n55 Guide Bimmerpost

TechnicaI training.
Product information.
BMW Service
N55 Engine.
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GeneraI information
SymboIs used
The following symbol/graphic represenIaIion is used in Ihis documenI Io faciliIaIe beIIer comprehen-
sion or Io draw aIIenIion Io very imporIanI informaIion:
conIains imporIanI safeIy noIes and informaIion IhaI needs Io be observed sIricIly in order Io guaran-
Iee Ihe smooIh operaIion of Ihe sysIem.
lnformation status and nationaI variants
BMW Group vehicles meeI Ihe requiremenIs of Ihe highesI safeIy and qualiIy sIandards. Changes in
requiremenIs for environmenIal proIecIion, cusIomer benefiIs and design render necessary conIinu-
ous developmenI of sysIems and componenIs. ConsequenIly, Ihere may be discrepancies beIween
Ihe conIenIs of Ihis documenI and Ihe vehicles available in Ihe Iraining course.
This documenI basically relaIes Io lefI-hand drive vehicles wiIh European specificaIions. Some con-
Irols or componenIs are arranged differenIly in righI-hand drive vehicles Ihan shown in Ihe graphics in
Ihis documenI. FurIher differences may arise as Ihe resulI of Ihe equipmenI varianIs used in specific
markeIs or counIries.
AdditionaI sources of information
FurIher informaIion on Ihe individual Iopics can be found in Ihe following:
Owner's Handbook
lnIegraIed Service Technical ApplicaIion.
ConIacI: concepIinfoGbmw.de
2009 BMW AG, Mnchen
Reprints of this pubIication or its parts require the written approvaI of BMW AG, Mnchen
The informaIion conIained in Ihis documenI form an inIegral parI of Ihe Iechnical Iraining of Ihe BMW
Group and are inIended for Ihe Irainer and parIicipanIs of Ihe seminar. Refer Io Ihe laIesI relevanI infor-
maIion sysIems of Ihe BMW Group for any changes/addiIions Io Ihe Technical DaIa.
lnformaIion sIaIus: JuIy 2009
VH-23llnternationaI TechnicaI Training
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N55 Engine.
Oontents
1. lntroduction............................................................................................................................................................................................................................................. 1
1.1. HighlighIs............................................................................................................................................................................................................................ 1
1.1.1. Technical daIa............................................................................................................................................................................ 1
1.1.2. Full load diagram...................................................................................................................................................................1
1.2. New feaIures/changes....................................................................................................................................................................................3
1.2.1. Overview............................................................................................................................................................................................. 3
2. ModeIs..............................................................................................................................................................................................................................................................6
2.1. N54B30O0 engine varianIs................................................................................................................................................................... 6
2.2. HisIory ................................................................................................................................................................................................................................... 7
3. Engine identification............................................................................................................................................................................................................. S
3.1. Engine designaIion and engine idenIificaIion.......................................................................................................... 8
3.1.1. Engine designaIion............................................................................................................................................................8
3.1.2. Engine designaIion............................................................................................................................................................9
4. Engine mechanicaI system................................................................................................................................................................................... 11
4.1. Engine housing..................................................................................................................................................................................................... 11
4.1.1. Engine block............................................................................................................................................................................ 11
4.1.2. Cylinder head......................................................................................................................................................................... 15
4.1.3. Cylinder head cover..................................................................................................................................................... 16
4.1.4. Oil pan................................................................................................................................................................................................21
4.2. CrankshafI drive sysIem......................................................................................................................................................................... 22
4.2.1. CrankshafI and bearings...................................................................................................................................... 22
4.2.2. ConnecIing rod and bearing.......................................................................................................................... 23
4.2.3. PisIons wiIh pisIon rings......................................................................................................................................26
4.3. CamshafI drive....................................................................................................................................................................................................... 28
5. VaIve gear.............................................................................................................................................................................................................................................. 29
5.1. Design.................................................................................................................................................................................................................................. 29
5.1.1. CamshafIs.................................................................................................................................................................................... 30
5.1.2. Valve Iiming............................................................................................................................................................................... 31
5.1.3. lnIake and exhausI valves................................................................................................................................... 32
5.1.4. Valve springs........................................................................................................................................................................... 32
5.2. ValveIronic..................................................................................................................................................................................................................... 32
5.2.1. VANOS.............................................................................................................................................................................................. 32
5.2.2. Valve lisI adjusImenI................................................................................................................................................... 35
6. BeIt drive and anciIIary components................................................................................................................................................. 42
6.1. BelI drive......................................................................................................................................................................................................................... 42
6.1.1. VibraIion absorber.......................................................................................................................................................... 43
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N55 Engine.
