Technicaltraining.

Productinformation.
N63TUEngine

BMWService

Generalnotes
Symbolsused
Thefollowingsymbol/schematicdiagramisusedinthisdocumenttofacilitatebettercomprehension
ortodrawattentiontoveryimportantinformation:

Containsimportantsafetyinformationandinformationthatneedstobeobservedstrictlyinorderto
guaranteethesmoothoperationofthesystem.
Informationstatusandnational-marketversions
BMWGroupvehiclesmeettherequirementsofthehighestsafetyandqualitystandards.Changesin
requirementsforenvironmentalprotection,customerbenefitsanddesignrendernecessarycontinuousdevelopmentofsystemsandcomponents.Consequently,theremaybediscrepanciesbetween
thecontentsofthisdocumentandthevehiclesavailableinthetrainingcourse.
ThisdocumentbasicallyrelatestotheEuropeanversionoflefthanddrivevehicles.Someoperatingelementsorcomponentsarearrangeddifferentlyinright-handdrivevehiclesthanshowninthegraphicsinthisdocument.Furtherdeviationsmayariseasaresultoftheequipmentspecificationinspecific
marketsorcountries.
Additionalsourcesofinformation
Furtherinformationontheindividualtopicscanbefoundinthefollowing:

Owner'sHandbook

IntegratedServiceTechnicalApplication.

Contact:conceptinfo@bmw.de
2012BMWAG,Munich,Germany
ReprintsofthispublicationoritspartsrequirethewrittenapprovalofBMWAG,Munich
Theinformationcontainedinthisdocumentformsanintegralelementofthetechnicaltrainingofthe
BMWGroupandisintendedforthetrainerandparticipantsintheseminar.RefertothecurrentrespectiveinformationsystemsoftheBMWGroupforanychanges/additionstothetechnicaldata.
Informationstatus:April2012
VH-23/InternationalTechnicalTraining

N63TUEngine
Contents
1.

Introduction............................................................................................................................................................................................................................................. 1
1.1.
Models..................................................................................................................................................................................................................................... 1
1.2.
Technicaldata............................................................................................................................................................................................................. 1
1.2.1.
Fullloaddiagram ................................................................................................................................................................ 3
1.3.
Newfeatures/Changes.................................................................................................................................................................................. 3
1.4.
Engineidentification......................................................................................................................................................................................... 5
1.4.1.
Enginedesignation............................................................................................................................................................ 5
1.4.2.
Engineidentification........................................................................................................................................................ 5

2.

EngineComponents................................................................................................................................................................................................................7
2.1.
Enginehousing......................................................................................................................................................................................................... 7
2.1.1.
Crankcase......................................................................................................................................................................................... 8
2.1.2.
Cylinderheadgasket..................................................................................................................................................... 8
2.1.3.
Cylinderhead..............................................................................................................................................................................8
2.1.4.
Cylinderheadcover..................................................................................................................................................... 10
2.1.5.
Oilsump......................................................................................................................................................................................... 18
2.2.
Crankshaftdrive................................................................................................................................................................................................... 19
2.2.1.
Crankshaftwithbearings..................................................................................................................................... 19
2.2.2.
Connectingrodwithbearing......................................................................................................................... 20
2.2.3.
Pistonwithpistonrings......................................................................................................................................... 21
2.3.
Camshaftdrive....................................................................................................................................................................................................... 22
2.4.
Valvetrain......................................................................................................................................................................................................................... 23
2.4.1.
Design................................................................................................................................................................................................ 23
2.4.2.
Valvetronic................................................................................................................................................................................... 27
2.5.
Beltdrive......................................................................................................................................................................................................................... 30

3.

Oil Supply...............................................................................................................................................................................................................................................32
3.1.
Overview.......................................................................................................................................................................................................................... 32
3.1.1.
Hydrauliccircuitdiagram..................................................................................................................................... 32
3.2.
Oilpumpandpressureregulation.......................................................................................................................................... 34
3.2.1.
Oilpump......................................................................................................................................................................................... 34
3.3.
Oilcoolingandfiltering............................................................................................................................................................................ 35
3.3.1.
Oilcooling.................................................................................................................................................................................... 36
3.3.2.
Oilfiltering................................................................................................................................................................................... 36
3.4.
Oilmonitoring.......................................................................................................................................................................................................... 36
3.4.1.
Oillevel............................................................................................................................................................................................. 36
3.5.
Oilspraynozzles.................................................................................................................................................................................................36
3.5.1.
Pistoncrowncooling..................................................................................................................................................36
3.5.2.
Chaindrive.................................................................................................................................................................................. 37
3.5.3.
Camshaft........................................................................................................................................................................................38
3.5.4.
Valvetronicservomotor........................................................................................................................................... 38

N63TUEngine
Contents
4.

Cooling.........................................................................................................................................................................................................................................................39
4.1.
Systemoverview................................................................................................................................................................................................. 39
4.1.1.
Enginecoolingcircuit................................................................................................................................................40
4.1.2.
ChargeaircoolersandDMEcoolingcircuit ........................................................................ 45
4.2.
Heatmanagement........................................................................................................................................................................................... 48
4.2.1.
Auxiliarywaterpump.................................................................................................................................................. 48
4.2.2.
Mapthermostat.................................................................................................................................................................. 48

5.

Intake/ExhaustEmissionSystem.............................................................................................................................................................. 49
5.1.
Overview.......................................................................................................................................................................................................................... 49
5.2.
Intakeairsystem.................................................................................................................................................................................................51
5.2.1.
Intakesilencer....................................................................................................................................................................... 52
5.2.2.
Hotfilmairmassmeter..........................................................................................................................................52
5.2.3.
Intakemanifold..................................................................................................................................................................... 52
5.3.
Exhaustturbocharger..................................................................................................................................................................................53
5.3.1.
Function.......................................................................................................................................................................................... 54
5.4.
Exhaustemissionsystem..................................................................................................................................................................... 54
5.4.1.
Exhaustmanifold.............................................................................................................................................................. 54
5.4.2.
Catalyticconverter......................................................................................................................................................... 55

6.

VacuumSystem.......................................................................................................................................................................................................................... 57

7.

FuelPreparation......................................................................................................................................................................................................................... 58
7.1.
Overview.......................................................................................................................................................................................................................... 58
7.2.
Fuelpumpcontrol............................................................................................................................................................................................ 59
7.3.
Highpressurepump..................................................................................................................................................................................... 59
7.4.
Injectors.............................................................................................................................................................................................................................60

8.

Fuel Supply......................................................................................................................................................................................................................................... 61

9.

EngineManagementSystem............................................................................................................................................................................. 62
9.1.
Overview.......................................................................................................................................................................................................................... 62
9.2.
Enginecontrolunit.......................................................................................................................................................................................... 68
9.2.1.
Overallfunction................................................................................................................................................................... 70

N63TUEngine
1.Introduction
TheN63TUengineisthepredecessortotheN63.ThefurtherdevelopedN63TUengineisthelatest
fuel-mixturegenerationtechnologyTurbo-ValvetronicDirectInjectionTVDI.TherearestrongsimilaritiesheretotheN20orN55engines.Thenewengineboastsbetterperformancedataatreducedfuel
consumptionandCO2emissions.
ThistrainingmaterialdescribesthedifferencestotheN63engine.

1.1.Models
Developmentseries

N63B44O1

Seriesintroduction

F01

BMW750i
BMW750ixDrive

07/2012

F02

BMW750Li
BMW750LixDrive

07/2012

F06

BMW650i
BMW650ixDrive

07/2012

F07

BMW550i
BMW550ixDrive

07/2012

F12

BMW650i
BMW650ixDrive

07/2012

F13

BMW650i
BMW650ixDrive

07/2012

1.2.Technicaldata
Unit

N63B44O0

N63B44O1

F01

F01LCI

BMW750i

BMW750i

V8

V8

4395

4395

1-5-4-8-6-3-7-2

1-5-4-8-6-3-7-2

[mm]

89/88.3

89/88.3

[kW](HP)
[rpm]

300(400)
5500-6400

330(445)
5500-6000

[rpm]

6500

6500

Poweroutputperliter

[kW(HP)xl]

68.3(90.9)

75.1(102)

Torque
atenginespeed

[Nm](lb-ft)
[rpm]

600(400)
1750-4500

650(480)
2000-4500

[]

10.0

10.0

95

98

Developmentseries
Modeldesignation
Design
Displacement

[cm]

Firingorder
Bore/Stroke
Poweroutput
atenginespeed
Cutoffspeed

Compressionratio
Valvespercylinder
Fuelrating

[RON]

N63TUEngine
1.Introduction
Unit

N63B44O0

N63B44O1

[RON]

91-98

91-98

[l/100km]

11.4

8.6

[g/km]

266

199

MSD85

MEVD17.2.8

EURO5(ULEVII)

EURO5(ULEVII)

[km/h(mph)]

250(155)

250(155)

Acceleration0100km/h/62mph

[s]

5.2

4.8

VehiclecurbweightDIN/EU

[kg]

1945/2020

1940/2015

Fuel
FuelconsumptioncomplyingwithEU
CO2emissions
DigitalEngineElectronics(DME)
Exhaustemissionslegislation
Maximumspeed

N63TUEngine
1.Introduction
1.2.1.Fullloaddiagram
BMWN63/N63TUintheF01

FullloaddiagramcomparingN63B44O0enginewithN63B44O1engine

1.3.Newfeatures/Changes
ThefollowingtableprovidesanoverviewofthechangestotheN63engine.

