary air ducts for subsequent exhaust gas treatment are
integrated in the cylinder heads. The cylinder heads are cooled by the “cross-flow” princi-
ple.
The inlet camshaft and the Valvetronic eccentric shaft are jointly guided by a bridge sup-
port. The cylinder heads are made from aluminum and are manufactured using gravity die-
casting. The upper timing chain housing is now an integral part of the cylinder head.
20
N62 Engine
Cylinder Head
1. Cylinder Head for Cylinder Bank 1-4 7. Mounting VANOS Intake Solenoid
2. Cylinder Head for Cylinder Bank 5-8 8. Mounting VANOS Outlet Solenoid
3. Upper Timing Chain Guide with Oil Jet 9. Oil Pressure Switch
4. Mounting for VANOS Intake Solenoid 10. Chain Tensioner Mount
5. Mounting for VANOS Outlet Solenoid 11. Upper Timing Chain Guide with Oil Jet
6. Chain Tensioner Mount43-02-20
Page 23 of 55
Downloaded from www.Manualslib.com manuals search engine Engine Covers
Each cylinder head has a plastic cover for the ignition coil cabling and top of the cylinder
head. The covers “push fit” into rubber grommets on the cylinder head covers.
A sound absorption cover for the top of the
engine also covers the two Valvetronic motors.
This cover is fixed to the intake manifold hous-
ing using four bolts.
The cylinder head covers are made from plastic. The retaining sleeves for the ignition coils
have molded-on gaskets. The sleeves must be replaced if any hardening or damage is vis-
ible on the gaskets. The sleeves are inserted into the cylinder head through the cylinder
head cover (nos. 1through 4).
N No
ot
te
es
s:
:
21
N62 Engine
42-02-21
Engine Covers
Cylinder Head Cover
1. Cylinder Head Top Cover
2. Sound Absorption Engine Cover
1-4. Opening for Spark Plugs
5. Pressure Control Valve
6. Opening for Valvetronic Motor
7. Opening for Valvetronic Sensor Connector
8. Camshaft Sensors (Intake and Exhaust)
43-02-12
Page 33 of 55
Downloaded from www.Manualslib.com manuals search engine 31
N62 Engine
VANOS Sectional Views
M Me
ec
ch
ha
an
ni
ic
ca
al
l
L
La
ay
yo
ou
ut
t:
:
The figures above show a sectional view of one VANOS unit. The VANOS unit is secured
by a central bolt through the hub (7) to the camshaft. The timing chain connects the crank-
shaft with the housing of the unit.
There is a recess in the hub in which the locking pin (6) engages without oil pressure
(sprung). When the solenoid valve is activated to supply oil pressure to the VANOS unit,
the locking pin is compressed and releases the VANOS for adjustment.
The internal blades (9) are spring loaded (10) to provide a seal between the oil pressure
chambers (11 and 12). The torsion spring (3) acts against the camshaft torque.
42-02-4942-02-45
VANO’S Components
1. Housing with Sprocket 7. Hub
2. Front Plate 8. Black Plate
3. Torsion Plate 9. Blade
4. Lock Spring 10. Spring
5. Retaining Plate for Lock Spring 11. Pressure Chamber A
6. Spring Loaded Locking Pin 12. Pressure Chamber B
Page 34 of 55
Downloaded from www.Manualslib.com manuals search engine 32
N62 Engine
H Hy
yd
dr
ra
au
ul
li
ic
c
A
Ac
ct
tu
ua
at
ti
io
on
n:
:
When oil pressure is applied to chamber A, the blades are forced away from the VANOS
housing (counterclockwise). The blades are keyed into the hub which results in the hub
position being rotated in relation to the housing (with sprocket). The hub is secured to the
camshaft which changes the camshaft to sprocket relationship (timing).
The example below shows the a ad
dj
ju
us
st
tm
me
en
nt
t
procedure together with the pressure progres-
sion based on the VANOS unit for the exhaust camshafts.
During this adjustment chamber B is open (through the solenoid) to allow the oil to drain
back through the cylinder head (internal reservoir).
Hydraulic Actuation - Chamber A
1. Front View of Vanos Unit 5. Engine Oil Pump
2. Side View of Vanos Unit 6. Supplied Oil from Pump (Switched Through Solenoid)
3. Camshaft Oil Port (Chamber B) 7. Supplied Oil Pressure (From Engine Oil Pump)
4. Solenoid Valve43-02-45
Page 35 of 55
Downloaded from www.Manualslib.com manuals search engine 33
N62 Engine
When the solenoid valve switches over, oil pressure is applied to chamber B. This forces
the blades (and hub) in a clockwise direction back to the initial position, again changing the
camshaft timing.
The example below shows the r re
es
se
et
t
procedure together with the pressure progression
based on the VANOS unit for the exhaust camshafts.
During this adjustment chamber A is open (through the solenoid) to allow the oil to drain
back through the cylinder head (internal reservoir).
N No
ot
te
es
s:
:
42-02-44 Hydraulic Actuation - Chamber B
1. Front View of VANOS Unit 5. Engine Oil Pump
2. Side View of VANOS Unit 6. Oil Return (Switched through Solenoid)
3. Camshaft Oil Port (Chamber B) 7. Supplied Oil Pressure (From Engine Oil Pump)
4. Solenoid Valve
Page 39 of 55
Downloaded from www.Manualslib.com manuals search engine 37
N62 Engine
Tensioning Rail Bearing Pin
The bearing pin for the cylinder bank 1-4 drive
chain tensioning rail is hollowed. There is a ball
(check) valve in the bearing pin. The valve
opens at an oil pressure of 1 bar and allows
engine oil to flow to the tensioning rail via a port
(1).
Chain Tensioner (cylinder bank 5-8)
An oil jet has been fitted to lubricate the cylinder bank
5-8 drive chain. There is a valve in the oil jet which
opens at a pressure of 1 bar and supplies the drive
chain with engine oil.
N No
ot
te
e:
:
Refer to the Repair Instructions when using the
Special Tools shown below to adjust the camshaft tim-
ing.
42-02-53
42-02-54 Tensioning Rail Bearing Pin
1. Engine Oil Port to Tensioning Rail
2. Ball (check) Valve
3. Bearing Pin
4. Sealing Rings for Sealing the Tensioning Rail
Chain Tensioner
1. Chain Tensioner
2. Tensioning Rail
3. Oil Jet
42-02-7842-02-79
Page 45 of 55
Downloaded from www.Manualslib.com manuals search engine 43
N62 Engine
Cooling Radiator
The radiator is made from aluminum and is divided into a high-temperature section and a
low-temperature section by a partition wall (see coolant circuit diagram). The coolant first
flows into the high-temperature section and then back to the engine, cooled.
Some of the coolant flows through an opening in the radiator partition wall to the low-tem-
perature section where it is cooled further. The coolant then flows from the low-tempera-
ture section (when the ÖWT thermostat is open) into the oil/coolant heat exchanger.
Coolant Expansion Tank
The expansion tank is mounted on the right hand wheel housing (engine compartment).
N No
ot
te
e:
:
The expansion tank should never be filled above the Max marking. Excess coolant is
expelled by the pressure relief valve in the cap as it heats up. Avoid overfilling the expan-
sion tank because the cooling circuit design ensures very good “self bleeding”.
Cooling Components
1. Cooling Radiator 4. Engine oil/air heat exchanger connection
2. Expansion Tank (hot countries only)
3. Water Pump 5. Transmission oil/coolant heat exchanger