Oontents
7. OiI suppIy................................................................................................................................................................................................................................................46
7.1. Oil circuiI......................................................................................................................................................................................................................... 46
7.1.1. Oil ducIs......................................................................................................................................................................................... 46
7.1.2. Oil reIurn........................................................................................................................................................................................ 50
7.1.3. Oil pump and pressure conIrol...................................................................................................................52
7.1.4. Oil filIraIion and oil cooling............................................................................................................................... 54
7.1.5. Oil spray nozzles............................................................................................................................................................... 54
7.1.6. Oil moniIoring........................................................................................................................................................................ 54
S. Air intake and exhaust system....................................................................................................................................................................... 55
8.1. Air inIake sysIem................................................................................................................................................................................................55
8.1.1. Overview......................................................................................................................................................................................... 55
8.1.2. Air inIake sysIem.............................................................................................................................................................. 58
8.1.3. Fuel Iank venIilaIion sysIem........................................................................................................................... 59
8.2. ExhausI sysIem.....................................................................................................................................................................................................60
8.2.1. Overview......................................................................................................................................................................................... 60
8.2.2. ExhausI manifold.............................................................................................................................................................. 61
8.2.3. ExhausI Iurbocharger................................................................................................................................................ 63
8.2.4. CaIalyIic converIer......................................................................................................................................................... 66
9. Vacuum system.......................................................................................................................................................................................................................... 6S
9.1. Design.................................................................................................................................................................................................................................. 68
9.1.1. Vacuum pump....................................................................................................................................................................... 68
10. FueI preparation........................................................................................................................................................................................................................ 71
10.1. Overview.......................................................................................................................................................................................................................... 71
10.1.1. Fuel pressure sensor................................................................................................................................................. 72
10.1.2. High pressure pump................................................................................................................................................... 73
10.1.3. Fuel injecIors.......................................................................................................................................................................... 74
11. OooIing system........................................................................................................................................................................................................................... 75
11.1. Overview.......................................................................................................................................................................................................................... 75
11.1.1. CoolanI ducIs...................................................................................................................................................................... 79
12. Engine eIectricaI system...........................................................................................................................................................................................S2
12.1. ConnecIion Io vehicle elecIrical sysIem....................................................................................................................... 82
12.1.1. Overview......................................................................................................................................................................................... 82
12.1.2. SysIem circuiI diagrams........................................................................................................................................83
12.1.3. Engine conIrol uniI........................................................................................................................................................ 89
12.2. FuncIions........................................................................................................................................................................................................................ 90
12.2.1. Fuel supply sysIem....................................................................................................................................................... 90
N55 Engine.
Oontents
12.2.2. BoosI pressure conIrol........................................................................................................................................... 91
12.2.3. Engine cooling...................................................................................................................................................................... 91
12.2.4. SysIem proIecIion.......................................................................................................................................................... 92
12.3. Sensors..............................................................................................................................................................................................................................92
12.3.1. CrankshafI sensor........................................................................................................................................................... 92
12.3.2. lgniIion coil and spark plug.............................................................................................................................. 94
12.3.3. Oil pressure sensor...................................................................................................................................................... 94
12.3.4. Oxygen sensors..................................................................................................................................................................95
12.3.5. HoI-film air mass meIer......................................................................................................................................... 96
12.4. AcIuaIors......................................................................................................................................................................................................................... 97
12.4.1. ValveIronic servomoIor........................................................................................................................................... 97
12.4.2. High pressure fuel injecIion valve.......................................................................................................... 99
13. Service information........................................................................................................................................................................................................ 102
13.1. Engine mechanical sysIem............................................................................................................................................................ 102
13.1.1. Engine casing componenIs...................................................................................................................... 102
13.2. Fuel condiIioning sysIem................................................................................................................................................................. 102
13.2.1. Overview.................................................................................................................................................................................... 102
13.3. Engine elecIrical sysIem....................................................................................................................................................................103
13.3.1. lgniIion coil and spark plug..........................................................................................................................103
N55 Engine.