N63TUEngine
1.Introduction
System
Enginemechanical

Oilsupply
Cooling

Intakeandexhaustemissionsystems

Vacuumsystem

Fuelpreparation

Enginemanagementsystem

Comment

NewcylinderheadduetouseoftheTurboValvetronicDirect
Injection(TVDI)procedure

3rdgenerationValvetronic

Newvalvetrainwithmodifiedtiming

AdoptionofVANOSfromtheN55engine

Newcylinderheadcoverwithadaptedcrankcaseventilation

Pistonswithmodifiedpistoncrowngeometry

Newconnectingrodwithevenpitchandadaptationofthe
crankcaseduetomodifiedconnectingrodshape

Adaptedcrankshaft

Chaindrivewithmodifiedguiderailsandanextrudedchain
with142elements.

Pendulumslidecellpumpwithsmalloverallwidth

Eightindividualoilspraynozzlesforpistoncrowncooling.

Integrationofthetwoenginecontrolunitsinthelow-temperaturecircuitandcoolingoverthebackpanelwithcooling
pipe

Expansiontankundertheleftsidewallwithseparatefilling
hopper.

Adaptationofthemanifoldfortheairintakeductduetonew
geometryofthecylinderheadcover

Useofthehotfilmairmassmeter7

Adoptionofthechargeairtemperatureandintake-manifold
pressuresensorfromtheN20engine

Exhaustturbochargerwithnewcompressorandmodified
wastegatevalves

Discontinuationoftheblow-offvalves.

Two-stagevacuumpumpwithnewarrangementofthebolt
connection

VacuumreservoirforthewastegatevalvesintheV-areaof
theengine.

Useoftheknownhigh-pressureinjectionwithinjectorsand
highpressurepumpHDP5

Discontinuationoffuellow-pressuresensor

Newdualcontrolunitconceptwithonecontrolunitperbank

Oillevelsensorwithanadditionaltemperaturesensorinthe
mainoilductbehindthestartermotor.

N63TUEngine
1.Introduction
1.4.Engineidentification
1.4.1.Enginedesignation
TheversionN63B44O1oftheN63TUengineisdescribedinthisdocument.
Theenginedesignationinthetechnicaldocumentation,isusedtoensureclearidentificationofthe
engine.
ThetechnicaldocumentationalsocontainstheshortformoftheenginedesignationN63TU,which
onlyindicatestheenginetype.
Itemization
Index

Explanation

BMWGroup"NewGeneration"

V8engine

Enginewithexhaustturbocharger,Valvetronic
anddirectfuelinjection(TVDI)

Gasolineengine,longitudinallyinstalled

44

4.4litersdisplacement

Upperperformanceclass

Firstrevision

1.4.2.Engineidentification
Theengineshaveanidentificationmarkonthecrankcasetoensureclearidentificationandclassification.Thisengineidentificationisnecessaryforapprovalbygovernmentauthorities.Thefirstsixdigits
oftheengineidentificationcorrespondtotheenginedesignation.
Theengineserialnumbercanbefoundontheengineabovetheengineidentification.Thisconsecutive(serial)number,inconjunctionwiththeengineidentification,permitsclearidentificationofeachindividualengine.

N63TUEngine
1.Introduction

N63TUengineidentificationandenginenumberontherightfrontoftheengine

Index

Explanation

22620097

Individualconsecutive(serial)enginenumber

BMWGroup"NewGeneration"

V8engine

Enginewithexhaustturbocharger,Valvetronicanddirectfuelinjection(TVDI)

Gasolineengine,longitudinallyinstalled

44

4.4litersdisplacement

Typetestconcerns,standard

N63TUEngine
2.EngineComponents
2.1.Enginehousing
Theenginehousingiscomprisedoftheengineblock,cylinderheads,cylinderheadcovers,oilsump
andthegaskets.

N63TUengine,structureofenginehousing

Index

Explanation

Cylinderheadcover

Profileseal

Cylinderhead

Cylinderheadgasket

Crankcase

Gasketforupperoilsumpsection

Upperoilsumpsection

N63TUEngine
2.EngineComponents
Index

Explanation

Gasketforoilsump

Oilsump

10

Gasket

11

Gearcasecover

2.1.1.Crankcase
Thecrankcaseismanufacturedfromdie-castaluminiumGL-AlSi917Cu4MG,asontheN63engine.
ThecylinderboresaremadefromAlusil.Thecrankcasehasbeenrevisedasnowonlyconnectingrods
withanevenpitchareused.

2.1.2.Cylinderheadgasket
Athree-layerspringsteelgasketisusedforthecylinderheadgasket.Thereisastopperplate(2)inthe
areaofthecylinderboresinordertoachievesufficientcontactpressureforsealing.Thecontactsurfacesforthecylinderheadandtheengineblockarelayeredandhaveapartialfluorocaoutchouccoatingwithanti-stickcoating.

N63TUengine,cylinderheadgasket

Index

Explanation

Topspringsteellayerwithanti-stickcoating

Stopperlayer

Bottomspringsteellayerwithanti-stickcoating

2.1.3.Cylinderhead
ThecylinderheadoftheN63TUtopengineisanewdevelopmentwithintegratedairductsforthe
crankcaseventilationintheintakearea.
3rdgenerationValvetronictechnology(fromtheN55engine)isalsousedintheN63TUtopengine.AlthoughinthiscasetheValvetronicservomotorismountedontheoutersideatthecylinderhead.

Thecombinationofexhaustturbocharger,ValvetronicanddirectfuelinjectionisknownasTurboValvetronicDirectInjection(TVDI).

N63TUEngine
2.EngineComponents

N63TUengine,cylinderheadwithValvetronic

Index

Explanation

VANOS,intakeside

VANOS,exhaustside

Rollertappet,highpressurepump

Eccentricshaft

Torsionspring

Gate

Intermediatelever

Valvetronicservomotor

N63TUEngine
2.EngineComponents
2.1.4.Cylinderheadcover
Design
Thecylinderheadcoverisanewdesignwithadaptedcrankcaseventilationandlinerouting.Aventilationregisterwithanadditionalventilationlineisused.Eachbankhasitsownoilseparator.Anadditionallinefromthecrankcaseventilationtotheairintakesystemisnotusedascorrespondingboreholes
fortheindividualintakeportsareintegratedinthecylinderhead.
Thecamshaftsensorsarepositionedonthefrontofthecylinderheadcover.
Alabyrinthoilseparatorisusedtoseparatetheoilfromtheblow-bygas.Apre-separator(7)andafine
separatingplatewithverysmallairholes(6)areinstalledintheflowdirection.Theoildropletsareseparatedatthesebarriersandreturnedtothecylinderheadviatheoilreturnlines(9and10).Animpact
surface(5)withanupstreamfinefiltermeshensuresfurtherseparationofoilparticles.Theoilreturn
(10)isequippedwithanon-returnvalveinordertopreventdirectintakeofblow-bygasseswithout
separation.Iftheoillevelincreasesinthispipe,thenon-returnvalveopensandtheoildropsintothe
cylinderhead.Finallythecleanedblow-bygasesarefedintotheintakesystemdependingontheoperatingconditionoftheengineviathenon-returnvalve(1)orviathevolumecontrolvalves(12and3).

