BMW M57 Manual

Diesel Engines

M57/M67 Common Rail

Course contents/Background material

Information status:

09/98

BMW

Service Training

DI Diesel Engines M57/M67 - Common Rail Sec. 1-10

Course contents/Background material

Contents

Page

Sec. 1 Introd ction 1

Concepts 3

ngine views 4

Technical features 6

DD control unit 7

Technical data 7

xhaust emission legislation 9

Notes on exhaust emission standards/

test cycles 10

Sec. 2 Engine components 1

System structure 1

Component description 2

ngine block 2

Cylinder head gasket 5

Cylinder head 6

Cylinder head cover 8

Valve gear 10

Crankshaft 12

Flywheel 14

Connecting rods with bearings 15

Pistons with rings and pins 17

Chain drive 18

Oil pan 20

Timing case cover (M57) 22

Rear end cover (M67) 22

Sec. 3 Ancillary components and belt drive 1

Brief description 1

Requirements and Objectives 1

System structure 2

Component description 4

Torsional vibration damper 4

Starter motor 5

Alternator 6

A/C compressor 6

Belts 6

Tensioning pulley or idler pulley 7

DI Diesel Engines M57/M67 - Common Rail Sec. 1-10

Course contents/Background material

Sec. 4 Engine mo nts 1

Brief description 1

Requirements and Objectives 1

System structure 2

Component description 3

Hydraulic mount 3

Functional description 5

DD parameters 5

Vacuum supply 6

Sec. 5 L brication system 1

Brief description 1

Requirements and Objectives 1

System structure 2

Component description 4

Oil pump 4

Oil filter with integrated oil-to-water

heat exchanger 6

Oil spray nozzles 7

Sec. 6 Cooling system 1

Brief description 1

Requirements and Objectives 1

System structure 2

Component description 4

Water pump 4

Thermostat 4

Radiator 5

xhaust hood/shutter 7

Fan 7

Auxiliary heater 7

DI Diesel Engines M57/M67 - Common Rail Sec. 1-10

Course contents/Background material

Sec. 7 F el system 1

Brief description of function 1

Requirements and objectives 2

System structure 3

Component description 6

Fuel tank 6

Advance delivery pump 6

Auxiliary delivery pump 7

Fuel filter 9

Inlet pressure sensor 10

Sec. 8

Pressure relief valve (LP system)

High pressure pump 12

Pressure control valve

High pressure fuel accumulator (Rail)

Rail pressure sensor

Injector

Fuel heating/cooling (air heat exchanger)

Distributor unit with throttle

Overview of injection systems 35

Distributor injection (radial piston principle) 36

Pump nozzle

Common rail

Conventional injection characteristics 39

Common rail injection characteristics

Summary of common rail system

Air intake and exha st systems

Brief description

Requirements and objectives 1

System structure 2

Component description

Unfiltered air intake 3

Intake silencer

xhaust turbocharger

Intercooler

Intake manifold (intake plenum)

xhaust manifold

xhaust gas recirculation ( GR)

xhaust system

DI Diesel Engines M57/M67 - Common Rail Sec. 1-10

Course contents/Background material

Sec. 9 Digital Diesel Electronics 1

Review of DD control units 2

System structure 3

Signal description 4

Analog inputs 4

Digital inputs 10

Frequency inputs 15

Power output stages 17

Switching outputs 19

Sec. 10

Signal output stages, bi-directional interfaces

Supply 32

Functional description

Signal preprocessing 36

Injection-rate control

High pressure control 42

xhaust gas recirculation ( GR)

Boost-pressure control

Additional functions

Monitoring of the DD control unit 54

Programming

Diagnosis

Service information 1

Diagnosis

Recommendations to repair instructions 2

M57 fuel system - engine start 2

High pressure system - fuel injectors 3

Valve timing M57

Camshafts M57

Repair instructions 5

Service information M57/M67 6

Special tools M57/M67

Appendix

Pin assignments (DD 4.0/4.1)

Abbreviations 5

DI Diesel Engines M57/M67 - Common Rail Sec. 1 P.1

Course contents/Background material

Introd ction

BMW is successively developing a new family of diesel engines

with direct injection (DI) that will include 4-cylinder,

6-cylinder and 8-cylinder engines.

Following the successful introduction of the M47D20

4-cylinder engine, a new 6-cylinder engine will soon be phased

into series production.

This engine features all the design characteristics of the second

generation of direct injection diesel engines and represents the

currently most advanced diesel technology available in passen

ger

vehicles.

Thanks to its outstanding performance and high comfort properties

in conjunction with excellent exhaust quality and integral

fuel

economy, this engine enjoys a leading position in the

competitive environment.

spec. output

6-cyl

4-cyl

Displacement

KT-3692

Fig. 1: Competitive situation M47/M57

Initially, the new M57 engine will be installed in the form of a top-

of-the-range diesel engine in the 5 and 7 Series. The M67 will

enhance the top end of the diesel engine range in the 7 Series.

Parallel to this, the well-proven indirect injection engines (IDI)

will

still remain in the product range.

DI Diesel Engines M57/M67 - Common Rail Sec. 1 P.2

Course contents/Background material

Objectives

The layout and design particularly of the six-cylinder engine is

based on the following primary objectives:

• The creation of a top-of-the-range diesel engine for all BMW

model series

• Maintaining the leading competitive position with regard to

output power and torque development as well as comfort in

the entire diesel vehicle segment

• Securing marketability by the use of future-oriented technical

concepts incorporating further development capabilities

DI Diesel Engines M57/M67 - Common Rail Sec. 1 P.3

Course contents/Background material

Concepts

The concept features of the new engines correspond to those of

second generation DI diesel engines.

The advantages in fuel consumption offered by the first series-

produced DI diesel engines were offset by a series of

disadvantages regarding acoustic comfort, performance, emission,

pas

senger compartment heating and costs compared to modern

IDI

diesel engines.

In contrast to this, with second generation DI diesel engines it

has been possible to improve all customer-relevant features,

with

the exception of costs, by incorporating new or further

developed

technical concepts.

In-line design Direct injection 4-valve technology

2nd generation

VNT DDE Common rail

F rther development

KT-3893

Fig. 2: Technical concepts

The superiority of these engines is the result of non-compromis-

ing basic engine design (modular system) in conjunction with

progressive technical concepts.

DI Diesel Engines M57/M67 - Common Rail

Engine views

Fig. 3: M57 engine - General view

Fig. 4: M57 engine - Sectional view

Sec. 1 P.4

Course contents/Background material

KT-3748

KT-3754

DI Diesel Engines M57/M67 - Common Rail Sec. 1 P.5

Course contents/Background material

D mmy-Graphik

Graphic currently

not available.

KT-1463

Fig. 5: M67 engine - General view

D mmy-Graphik

Graphic currently

not available.

KT-1463

Fig. 6: M67 engine - Sectional views

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