1. lntroduction
1
1.1. HighIights
The N55 engine is Ihe successor Io Ihe N54 engine. Re-engineering and modificaIions have made iI
possible Io now use only one exhausI Iurbocharger. AgainsI Ihe backdrop of reduced cosIs and im-
proved qualiIy, Ihe Iechnical daIa have remained virIually Ihe same.
1.1.1. TechnicaI data
Unit N54B30O0 {E71l
X6 xDrive35i)
N55B30M0 {F07l535i)
Oonfiguration 6 inline 6 inline
OyIinder capacity [cmj 2979 2979
Borelstroke [mmj 84.0/89.6 84.0/89.6
Power output
at engine speed
[kW/bhpj
[rpmj
225/306
5800-6250
225/306
5800-6400
Power output per Iitre [kW/lj 75.53 75.53
Torque
at engine speed
[Nmj
[rpmj
400
1300 - 5000
400
1200 - 5000
Oompression ratio [sj 10.2 10.2
VaIveslcyIinder 4 4
FueI consumption, EU
combined
[l/100 kmj 10.9 8.9
OO
2
emission g/km 262 209
DigitaI Motor EIectron-
ics
MSD81 MEVD17.2
Exhaust emission Ieg-
isIation EURO, US
EURO 4 EURO 5
Engine oiI specifica-
tion
BMW Longlife-01
BMW Longlife-01 FE
BMW Longlife-04
Top speed [km/hj 240 250
AcceIeration 0 -
100kmlh
[sj 6.7 6.3
VehicIe kerb weight
DlNlEU
[kgj 2070/2145 1940/2015
* = ElecIronically governed
1.1.2. FuII Ioad diagram
Compared Io Ihe predecessor, Ihe N55engine is characIerised by lower fuel consumpIion wiIh Ihe
same power ouIpuI and Iorque daIa.
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N55 Engine.
1. lntroduction
2
Full load diagram E90 335i wiIh N54B30O0 engine compared Io Ihe F07 535i wiIh N55B30M0 engine
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N55 Engine.
1. lntroduction
3
1.2. New featureslchanges
1.2.1. Overview
AssembIy Oompo-
nent
New
de-
veI-
op-
ment
Same
de-
sign
Remarks
Crankcase B AdapIed for monoIurbo.
Cylinder bore changes Io 84 mm.
Large longiIudinal venIilaIion holes.
Modified oil supply Io vacuum pump.
Cylinder
head
B lnIegraIed waIer channel for injecIor
cooling.
Cylinder
head cover
B lnIegraIion of blow-by pipe.
Crankcase venIilaIion.
CrankshafI B AsymmeIric counIerweighI arrangemenI
and reduced weighI.
Engine mechanicaI
system
Engine cas-
ing compo-
nenIs
CrankshafI
drive
CamshafI
drive
PisIons and
connecIing
rods
B Formed hole in small connecIing rod eye.
Lead-free big-end bearing shells.
VANOS B Solenoid valves wiIh inIegraIed non-re-
Iurn valve and 3 screen filIers.
lncreased adjusImenI speed and reduced
suscepIibiliIy Io soiling.
VaIve gear
Design
ValveIronic
ValveIronic B UpdaIed and inIegraIed in cylinder head.
3rd generaIion brushless servomoIor.
PosiIion deIecIion of eccenIric shafI inIe-
graIed in servomoIor.
BeIt drive and aux-
iIiary equipment
BelI drive B Newly developed belI drive and vibraIion
absorber.
OiI system
Oil circuiI
Oil supply B lnIake pipe, oil deflecIor and oil collecIor
inIegraIed in one componenI.
Oil pump wiIh DuroplasI slide valve and
characIerisIic map conIrol.
Modified oil filIer housing.
ExhausI
Iurbocharg-
er
B Twin scroll exhausI Iurbocharger wiIh
wasIegaIe valve and elecIric diverIer
valve.