10

N63TUEngine
2.EngineComponents

N63TUengine,cylinderheadcoverwithcrankcaseventilation

Index

Explanation

Non-returnvalveforthecleanairpipewithleakhole

Purgeairline

Intakepipewithvolumecontrolvalve

Linetocleanairpipe

Impactsurfacewithupstreamfinefiltermesh
11

N63TUEngine
2.EngineComponents
Index

Explanation

Fineseparatingplatewithverysmallairholes

Pre-separator

Inletforblow-bygases

Oilreturn

10

Oilreturnwithnon-returnvalve

11

Connectinglineviablow-by-gaschannelfortheintakeport

12

Volumecontrolvalvefortheairintakesystemwiththrottlefunction

13

Oilseparator

Crankcaseventilationinnaturallyaspiratedmode
Inthenaturallyaspiratedmodethereisvacuumintheairintakesystem(12).Thetwovolumecontrol
valves(3)areopened.Thecleanedblow-bygasesreachtheinletareasofbothbanksandthustheair
intakesystemthroughtheleftoilseparatorviatheintakepipe(5)andductsinthecylinderhead(19).
Asthereisariskthatoilmaybedrawninviathecrankcaseventilationinthecaseoflargevacuums,the
volumecontrolvalvehasathrottlefunctionandlimitstheflowandthusalsothepressurelevelinthe
crankcase.
Thevacuuminthecrankcaseventilationkeepsthenon-returnvalves(2and6)closed.Freshairflows
frombothcleanairpipesthroughtherightoilseparatorintotheinsideoftheengineviatheleakage
holes.Thevacuuminthecrankcaseventilationisthusrestricted.Atthesametimethechemicalageingofthelubricatingoilandalsothewatercontentintheblow-bygasesarereducedbyflushingthe
crankcasewithfreshair.

12

N63TUEngine
2.EngineComponents

N63TUengine,overviewofcrankcaseventilationinthenaturallyaspiratedengineoperation

Index

Explanation

Ambientpressure

Vacuum

Exhaustgas

Oil

Blow-bygases

Leakageholeinthehousingofthenon-returnvalve

Non-returnvalveforthecleanairpipe

Volumecontrolvalvefortheairintakesystemwiththrottlefunction

Purgeairline

Intakesystemfrombank2tobank1
13

N63TUEngine
2.EngineComponents
Index

Explanation

Linetothecleanairpipewithnon-returnvalveandleakagehole

Cleanairpipe

Oilseparator

Chargeaircooler

10

Intakesilencerwithhotfilmairmassmeter7

11

Throttlevalve

12

Intakemanifold

13

Oilreturn

14

Ventilationduct

15

Crankchamber

16

Oilsump

17

Exhaustturbocharger

18

Oilreturnduct

19

Ductinthecylinderhead

N63TUengine,componentsofthecrankcaseventilationinthenaturallyaspiratedmode

14

N63TUEngine
2.EngineComponents
Index

Explanation

Freshairsupplyvialeakageholeswhennon-returnvalvesareclosed

Volumecontrolvalvesopen

Inletoftheblow-bygasestotheinletareaofthecylinderhead

Supplyofscavengingairviatheoilseparatortothecrankcase

Purgeairline

Intakeofblow-bygasestotheoilseparator

Intakeofthecleanedblow-bygasesviaductstotheinletareaofthecylinder
head

Crankcaseventilationinboostmode
Inboostmodethepressureintheintakesystem(12)increasesandthusclosesthevolumecontrol
valves(3).Asthereisavacuuminthisoperatingconditioninthecleanairpipe(7),thenon-return
valves(2and6)forthecleanairpipethusopenandthecleanedblow-bygasesaresentviathecompressoroftheturbochargerandthechargeaircooler(9)intotheairintakesystem.

15

N63TUEngine
2.EngineComponents

N63TUengine,overviewofventilationinboostmode

Index

Explanation

Chargingpressure

Vacuum

Exhaustgas

Oil

Blow-bygases

Leakageholeinthehousingofthenon-returnvalve

Non-returnvalveforthecleanairpipeopen

Volumecontrolvalvesfortheintakesystemwiththrottlefunction,closed

Purgeairline

Intakepipefrombank2tobank1

16

N63TUEngine
2.EngineComponents
Index

Explanation

Linetothecleanairpipewithopennon-returnvalve

Cleanairpipe

Oilseparator

Chargeaircooler

10

Intakesilencerwithhotfilmairmassmeter7

11

Throttlevalve

12

Intakesystem

13

Oilreturn

14

Ventilationduct

15

Crankchamber

16

Oilsump

17

Exhaustturbocharger

18

Oilreturnduct

19

Ductinthecylinderhead

N63TU,componentsofthecrankcaseventilationinboostmode

Index

Explanation

Non-returnvalvesforthecleanairpipeopen

Intakeofblow-bygasestotheoilseparator

Volumecontrolvalvesclosed
17

N63TUEngine
2.EngineComponents
2.1.5.Oilsump
Theoilsumpismadefromaluminium.Itisdesignedasaone-piececomponent,knownfromtheN63
engine.Theoilfilterscreenisintegratedintheupperoilsumpsection.
Theoilpumpisboltedtotheupperoilsumpsectionanddrivenviaachainbythecrankshaft.Theoil
deflectorisintegratedintheupperoilsumpsection.Theoildrainplugintheoilfiltercoverisnolonger
used.

N63TUengine,upperoilsumpsectionwithoilpump

Index

Explanation

Oillevelsensor

Intakepipeforthepressurepump

Pendulumslidecellpump

Chaindriveofthecrankshaft

Oilpressureswitch

Oilfiltercoverwithoutoildrainplug

Oiltemperaturesensor

Connectionfromtheengineoilcooler

Connectiontotheengineoilcooler

18

N63TUEngine
2.EngineComponents
2.2.Crankshaftdrive
ThecrankshaftwithconnectingrodsandpistonshavechangedincomparisontotheN63engine.The
weightofthecrankshafthasbeenoptimizedandtheconnectingrodsarenolongerdiagonal,buthave
anevenpitch.Thepistonweightwasalsoreduced.

N63TU,crankshaftdrivewithconnectingrodandpiston

Index

Explanation

Crankshaft

Oilpumpdrivegear

Camshaftsdrivegear

2.2.1.Crankshaftwithbearings
Crankshaft
ThecrankshaftoftheN63TUenginehasastrokeof88.3mmandismadeofthematerialC38.Itisa
forgedwithahardenedsurfacelayerandsixbalanceweights.
Crankshaftbearings
Thecrankshaftissupportedbyfivebearings.Thetwo-materialthrustbearingislocatedinthemiddle
atthethirdbearingposition.Robustlead-freetwo-materialbearingsareused.

19

N63TUEngine
2.EngineComponents

N63TU,crankshaftbearings

Index

Explanation

Upperbearingshellwithgrooveandoilhole

Thrustbearingwithgrooveandoilhole

Lowerbearingshellwithoutgroove

Theidentificationmarkingsforthebearingsarestampedonthecrankcaseandonthecrankshaft.
Pleaserefertotherepairinstructionsifthecrankshaftistobefittedwithnewbearings.

2.2.2.Connectingrodwithbearing
Connectingrod
TheconnectingrodoftheN63TUenginehasbeenredesigned.Itisacrackedforgedconnectingrod
withevenpitch.Ashapedboreisfittedintheconnectingrodeye.Theforceactingfromthepistonvia
thepistonpinisoptimallydistributedtothebushingsurfacebythisshapedboreandtheedgeload.

20

N63TUEngine
2.EngineComponents

N63TU,crackedconnectingrodwithevenpitch

Bearings
Theconnectingrodbearingshellsarelead-freeandrobustelectroplated.Thebearingpairsare
markedinred/blue.Thebluebearingisontherodside,theredbearingisinstalledonthecap.

2.2.3.Pistonwithpistonrings
CastpistonswithaMahlepistonringpackageareused.Thepistoncrownshapeisadaptedaccordinglytothecombustionprocess,thevalvepositionsandtheuseoftheinjectorswithmultiplenozzles.
Thepistonpinwasmanufactured3mm(0.11in)shorterasaresultofthenewpistonandisnow57
mm(2.24in)long.Thepistonweightwasreducedby60g(2.1oz)perpistonwiththenewdesigndespitetheincreasedignitionpressure.

21

N63TUEngine
2.EngineComponents

N63TU,castpistonwithpistonrings

Index

Explanation

Plainrectangularcompressionringwithroundedgroove(B-ring)

Taperfacedpistonring(NM-ring)

Oilscraperringwithspiralexpander(DSF-ring)

2.3.Camshaftdrive
Atoothedroller-typechainwith142elementsisusedperbanktodrivethecamshafts.Thisissupplied
withoilviatheoilspraynozzleinthechaintensioner.Tensioningrail,guideandsliderailsarenowdifferentpartsforbothbanks.Thetensioningrailwithanintegratedthrustpieceismadecompletelyfrom
plastic.