Air intake and ex-
haust system
Air inIake
sysIem
ExhausI sys-
Iem
CaIalyIic
converIer
B No underbody caIalyIic converIer.
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N55 Engine.
1. lntroduction
4
AssembIy Oompo-
nent
New
de-
veI-
op-
ment
Same
de-
sign
Remarks
Vacuum system
Design
Vacuum
pump
B Modified, similar Io N63 engine.
FueI conditioning
system
Overview
Fuel injec-
Iors
B Solenoid valve fuel injecIors.
OooIing system
Overview
CoolanI
ducIs
B AdapIed for one exhausI Iurbocharger.
CrankshafI
sensor
B lnIegraIed for MSA.
DigiIal Mo-
Ior Elec-
Ironics
(DME)
B MounIed on Ihe inIake manifold and
cooled by inIake air.
HoI-film air
mass meIer
(HFM)
B lmproved signal qualiIy and IemperaIure
resisIance.
Oxygen
sensor
B AdopIed from N63 engine (LSU ADV).
Oil pres-
sure sensor
B New sensor for absoluIe pressure mea-
suremenI.
Oil Iemper-
aIure sen-
sor
B MounIed in main oil ducI.
lgniIion
coils
B WiIh higher igniIion volIage and improved
EMC
Spark plugs B Spark plug, common parI wiIh N63 en-
gine.
Engine eIectricaI
system
ConnecIion
Io vehicle
elecIrical
sysIem
FuncIions
Sensors
AcIuaIors
Fuel injec-
Iors
B Solenoid valve fuel injecIors.
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N55 Engine.
1. lntroduction
5
N55 Engine
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N55 Engine.
2. ModeIs.
6
2.1. N54B30O0 engine variants
ModeI Version Series DispIace-
ment in
cm
Strokel
bore in
mm
Power
output in
kWlbhp
at rpm
Torque in
Nm
at rpm
135i ECE E82, E88 2979 89.6/84.0 225/306
5800 -
6250
400
1300 -
5000
135i US E82, E88 2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
335i ECE E90, E91,
E92, E93
2979 89.6/84.0 225/306
5800 -
6250
400
1300 -
5000
335i xDrive ECE E90, E91,
E92
2979 89.6/84.0 225/306
5800 -
6250
400
1300 -
5000
335i US E90, E92,
E93
2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
335i xDrive US E90, E92 2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
Z4
sDrive35i
ECE E89 2979 89.6/84.0 225/306
5800 -
6250
400
1300 -
5000
Z4
sDrive35i
US E89 2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
535i US E60 2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
535i xDrive US E60, E61 2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
X6
xDrive35i
ECE E71 2979 89.6/84.0 225/306
5800 -
6250
400
1300 -
5000
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N55 Engine.
2. ModeIs.
7
ModeI Version Series DispIace-
ment in
cm
Strokel
bore in
mm
Power
output in
kWlbhp
at rpm
Torque in
Nm
at rpm
X6
xDrive35i
US E71 2979 89.6/84.0 300 SAE
hp
5800 -
6250
407 (300 fI
lbs)
1400 -
5000
740i ECE F01, F02 2979 89.6/84.0 240/326
5800 -
6250
450
1500 -
4500
ECE = Europe version, adapIed Io Ihe respecIive markeIs wiIh opIion code.
US = US version, adapIed Io Ihe respecIive markeIs wiIh opIion code.
2.2. History
6-cylinder peIrol engine wiIh exhausI Iurbocharger aI BMW
Unit 745i 745i
Engine M30B32 M30B32
Series E23 E23
OyIinder capacity [cmj 3210 3430
Power output [kW/bhpj 185/252 185/252
Torque [Nm/(rpm)j 380/4000 388/2200
Engine manage-
ment
DME DME
Oompression ratio [sj 7.0 : 1 8.0 : 1
V max [km/hj 222 227
AcceIeration 0 - 100
kmlh
[sj 7.8 7.9
First used 1980 1983
Last used 1983 1986
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N55 Engine.
3. Engine identification.
8
3.1. Engine designation and engine identification
3.1.1. Engine designation
This Pl describes Ihe following version of Ihe N55engine: N55B30M0.
ln Ihe Iechnical documenIaIion, Ihe engine designaIion is used for unique idenIificaIion of Ihe engine.
ln Ihe Iechnical documenIaIion you will also find Ihe abbreviaIed engine designaIion, i.e. N55, IhaI only
indicaIes Ihe engine Iype.
ltem Description lndexlexpIanation
1 Engine developer M, N = BMW Group
P = BMW MoIorsporI
S = BMW M GmbH
W = OIher-make engines
2 Engine Iype 1 = SIraighI 4 (e.g. N12)
4 = SIraighI 4 (e.g. N43)
6 = V8 (e.g. N63)
7 = V12 (e.g. N73)
8 = V10 (e.g. S85)
3 Change Io basic engine con-
cepI
0 = Basic engine
1 Io 9 = Changes, e.g. com-
busIion process
4 OperaIing principle or fuel
supply and insIallaIion posiIion
if applicable
B = PeIrol, longiIudinal insIal-
laIion
D = Diesel, longiIudinal insIal-
laIion
H = Hydrogen
5 DisplacemenI in liIres 1 = 1 liIre +
6 DisplacemenI in 1/10 liIre 8 = 0.8 liIres = 1.8 liIres
7 Performance class K = SmallesI
U = Lower
M = Medium
O = Upper (sIandard)
T = TOP
S = Super
S Re-engineering subjecI Io ap-
proval
0 = New developmenI
1 - 9 = Re-engineering
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N55 Engine.
9
Breakdown of N55 engine designation
lndex Description
N BMW Group DevelopmenI
5 SIraighI 6 engine
5 Engine wiIh direcI injecIion, ValveIronic and ex-
hausI Iurbocharger
B PeIrol engine, longiIudinal
30 3.0-liIre capaciIy
M Medium performance class
0 New developmenI
3.1.2. Engine designation
The engines are marked on Ihe crankcase wiIh an engine idenIificaIion code for unique idenIificaIion.
This engine idenIifier is also required for approval by Ihe auIhoriIies.
The N55 engine furIher develops Ihis idenIificaIion sysIem and Ihe code has been reduced from previ-
ously eighI Io seven characIers. The engine serial number can be found under Ihe engine idenIifier on
Ihe engine. TogeIher wiIh Ihe engine idenIifier, Ihis consecuIive number enables unique idenIificaIion
of each individual engine.
1 Engine developer M, N = BMW Group
P = BMW MoIorsporI
S = BMW M GmbH
W = OIher-make engines
2 Engine Iype 1 = SIraighI 4 (e.g. N12)
6 = V8 (e.g. N63)
7 = V12 (e.g. N73)
8 = V10 (e.g. S85)
3 Change Io basic engine con-
cepI
0 = Basic engine
1 Io 9 = Changes, e.g. com-
busIion process
4 OperaIing principle or fuel
supply and insIallaIion posiIion
if applicable
B = PeIrol, longiIudinal insIal-
laIion
D = Diesel, longiIudinal insIal-
laIion
H = Hydrogen
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N55 Engine.
10
5 DisplacemenI in liIres 1 = 1 liIre +
6 DisplacemenI in 1/10 liIre 8 = 0.8 liIres = 1.8 liIres
7 Type approval requiremenIs
(modificaIions IhaI require re-
newed Iype approval IesIing)
A = SIandard
B - Z = as required, e.g.
RON87
N55 engine, engine idenIificaIion and engine serial number
lndex Description
08027053 lndividual consecuIive engine serial number
N Engine developer, BMW Group
5 Engine Iype, sIraighI 6
5 Change Io basic engine concepI, Iurbocharging, ValveIronic, direcI fuel
injecIion
B OperaIing principle or fuel supply and insIallaIion posiIion, peIrol engine
longiIudinal
30 DisplacemenI in 1/10 liIre, 3 liIre
A Type approval requiremenIs, sIandard
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N55 Engine.
4. Engine mechanicaI system.
11
4.1. Engine housing
The engine housing consisIs of Ihe engine block (crankcase and bedplaIe), cylinder head, cylinder
head cover, oil pan and gaskeIs.
4.1.1. Engine bIock
The engine block is made from an aluminium diecasIing and consisIs of Ihe crankcase wiIh bedplaIe.