22

N63TUEngine
2.EngineComponents

N63TU,camshaftdrive

Index

Explanation

VANOS,exhaustside

VANOS,intakeside

Chaintensioner

Tensioningrail

Tooth-typechain

Crankshaftgear

2.4.Valvetrain
2.4.1.Design
IntheN63TUenginethefullyvariablevalveliftcontrolisalsousedinadditiontodoubleVANOS.The
valvetrainitselfiscomprisedofallknowncomponents.

23

N63TUEngine
2.EngineComponents

N63TU,valvetrain

Index

Explanation

Exhaustcamshaft

Intakecamshaft

Gate

Intermediatelever

Torsionspring

Valvetronicservomotor

Valvespring,intakevalve

VANOS,intakeside

Intakevalve

10

Exhaustvalve

11

Valvespring,exhaustvalve

12

VANOS,exhaustside

24

N63TUEngine
2.EngineComponents
Camshafts
TheN63TUengineusesthesamelightweightconstructioncamshaftsasN63.Thesecomposite
camshaftsareassembledfromindividualcomponents(pressfittedontoknurledpoints)ratherthan
machinedfromansolidblank.

N63TU,assembledcamshafts

Index

Explanation

Exhaustcamshaft

Intakecamshaft

25

N63TUEngine
2.EngineComponents

N63TU,cam/valvetimingdiagram

Index

Explanation

Valvelift[mm]

Crankshaftdegrees[KW]

Exhaustvalveopen

Intakevalveopen

Openingperiodofexhaustvalve

Exhaustvalvecloses

Intakevalvecloses

Openingperiodofintakevalve

Technicaldataofthevalvetrain
N63B44O0

N63B44O1

Intakevalvediameter/Shaftdiameter

[mm]

33.0/6

33.2/6

Exhaustvalvediameter/Shaftdiameter

[mm]

29/6

29/6

Maximumvalvelift,intake/exhaustvalve

[mm]

8.8/9.0

8.8/9.0

VANOSadjustmentrange,intake
(camshaftspread)

[crankshaft
degrees]

50

70

VANOSadjustmentrange,exhaust
(camshaftspread)

[crankshaft
degrees]

50

55

26

N63TUEngine
2.EngineComponents
Intakecamshaftopeningangle
(max.-min.spread)

[crankshaft
degrees]

70120

55125

Exhaustcamshaftopeningangle
(max.-min.spread)

[crankshaft
degrees]

64114(cylinders2,4,7,8)
70-120(cylinders1,3,5,6)

60115

Openingperiod,intakecamshaft

[crankshaft
degrees]

231

260

Openingperiod,exhaustcamshaft

[crankshaft
degrees]

215(cylinders2,4,7,8)
231(cylinders1,3,5,6)

252

Intakeandexhaustvalves
Theintakeandexhaustvalvesbothhaveashaftdiameterof6mm.Theexhaustvalvesarehollowand
filledwithSodium.Thisresultsinimprovedandquickerheatdissipation.

2.4.2.Valvetronic

TheValvetroniciscomprisedoffullyvariablevalveliftcontrolandvariablecamshafttimingcontrol
(doubleVANOS),whichmakestheclosingtimeoftheintakevalvefreelyselectable.
AswithperviousValvetronicenginesvalveliftcontrolisperformedontheintakeside,whilecamshaft
controlisperformedonboththeintakeandexhaustsides.
Throttle-freeloadcontrolisonlypossibleif:

thevalveliftoftheintakevalveand

thecamshaftadjustmentoftheintakeandexhaustcamshaftsarevariablycontrollable.

Result:
Theopeningandclosingtimesandthustheopeningperiodandtheliftoftheintakevalveareselectablefreely.
VANOS
TheVANOS(variablecamshafttimingcontrol)componentsknownfromtheN55engineareused.
Intheprocess:

TheadjustmentrangeoftheVANOSwasincreasedfrom50to70throughtheuseoffour
flanksinsteadoffive

Theweightwasreducedfrom1050gto650g(37to22.3oz)throughtheuseofaluminium
insteadofsteel.

27

N63TUEngine
2.EngineComponents

N63TU,VANOSwithoilsupply

Index

Explanation

Oilductfortimingadvance

Rotor

Oilductfortimingretardation

VANOS,exhaustside

VANOS,intakeside

VANOSsolenoidvalve,intakeside

VANOSsolenoidvalve,exhaustside

Valveliftcontrol
Ascanbeseeninthefollowingdiagram,theValvetronicservomotorisattachedattheintakesideto
thecylinderhead.TheeccentricshaftsensorisintegratedintotheValvetronicservomotor.
ThesystemusesValvetronicIII,whichwasintroducedintheN55engine.
Therollercamfolloweroftheintakesideandtheintermediateleveraremadefromsheetmetalanddividedintovariousclasses.Thiscanbeseenonthepunched-onnumbers.
28

N63TUEngine
2.EngineComponents

N63TU,valveliftcontrol

Index

Explanation

VANOS,exhaustside

Exhaustcamshaft

Rollercamfollower

Hydraulicvalveclearancecompensation(HVCC)

Valvespringonexhaustside

Exhaustvalve

Intakevalve

Hydraulicvalveclearancecompensation(HVCC)

Valvespringonintakeside
29

N63TUEngine
2.EngineComponents
Index

Explanation

10

Rollercamfollower

11

Valvetronicservomotor

12

Eccentricshaft

13

Spring

14

Intermediatelever

15

Intakecamshaft

16

VANOS,intakeside

2.5.Beltdrive
ThebeltdrivefromtheN63engineisusedandremainsunchanged.
Thebeltdriveincludesamainbeltdrivewithanalternator,coolantpumpandpowersteeringpump.
Themainbeltdriveisoperatedwithatensioningpulleywithtorsionspringtensioner.
Thesecondarybeltdriveincludestheairconditioningcompressorandisequippedwithanelasticbelt.
TherevolvertensioningsystemknownfromtheN63engineisusedforreplacingtheelasticbelt.

30

N63TUEngine
2.EngineComponents

N63TU,beltdrive

Index

Explanation

Beltpulley,alternator

Belt

Beltpulley,coolantpump

Beltpulley,powersteeringpump

Belttensioner

Beltpulley,crankshaft

Beltpulley,A/Ccompressor

31

N63TUEngine
3.OilSupply
3.1.Overview
Thefollowinggraphicsprovideanoverviewoftheoilsupplyandshowthehydrauliccircuitdiagram
andtheactuallayoutoftheoilpassagesintheengine.

3.1.1.Hydrauliccircuitdiagram

N63TU,hydrauliccircuitdiagram

32

N63TUEngine
3.OilSupply
Index

Explanation

Oilsump

Crankcase

Cylinderhead2x

Chaintensioner

VANOSvalve,intake

VANOSvalve,exhaust

Oilsump

Volume-controlledpendulumslidecellpump

Pressurelimitingvalve

Oilfilter

Filterbypassvalve

Thermostat

Oilcooler(oil-airheatexchanger)

Oilpressureswitch

Oiltemperaturesensor

10

Oilspraynozzlesforpistoncrowncooling

11

Lubricationpointoncrankshaftmainbearing

12

Lubricationpointsonexhaustturbocharger

13

Non-returnvalve,cylinderhead

14

Lubricationpointsoncamshaftbearing

15

Oilspraynozzlefortimingchain

16

Chaintensioner

17

Hydraulicvalveclearancecompensatingelements(16x)

18

Non-returnvalve

19

Strainer

20

VANOSsolenoidvalve

21

Swivelmotor

22

Non-returnvalve

23

Strainer

24

VANOSsolenoidvalve

25

Swivelmotor

33

N63TUEngine
3.OilSupply
3.2.Oilpumpandpressureregulation
TheN63TUengineisequippedwithavolume-flow-controlledoilpump.Itisdrivenviaachainbythe
crankshaft.ItisapendulumslidecellpumpwhosecontrollerfunctionssimilartotheN63engine.The
widthofthehousingwasreducedby6mmandonlyhasanoverallwidthof40mm.Thefunctionisthe
sameastheexistingpendulumslidecellpump.Theintakesnorkelispositioneddeepinthereararea
oftheoilsumptoguaranteeanadequateoilsupply.
Informationontheoperatingprincipleofavolume-flow-controlledoilpumpcanbefoundintheST501
EngineTechnology"N63Engine"trainingmaterialavailableonTISandICP.

3.2.1.Oilpump

N63TU,oilpumpwithcounterbalanceshafts

Index

Explanation

Oilpumpoutlet

Oilreturntotheoilchamber

Pressurelimitingvalve(maximum18bar)

Intakepipe

Pendulumslidewithawidthof40mm

Oilchamberforpendulumslide

Driveforoilpumpshaft

34

N63TUEngine
3.OilSupply
3.3.Oilcoolingandfiltering
TheN63TUengineusesthefull-flowoilfilterfamiliarfromtheN63engine.Itisboltedontotheoil
sumpfrombelow.Theoildrainplugisnotusedintheoilfiltercover.Afilterbypassvalveisintegrated
intotheoilfilterhousing.

N63TU,oilfiltermodule

35

N63TUEngine
3.OilSupply
Index

Explanation

Thermostat

Connectionforengineoilcooler

Engineoilcooler

3.3.1.Oilcooling
TheN63TUenginehasanairtocoolantheatexchangerforcoolingtheengineoilwhichisattached
belowthecoolingmodule.Toensurequickheating-upoftheengineoil,athermostatisintegratedin
theoilsump.Thethermostatreleasesthesupplytotheoilcoolerfromanengineoiltemperatureof
100C(212F).

3.3.2.Oilfiltering
AswithallBMWengines,theN63TUhasafilterbypassvalvewhichcanopenabypassroundthefilter
if,forexample,theengineoiliscoldandviscous.Thisoccursifthepressuredifferencebetweenbeforeandafterthefilterexceeds2.5bar(36.25psi).Thepermissiblepressuredifferencehasbeenincreasedfrom2.0to2.5bar(29to36.25psi)inordertoprotectthelead-freecrankshaftandconnectingrodbearings.Thisensuresthatthefilterisbypassedmuchlessfrequentlyandanydirtparticlesare
reliablyfilteredout.Thefilterbypassvalveisintegratedintotheoilfilterhousing.

3.4.Oilmonitoring
3.4.1.Oillevel
ThefamiliaroillevelsensorisusedwhichisalreadyinstalledintheN20andN55engineswithBN
2020vehicleelectricalsystem.

3.5.Oilspraynozzles
Aswithpreviousenginescomponentswhichcannotbereacheddirectlybyanoilductarelubricated
and/orcooledbyoilspraynozzles.

3.5.1.Pistoncrowncooling
TheoilspraynozzlesforpistoncrowncoolingaresimilartotheN63engineinprinciple.Theyincorporateanon-returnvalvetoenablethemtoopenandcloseonlyfromaspecificoilpressure.Eachcylinderhasitsownoilspraynozzle,whichobtainsthecorrectinstallationpositionthroughitsstyling.In
additiontothepistoncrowncooling,thesearealsoresponsibleforthelubricationofthepistonwrist
pins.

36

N63TUEngine
3.OilSupply

N63TU,oilspraynozzlesforthepistoncrowncooling

Index

Explanation

Oilspraynozzle

Openingpressure

2.25-2.65bar(32.6-38.4psi)

Closingpressure

2.0bar(29psi)

3.5.2.Chaindrive
ThechaindriveintheN63TUengineisdividedintoanuppersectionforthecamshaftdriveandalowersectionfortheoilpumpdrive.
Camshaftdrive
Theoilspraynozzlesforlubricatingthetimingchainsareintegratedintotherespectivechaintensionerofthebanks.Theyspraytheoildirectlyontothetimingchain.Athrottleintheoilspraynozzlelimits
theemergingoil.Thetimingchainofthecamshaftdriveisdesignedasatoothedroller-typechain.

37

N63TUEngine
3.OilSupply

N63TU,chaintensionerwithoilspraynozzlefortimingchain

Index

Explanation

Toothedroller-typechainwith142elements

Oilspraynozzle

Chaintensioner

Oilpumpdrive
Theoilpumpisdrivenviaaroller-typechainbythecrankshaft.Theroller-typechainiskepttensioned
byatensioningrail.Thesecondarydriveislubricatedviatheoilsump.

3.5.3.Camshaft
Theoilsupplyofthechaintensioner,thehydraulicvalveclearancecompensatingelementsandthe
bearingpositionsinthecylinderheadisdoneviaarisingpipefromtheenginehousinginthecylinder
head.Anon-returnvalveinthecylinderheadintherisingpipepreventstheoilductidling.

3.5.4.Valvetronicservomotor
Thewormgearforadjustingtheeccentricshaftislubricatedusingtheoilsprayfromthecamshaft.

38

N63TUEngine
4.Cooling
ThecoolingsystemalsosharessimilaritieswiththeN63engine.Theengineandchargeaircooling
bothhaveseparatecoolingsystems.ThecoolingcircuitforbothDigitalEngineElectronicscontrol
unitswasintegratedintothechargeaircoolingsystem.

4.1.Systemoverview

N63TU,completecoolingsystem

Index

Explanation

ElectriccoolantpumpforthecoolingcircuitofthechargeairandDME

Ventlineforchargeaircooling

Chargeaircooler

DigitalEngineElectronics(DME1)

DigitalEngineElectronics(DME2)
39

N63TUEngine
4.Cooling
Index

Explanation

Expansiontank

Cross-flowcoolerforthecoolingcircuitofchargeairandDME

Radiator

Radiatorforthetransmissionoilcooling

Coolanttemperaturesensoratradiatoroutlet

Electricfan

Mapthermostatwithheatingelement

Electricauxiliarywaterpumpforexhaustturbochargercooling

Temperature-dependentcoolantpump

Exhaustturbocharger

Heatercore

10

Duoheatercontrolvalve

11

Electricauxiliarywaterpumpforvehicleheating

12

Ventlineforbanks

13

Coolanttemperaturesensoratengineoutlet

14

Expansiontank

15

Coolantfillerpipe

16

Ventlineforcoolingcircuit,engine

17

Transmissionoil-to-coolantheatexchanger

4.1.1.Enginecoolingcircuit
Theenginecoolingisrealizedviaaconventionalcoolantpumpwithamapthermostat.Theimpeller
hasadiameterof70mm.
Anauxiliaryradiatorisconnectedtothecoolingcircuitinthedirectionoftravelontheleft.Theadditionalradiatorisequippedwithanon-returnvalvewithcompressionspringtopreventareturnbythe
electricauxiliarywaterpumpinthecaseofalowvolumetricflowofthecoolant.
Theelectricfanhasanominalpowerof850W.
Thefollowinggraphicsshowtheinstallationlocationsandlayoutofthecomponents.

40

N63TUEngine
4.Cooling

N63TUenginecoolingcircuit

Index

Explanation

Radiator

Radiatorforthetransmissionoilcooling

Coolanttemperaturesensoratradiatoroutlet

Electricfan

Mapthermostatwithheatingelement

Electricauxiliarywaterpumpforexhaustturbochargercooling

Temperature-andspeed-dependentcoolantpump

Exhaustturbocharger

Heatercore

10

Duoheatercontrolvalve
41

N63TUEngine
4.Cooling
Index

Explanation

11

Electricauxiliarywaterpumpforvehicleheating

12

Ventlineforbanks

13

Coolanttemperaturesensoratengineoutlet

14

Expansiontank

15

Coolantfillerpipe

16

Ventlineforcoolingcircuit,engine

17

Transmissionoil-to-coolantheatexchanger

42

N63TUEngine
4.Cooling
Componentsoftheenginecoolingcircuit(withouttheturbochargercoolingcircuitshown)

N63TUenginecoolingsystemcomponentsshownwithoutturbochargercoolingcircuit

Index

Explanation

Electricauxiliarywaterpump

Coolantpump

Duoheatercontrolvalve

Expansiontank

Fillingcup

Coolanttemperaturesensoratengineoutlet
43

N63TUEngine
4.Cooling
Index

Explanation

Electricfan

Radiator

Plugconnectionforelectricfan

10

Coolanttemperaturesensoratradiatoroutlet

11

Mapthermostat

12

Returnofheatedcoolantfromenginehousingtocoolantpump

13

Supplyofcooledcoolantviaimpellertotheenginehousing

14

Heatercore

15

Coolantlevelsensor

Componentsofturbochargercoolingcircuit
Themechanicalcoolantpumpisdrivenviaabeltandcannotbeusedforcoolingtheexhaustturbochargeraftertheenginehasshutdown.Thereforethereisa20Welectriccoolantpumptofeed
coolantthroughthisseparatecoolingcircuit.Theelectriccoolantpumpisswitchedonalsoduringengineoperationdependingonthecoolanttemperatureattheengineoutlet.
Theafter-runoftheelectriccoolantpumpcanlastupto30minutesforastationaryengineandwhen
theignitionisturnedoff.
Thisiscalculatedaccordingtothefollowingvalues:

Engineoiltemperature

Injectedfuelquantity

Intakeairtemperature

Exhaust-gastemperature

Fueltemperature.