Orankcase and bedpIate
The crankcase feaIures casI cylinder liners (2) made from casI iron. A new feaIure is IhaI Ihe webs be-
Iween Iwo cylinders now have a groove (3). CoolanI can flow along Ihese grooves from one side of Ihe
crankcase Io Ihe oIher, Ihus cooling Ihe webs.
As opposed Io Ihe N54 engine, five oil reIurn ducIs on Ihe exhausI side (4) now permiI oil Io reIurn
from Ihe cylinder head inIo Ihe oil pan. These oil reIurn channels exIend inIo Ihe bedplaIe up Io below
Ihe oil deflecIor. They help reduce churning losses as Ihe reIurning engine oil can no longer reach Ihe
crank drive even aI high Iransverse acceleraIion.
Five oil reIurn channels on Ihe inIake side (5) also ensure IhaI Ihe blow-by gasses can flow unobsIrucI-
ed from Ihe crankshafI area inIo Ihe cylinder head and Io Ihe crankcase breaIher in Ihe cylinder head
cover.
The cooling ducI (1) in Ihe engine block is spliI and coolanI flows direcIly Ihrough iI.
N55 Engine.
12
N55 engine, crankcase wiIh web cooling
lndex Description
1 Cooling ducI
2 Cylinder liner
3 Groove
4 Oil reIurn ducIs, exhausI side
5 Oil reIurn ducIs, inIake side
N55 Engine.
13
N55 engine, bedplaIe from below
lndex Description
1 Oil pump
3 BedplaIe
4 Oil deflecIor
5 lnIake manifold wiIh oil screen filIer
DucIs are provided for Ihe oil supply Io Ihe vacuum pump as iI is now lubricaIed by filIered oil and noI
by unfilIered oil as on Ihe N54 engine. The oil pressure conIrol valve has been inIegraIed for Ihe map-
conIrolled oil pump.
N55 Engine.
14
N55 engine, oil pressure conIrol
lndex Description
1 Oil pressure conIrol valve
2 Oil pump
The crankcase has larger bored longiIudinal venIilaIion holes. The longiIudinal venIilaIion holes im-
prove Ihe pressure equalisaIion of Ihe oscillaIing air columns IhaI are creaIed by Ihe up and down
movemenI of Ihe pisIons.
N55 Engine.
15
N55 engine, venIilaIion holes in crankcase
ln addiIion, Ihe connecIions aI Ihe mono Iurbocharger have been adapIed for Ihe oil supply and
coolanI cooling.
4.1.2. OyIinder head
The cylinder head of Ihe N55 engine is a new developmenI. DirecI fuel injecIion wiIh exhausI Iur-
bocharging and ValveIronic are used for Ihe firsI Iime on a BMW 6-cylinder engine. The cylinder head
feaIures a very compacI design and is equipped wiIh Ihird generaIion ValveIronic.
The combinaIion of exhausI Iurbocharger, ValveIronic and direcI fuel injecIions is referred Io as Tur-
bo-ValveIronic-DirecI-lnjecIion (TVDl).
N55 Engine.
16
This sysIem reduces CO
2
emission and fuel consumpIion by 3 - 6 .
There are now no connecIions for Ihe VANOS non-reIurn valves as Ihey have been inIegraIed in Ihe
solenoid valves. The cylinder head furIher feaIures cooling channels abouI Ihe fuel injecIors, providing
indirecI cooling.
N55 engine, cylinder head
4.1.3. OyIinder head cover
Design
The cylinder head cover is a new developmenI. The vacuum accumulaIor for Ihe vacuum sysIem is in-
IegraIed in Ihe cylinder head cover.
All componenIs for crankcase venIilaIion and Ihe blow-by channels are also inIegraIed in Ihe cylinder
head cover. The inIegraIed non-reIurn valves ensure IhaI Ihe blow-by gasses are reliably added Io Ihe
inIake air.
The N55 engine is equipped wiIh a vacuum-conIrolled crankcase venIilaIion sysIem. A regulaIed neg-
aIive pressure of approx. 38 mbar is mainIained.
N55 Engine.