Theelectricfancanalsorunforamaximumof11minutesaftertheengineisturnedoff.

44

N63TUEngine
4.Cooling

N63TU,turbochargercoolingcircuitwithelectricauxiliarywaterpump

Index

Explanation

Supplylinetotheexhaustturbochargers

Returnlinefromtheexhaustturbochargerstotheauxiliarywaterpump

Electricauxiliarywaterpump

Coolanttemperaturesensoratradiatoroutlet

Mapthermostat

Coolanttemperaturesensoratengineoutlet

Returnoftheheatedcoolantfromtheenginehousingtothecoolantpump
housing

Supplyofthecooledcoolanttotheenginehousing

4.1.2.ChargeaircoolersandDMEcoolingcircuit
Anindependentcoolingsystemwithanelectriccoolantpumpisusedforthecoolingcircuitofthe
chargeaircoolerandDMEcontrolunits.ThecoolingcircuitforthechargeaircoolingandtheDigital
EngineElectronics(DME)containsacross-flowradiatorandtwoauxiliaryradiators.
45

N63TUEngine
4.Cooling

N63TUchargeaircoolingandDMEcoolingcircuit

Index

Explanation

ElectriccoolantpumpforthechargeaircoolersandDMEcoolingcircuit

Ventlineforchargeaircooling

Chargeaircoolers

DigitalEngineElectronics(DME1)

DigitalEngineElectronics(DME2)

Expansiontank

Cross-flowheatexchangerforthechargeaircoolersandDMEcoolingcircuit

46

N63TUEngine
4.Cooling
ComponentsofthechargeaircoolingandDMEcoolingcircuit
The50Wpumphasaself-diagnosisanddry-runprotection.Iftheenginespeedisincreasedby15
minutesoveraperiod,theauxiliarywaterpumpsareswitchedoffandafaultcodeisstoredintheDME.
Theexpansiontankdoesnothaveacoolantlevelsensoranddoesnotautomaticallydetectwhenthe
fluidlevelistoolow.

N63TUcomponentsofthechargeaircoolersandDMEcoolingcircuit

47

N63TUEngine
4.Cooling
Index

Explanation

DigitalEngineElectronics(DME1)

Ventilationlineforchargeaircooling

Chargeaircooler

Expansiontank

DigitalEngineElectronics(DME2)

Cross-flowheatexchangerforthechargeaircoolersandDMEcoolingcircuit

ElectriccoolantpumpforthechargeaircoolersandDMEcoolingcircuit

4.2.Heatmanagement
TheN63TUenginehasthesameheatmanagementfunctionsintheDigitalEngineElectronics(DME)
asintheN55engine.Thiscomprisesindependentcontroloftheelectriccoolingcomponentsofelectricfan,mapthermostatandcoolantpumps.

4.2.1.Auxiliarywaterpump
TheN63TUenginealsohasthreeelectricauxiliarywaterpumpsinadditiontothemechanicalcoolant
pump:

forheatingtheinterior

forcoolingtheexhaustturbocharger

forcoolingthechargeaircoolerandthetwoDMEcontrolunits.

TheelectriccoolantpumpforthecoolingcircuitofthechargeairandDMEshasapowerof50W.The
othertwopumpshavea20Wpowerrating.

Ifthecoolantpumpisremovedandthentobereused,itisimportanttoensurethatitissetdownstill
filledwithcoolant.Dryingoutthepumpmaycausethebearingstostickinposition.Thiswillcausethe
coolantpumpnottostart,whichinturnmayresultinenginedamage.
Beforeinstalling,turntheimpellermanuallytoensurethatitmovesfreely.

4.2.2.Mapthermostat
TheN63TUengineisfittedwithaconventionalmapthermostatwhichhasthefollowingtechnicaldata
innon-electricallycontrolledmode:

Openingstartat105C(221F)

Completeopeningat120C(248F).

Inaddition,anelectricheaterinthemapthermostatscanbeusedtomakethethermostatopenata
lowercoolanttemperature.
48

N63TUEngine
5.Intake/ExhaustEmissionSystem
TheintakeandexhaustemissionsystemsareinprinciplecomparablewiththoseintheN63engine.
Thelistbelowitemizesthemostimportantchangestotheintakeandexhaustemissionsystems:

Flow-optimizedairintakeductwithadaptationofthemanifoldtothenewcylinderheadcover
geometry

Hotfilmairmassmeter7

AdaptationoftheintakesystemwithregardtotheValvetronicservomotorattachedattheside

Adaptationoftheexhaustsystembyintegrationofthepipeelbowsinthecatalyticconverter
neartheengineanddiscontinuationofthebolt-onflanges.

5.1.Overview

N63TU,airintakeandexhaustemissionsystems

49

N63TUEngine
5.Intake/ExhaustEmissionSystem
Index

Explanation

Throttlevalve

Chargingpressuresensor

Chargeaircooler

Intakesilencer

Hotfilmairmassmeter7

Exhaustturbocharger

Wastegatevalve

Electropneumaticpressureconverter

Oxygensensorbeforecatalyticconverter,controlsensorLSUADV

10

Oxygensensoraftercatalyticconverter,monitoringsensorLSF4.2

11

Catalyticconverter

12

DigitalEngineElectronics(DME)

13

Chargeairtemperatureandintake-manifoldpressuresensor

50

N63TUEngine
5.Intake/ExhaustEmissionSystem
5.2.Intakeairsystem

N63TU,airintakesystem

Index

Explanation

Intakeair

Compressed,heatedchargeair

Cooledchargeair

Intakesilencer

Exhaustturbochargerwithoutblow-offvalve

Hotfilmairmassmeter7

Connectionforcrankcaseventilationforcleanairpipe

Cleanairpipe

Unfilteredairpipe

Connectionfortankventvalve
51

N63TUEngine
5.Intake/ExhaustEmissionSystem
Index

Explanation

Chargeaircooler

Chargeairpipe

10

Chargingpressuresensor

11

Throttlevalvewithservomotor

12

Chargeairtemperatureandintake-manifoldpressuresensor

13

Intakemanifold

5.2.1.Intakesilencer
TheN63TUenginehasitsownintakesilencerforeachbank.Thesearefixedinthevehicleandhold
thehotfilmairmassmeters.

5.2.2.Hotfilmairmassmeter
TheN63TUengineisequippedwiththehotfilmairmassmeter7whichisfamiliarfromtheN20engine.

Malfunctionordisconnectionofthehotfilmairmassmeterdoesnotimmediatelyresultinemergency
engineoperation.However,impairedmixturepreparationandthereforepooremissionvaluesarepossible,whichiswhytheemissionswarninglamplightsup.

5.2.3.Intakemanifold
Thevolumeoftheairintakesystemhasbeenoptimizedandithasaflow-optimizedconnectionforthe
throttlebody.Italsoincludesthechargeairtemperatureandchargingpressuresensor.

N63TU,intakemanifoldwiththrottlevalve

52

N63TUEngine
5.Intake/ExhaustEmissionSystem
Index

Explanation

Throttlevalve

Intakemanifold

Chargeairtemperatureandintake-manifoldpressuresensor

Connectionfromtankventvalve

5.3.Exhaustturbocharger
TheN63TUenginehastwoexhaustturbochargers.Thecompressorwasslightlyrevisedandisnow
equippedwithninebladesofthesamesize.Uptonowdoublebladeswithfivelargeandfivesmall
bladeswereused.IncomparisontopreviousturbochargedBMWenginestheN63TUdoesnotusea
blow-offvalve.TheuseofValvetronicandspecialtuningandturboupgradesrendereditunnecessary.
Theexhaustturbochargerhasthefamiliarstructurewithanadaptedhousingandawastegatevalve.

N63TU,exhaustturbochargers

53

N63TUEngine
5.Intake/ExhaustEmissionSystem
Index

Explanation

Turbine

Bearingseat

Compressor

Vacuumunit

Wastegatevalve

Precisealignmentoftheexhaustturbochargersisnecessaryforassembly.Alwaysfollow
properrepairinstructions.

5.3.1.Function
Theblow-offvalvesattheexhaustturbochargerarediscontinuedonthisengineastheirjobiseffectivelyreplacedbytheengineinterventions.Thisisduetotheuseofanoptimizedcompressorwhich
permitsamorestablepumpdesignincomparisontothepredecessorcompressor.
Reasonsfortheinstallationofablow-offvalvetodatewere:

Preventcompressorsurge(transitionfromtractiontocoasting/overrunmode)

Possiblepumpingcausespulsating,acousticinterferencenoise

Arisingpressurewavesasaresultwhichstressthethrustbearingoftheturbocharger.

Inthecaseofloadsheddingwithoutablow-offvalvetheaimistoavoidacompressorpump.Apumpingcompressorarisesifhighpressureratiosandlowmassflowsoccur.Incontrasttheenginemeasuresarethatthroughtheenginecontrolthetargetmassflowisincreaseduntilthepumplimitcanfall
belowthelimitandthechargingpressurecandissipate.Thenecessarymassflowisadjustedbyactivatingthethrottlevalveandvalvelift.Excessivecylinderfillingandtheresultinghightorqueisthen
torque-controlledforexamplereducedviaretardingtheignitiontiming.Theresultsinneutraldriveability.

5.4.Exhaustemissionsystem
5.4.1.Exhaustmanifold
Thecast-ironexhaustmanifoldoftheN63TUengineremainsunchangedfromitspredecessor.

54

N63TUEngine
5.Intake/ExhaustEmissionSystem

N63TUexhaustmanifold

Index

Explanation

Exhaustmanifold

Sliderail

Nut

Beadedmetalgasket

5.4.2.Catalyticconverter
TheN63TUenginehasonecatalyticconverterperbank.Theoutlethoppersarenowsingle-walled.
Thecatalyticconverterneartheenginecomprisesfirstandsecondmonoliths.Thecatalyticconverters
havedecouplingelementswhicharealsodescribedasexpansionelements.

55

N63TUEngine
5.Intake/ExhaustEmissionSystem

N63TU,sectionalviewofthecatalyticconverter

Index

Explanation

Controlsensor

Ceramicmonolith1

Connectionoftheturbine

Monitoringsensor

Ceramicmonolith2

Exhaustpipe

Oxygensensors
ThetypicalBoschoxygensensorsareused:

Controlsensor:LSUADV

Monitoringsensor:LSF4.2.

Thecontrolsensorislocatedaheadoftheprimaryceramicmonolith,ascloseaspossibletotheturbineoutlet.Itspositionhasbeenchosensothatallthecylinderscanberecordedseparately.The
monitoringsensorispositionedbetweenthefirstandsecondceramicmonoliths.

56

N63TUEngine
6.VacuumSystem
ThevacuumsystemoftheN63TUenginedemonstratessomechangeswithregardtotheN63engine.
Thevacuumreservoirandthepressureconverterareinthefamiliarlocations.Theboltingpointsofthe
vacuumpumphaveanewarrangementduetothenewcylinderhead.

N63TU,vacuumsystem

Index

Explanation

Vacuumpump

Connection,brakeservo

Connectionforsecondaryconsumer

Vacuumreservoir

Vacuumunitsforwastegatevalves

Connectionforvacuumlinetotheelectricchangeovervalveforvacuumunits
ofexhaustflaps

Electropneumaticpressureconverter(EPDW)forwastegatevalves

Thevacuumpump(asusual)isdesignedtohavetwostagessothatthemajorityofthegeneratedvacuumismadeavailabletothebrakeservo.ThevacuumreservoirispositionedintheV-spaceandis
nowmadeoutofplastic.

57

N63TUEngine
7.FuelPreparation
TheN63TUenginemakesuseofhigh-pressureinjection,whichwasintroducedintheN55engine.It
differsfromhigh-precisioninjection(HPI)inthatitusessolenoidvalvetypeinjectorswithmulti-hole
nozzles.

7.1.Overview
ThefollowingoverviewshowsthefuelpreparationsystemoftheN63TUengine.ItessentiallycorrespondstothesystemswithdirectfuelinjectionfamiliarinBMWmodels.Onlytheguideofthefuelline
hasbeenadaptedintheareaofthealternator.

N63TU,fuelpreparation

Index

Explanation

Fuelline

Fuelquantitycontrolvalve

Injector

Highpressureline,rail-injector

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N63TUEngine
7.FuelPreparation
Index

Explanation

Rail

Highpressureline,highpressurepumptorail

Highpressurepump

Fuelsupplyline

Boschhigh-pressurefuelinjectionvalveswiththedesignationHDEV5.2areused.Thehighpressure
pumpisalreadyknownfromthe4-,8-and12-cylinderengines.AninnovationintheN63TUengine
isthefactthatthehighpressurelinesfromrailtoinjectorarenownolongerboltedattherailend,but
weldedasonN20.

Donotopenthefuelsystemifthecoolanttemperatureisabove40C/104F.Theresidual
pressureinthehighpressurefuelsystemcouldcausebodilyinjury.
Itisessentialtoobservetheutmostcleanlinesswhenworkingonthehighpressurefuelsystemandto
followtheproperworkingproceduresdescribedintherepairinstructions.Evenminutesoilingordamageatthethreadconnectionsofthehighpressurelinescouldcauseleaks.
WhenworkingonthefuelsystemoftheN63TUengine,itisimportanttoensurethattheignitioncoils
arenotwetwithfuel.Theresistanceofthesiliconematerialisgreatlyreducedbysustainedcontact
withfuel.Thiscouldresultinarcingatthetopofthesparkplugandmisfiring.

Beforemakinganymodificationstothefuelsystem,alwaysremovetheignitioncoilsandprotectthesparkplugshaftagainsttheingressoffuelbycoveringthemwithacloth

Beforereinstallingthesolenoidvalveinjectors,removetheignitioncoilsandensurethatgreatestpossiblecleanlinessismaintained.

Ignitioncoilsheavilysaturatedwithfuelmustbereplaced.

7.2.Fuelpumpcontrol
Thefuelisdeliveredfromthefueltankthroughtheelectricfuelpumpviathefeedlineataprimary
pressureof5.9bar(85.57psi)tothehighpressurepump.Theon-loadspeedcontrolisdoneviathe
DME.Thelow-pressuresensorhasbeeneliminated.

7.3.Highpressurepump
TheknownBoschhighpressurepumpisused.Thisisasingle-plungerpumpwhichisdrivenfromthe
exhaustcamshaftviaatriplecam.Sothatsufficientfuelpressureisguaranteedineachloadcondition
oftheengine,ahighpressurepumpisusedintheN63TUengineforeachbank.
Forfurtherinformationonthehighpressurepump,pleaserefertothe"N74Engine"trainingmaterial
availableonTISandICP.

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N63TUEngine
7.FuelPreparation
7.4.Injectors
TheBoschHDEV5.2solenoidvalveinjectorisaninward-openingmulti-holevalveunliketheoutward-openingpiezoinjectorusedinHPIengines.TheHDEV5.2isalsocharacterizedbyhighvariabilitywithregardtosprayangleandsprayshape,andisconfiguredforasystempressureofupto200bar
(2900psi).
TheseinjectorsarealreadyusedintheN55andN20engines.
Forfurtherinformationoninjectoractivation,refertotheEngineManagementSystemsection.

N63TU,injector

Thestemsofthesolenoidvalveinjectorscanonlywithstandacertaintensileforceandacertain
torque.Itisessentialwhenremovingandinstallingtheinjectorstofollowthespecificproceduredescribedintherepairinstructions,asotherwisetheinjectorswillbedamaged.
Ifaninjectororacylinderwasreplaced,aninjectionquantitycompensationmustbeperformed.This
isperformedwithhelpoftheadjustmentvalue.Theadjustmentvalueisimprintedontheinjectorbody
withthreefigures.TheadjustmentvaluemustbereadbeforetheinstallationandinputintheDMEwith
theuseofatestplaninISTA.

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N63TUEngine
8.FuelSupply
Thefuelsupplyisvehicle-specific.Thepreviouslyknowncomponentsareused.

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9.EngineManagementSystem
9.1.Overview

N63TU,DME1/systemwiringdiagramMEVD17.2.8

62

N63TUEngine
9.EngineManagementSystem
Index

Explanation

EngineelectronicsValvetronicdirectfuelinjectionMEVD17.2.8DME1

Ambientpressuresensor

Temperaturesensor

FlexRay

PT-CAN

PT-CAN2

Tankleakdiagnosis,NaturalVacuumLeakDetectionNVLD(onlyUSversion)

Zero-gearsensor(onlywithautomaticenginestart-stopfunction,manual
gearbox)

CarAccessSystem(CAS)

10

Clutchswitch(withmanualgearboxonly)

11

Activecowlflapcontrol

12

Relayforelectricfan

13

Electricfan

14

Mapthermostat

15

Exhaustflaps(1valve,2flaps)

16

Tankventvalve

17

VANOSsolenoidvalve,intakecamshaft

18

VANOSsolenoidvalve,exhaustcamshaft

19

Electriccoolantpump,exhaustturbocharger

20

Electropneumaticpressureconverter(EPDW)wastegate

21

Quantitycontrolvalve

2225

Injectors

2629

Ignitioncoils

30

Ground

31

Speedsensor(manualgearboxonly)

32

OxygensensorLSF4.2

33

OxygensensorLSUADV

34

Enginespeedsignaldiagnosticconnector

35

Chargingpressuresensorbeforethrottlevalve

36

Railpressuresensor

37

Chargeairtemperatureandintake-manifoldpressuresensorafterthrottle
valve

38

Knocksensors12

39

Knocksensors3-4

40

Hotfilmairmassmeter(HFM)7
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N63TUEngine
9.EngineManagementSystem
Index

Explanation

41

Camshaftsensor,intakecamshaft

42

Camshaftsensor,exhaustcamshaft

43

Crankshaftsensor,signalisloopedthroughtoDMEslave

44

Acceleratorpedalmodule

45

Throttlevalve

46

Enginetemperature(sensorathousingofcoolantpump)

47

Coolanttemperatureatradiatoroutlet

48

Oiltemperaturesensor

49

Oilpressureswitch

50

Brakevacuumsensor(onlywithautomaticenginestart-stopfunction,manual
gearbox)

51

Valvetronicservomotor

52

Oillevelsensor

53

Intelligentbatterysensor(IBS)

54

Electriccoolantpump,chargeaircoolerandDigitalEngineElectronics(DME)

55

DC/DCconverter(forautomaticenginestart-stopfunction)

56

Alternator

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N63TUEngine
9.EngineManagementSystem

N63TU,DME2/systemwiringdiagramMEVD17.2.8

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N63TUEngine
9.EngineManagementSystem
Index

Explanation

EngineelectronicsValvetronicdirectfuelinjectionMEVD17.2.8DME2

Ambientpressuresensor

Temperaturesensor

FlexRay

PT-CAN

PT-CAN2

CarAccessSystem(CAS)

Tankventvalve

VANOSsolenoidvalve,intakecamshaft

10

VANOSsolenoidvalve,exhaustcamshaft

11

Relay,transmissionoilpump(manualgearboxonly)

12

Pressureconverter(EPDW)

13

Quantitycontrolvalve

1417

Injector

1821

Ignitioncoil

22

Ground

23

OxygensensorLSF4.2

24

OxygensensorLSUADV

25

Chargingpressuresensorbeforethrottlevalve

26

Railpressuresensor

27

Chargeairtemperatureandintake-manifoldpressuresensorafterthrottle
valve

28

Knocksensors5-6

29

Knocksensors7-8

30

Hotfilmairmassmeter(HFM)7

31

Camshaftsensor,intakecamshaft

32

Camshaftsensor,exhaustcamshaft

33

Crankshaftsensor

34

DigitalEngineElectronics(DME)master

35

Throttlevalve

36

NTCtransmissionoiltemperature(onlywithmanualgearbox)

37

DME1/DME2encoding

38

Valvetronicservomotor

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9.EngineManagementSystem

N63TU,vehicleconnectionmodule100ofDME1andDME2

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9.EngineManagementSystem
Index

Explanation

DigitalEngineElectronics(DME2)

Automaticairflapcontrol

Electricfan

Solenoidfortheautomaticairflapcontrol

Powerdistributionboxes

ElectricauxiliarywaterpumpforchargeairandDME

DigitalEngineElectronics(DME1)

Transmissionspeedsensor(manualgearboxonly)

A/Ccompressor

10

Junctionbox(JB)

11

Fuse,terminal30B

12

DC/DCconverter(forautomaticenginestart-stopfunction)

13

Rearrightpowerdistributionbox

14

Fuse,terminal30

15

Intelligentbatterysensor(IBS)

16

Valve,exhaustflap

17

Relayforelectricfan

18

Tankleakdiagnosis(onlyforUS)

19

Gearselectorlever(onlyautomatic)

20

IntegratedChassisManagement(ICM)

21

Acceleratorpedalmodule

22

Couplingswitchmodule(manualgearboxonly)

23

Instrumentcluster

24

CarAccessSystem(CAS)

25

Centralgatewaymodule(CGM)

26

Footwellmodule(FRM)

27

Startermotor

28

Switchreversinglight(manualgearboxonly)

29

DynamicStabilityControlDSC

9.2.Enginecontrolunit
TheN63TUenginehasaBoschDMEwiththedesignationMEVD17.2.8.Itisstronglyrelatedtothe
DigitalEngineElectronicsoftheN55engine.Thereisaseparatewater-cooledenginecontrolunit
fixedtotheengineforeverybank.TheactuatorsandsensorsofbankoneareassignedtotheDME
1controlunit,theDME2controlunitisresponsibleforthefunctionsofbanktwo.DME1isthemas68

N63TUEngine
9.EngineManagementSystem
tercontrolunitandalsoassumesallinformationconcerningtheentireengine,suchasturningonthe
crankshaftsensorandmakingitavailabletotheDME2controlunitdirectlyorviathebussystem.Due
tothevarietyofsensorsandactuatorsadistributiontotwocontrolunitswasnecessary.

N63TU,DigitalEngineElectronics

Index

Explanation

DMEcontrolunit,bank1

Powerdistributionboxes

DMEcontrolunit,bank2

Donotattemptanytrialreplacementofcontrolunits.
Becauseoftheelectronicimmobilizer,atrialreplacementofcontrolunitsfromothervehiclesmustnot
beattemptedunderanycircumstances.Animmobilizeradjustmentcannotbereversed.
ThecoolingofthetwocontrolunitsoftheDigitalEngineElectronicsisdonebyconnectiontothe
coolingcircuitofthechargeaircooling.Analuminiumcoolingloopisintegratedinthehousingbaseof
thecontrolunitsforthissystem.
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9.EngineManagementSystem
TheplugconnectorconceptisidenticaltotheMEVD17.2intheN55engine.Thereisalogicaldivision
intosixmodules.

N63TU,MEVD17.2.8DMEconnections

Index

Explanation

Module100,vehicleconnection,48pins

Module200,sensorsandactuators1,58pins

Module300,sensorsandactuators2,58pins

Module400,Valvetronicservomotor,11pins

Module500,DMEsupply,12pins

Module600,fuelinjectionandignition,24pins

9.2.1.Overallfunction
TheDigitalEngineElectronics(DME)isthecomputingandswitchingcenteroftheenginecontrolsystem.Sensorsontheengineandthevehicledelivertheinputsignals.Thesignalsforactivatingtheactuatorsarecalculatedfromtheinputsignals,theset-pointvaluescalculatedusingacomputingmodel
intheDMEcontrolunitandthestoredprogrammaps.TheDMEcontrolunitactivatestheactuatorsdirectlyorviarelays.
TheDMEcontrolunitiswokenupviathewake-upline(terminal15Wake-up)bytheCarAccessSystem(CAS).
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N63TUEngine
9.EngineManagementSystem
Theafter-runstartsafterterminal15OFF.Theadaptationvaluesarestoredduringtheafter-run.The
DMEcontrolunitusesabussignaltosignalitsreadinessto"gotosleep".Whenalltheparticipating
controlunitshavesignalledtheirreadinessto"gotosleep",thebusmasteroutputsabussignaland
thecontrolunitsterminatecommunicationfivesecondslater.
TheboardintheDMEcontrolunitaccommodatestwosensors:atemperaturesensorandanambient
pressuresensor.Thetemperaturesensorisusedtomonitorthetemperatureofthecomponentsinthe
DMEcontrolunit.Theambientpressureisrequiredforcalculatingtheair/fuelmixturecomposition.

71

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