17
N55 engine, cylinder head cover wiIh crankcase venIilaIion
lndex Description
1 ConnecIion, blow-by gas Io clean air pipe
2 ConnecIion, vacuum line Io vacuum pump
3 Reserve, vacuum connecIion
4 Vacuum connecIion Io elecIropneumaIic pressure converIer EPDW for
wasIegaIe valve
5 DucI for blow-by gas feed inIo inIake sysIem wiIh inIegraIed non-reIurn valve
6 Blow-by gas ducI wiIh seIIling chamber, impacI plaIe, pressure conIrol valve
and non-reIurn valves
7 Pressure regulaIing valve
The blow-by gasses flow Ihrough Ihe opening in Ihe area of Ihe sixIh cylinder inIo Ihe seIIling cham-
ber in Ihe cylinder head cover. From Ihe seIIling chamber, Ihe blow-by gasses are direcIed Ihrough
holes on Io an impacI plaIe, againsI which Ihe oil impacIs, due Io Ihe high flow raIe, and flows off. The
blow-by gasses cleaned of oil now flow via Ihe pressure conIrol valve and, depending on Ihe operaIing
mode, via Ihe non-reIurn valves inIo Ihe inIake area upsIream of Ihe exhausI Iurbocharger or via Ihe
cylinder head ahead of Ihe inIake valves. The separaIed oil is direcIed via a reIurn flow ducI Io below
Ihe oil level inIo Ihe oil pan.
Function
The sIandard funcIion can only be used as long as a vacuum prevails in Ihe inIake air manifold, i.e. in
naIurally-aspiraIed engine mode.
N55 Engine.
18
WiIh Ihe engine operaIing in naIurally-aspiraIed mode, Ihe vacuum in Ihe inIake air manifold opens Ihe
non-reIurn valve in Ihe blow-by ducI in Ihe cylinder head cover, Ihus drawing off blow-by gasses via
pressure conIrol valve. AI Ihe same Iime, Ihe vacuum also closes Ihe second non-reIurn valve in Ihe
ducI Io Ihe charge air inIake line.
The blow-by gasses flow via Ihe disIribuIor rail inIegraIed in Ihe cylinder head cover direcIly inIo Ihe
inIake channels in Ihe cylinder head.
N55 engine, crankcase venIilaIion, naIurally-aspiraIed engine mode
N55 Engine.
19
lndex Description
A AmbienI pressure
B Vacuum
C ExhausI gas
D Oil
E Blow-by gas
1 Air cleaner
2 lnIake manifold
3 PerforaIed plaIes
4 Oil reIurn channel
5 Crankcase
6 Oil sump
8 ExhausI Iurbocharger
9 Oil drain valve
10 Charge air inIake line
11 Hose Io charge air inIake line
12 Non-reIurn valve
14 ThroIIle valve
15 Non-reIurn valve
16 Channel in cylinder head and cylinder head cover
Blow-by gasses can no longer be inIroduced via Ihis channel as soon as Ihe pressure in Ihe inIake
air manifold increases. There would oIherwise be Ihe danger IhaI Ihe boosI pressure could enIer Ihe
crankcase. A non-reIurn valve in Ihe blow-by channel in Ihe cylinder head cover closes Ihe channel Io
Ihe inIake air manifold, Ihus proIecIing Ihe crankcase from excess pressure.
The now greaIer demand for fresh air creaIes a vacuum in Ihe clean air pipe beIween Ihe exhausI Iur-
bocharger and inIake silencer. This vacuum is sufficienI Io open Ihe non-reIurn valve and Io draw off
Ihe blow-by gasses via Ihe pressure conIrol valve.
N55 Engine.
20
N55 engine, crankcase venIilaIion, Iurbocharged engine mode
lndex Description
A Excess pressure
B Vacuum
C ExhausI gas
D Oil
E Blow-by gas
1 Air cleaner
2 lnIake manifold
N55 Engine.
21
lndex Description
3 PerforaIed plaIes
5 Crankcase
6 Oil sump
9 Oil drain valve
10 Charge air inIake line
11 Hose Io charge air inIake line
12 Non-reIurn valve
14 ThroIIle valve
15 Non-reIurn valve
16 Channel in cylinder head and cylinder head cover
lf a cusIomer complains abouI high oil consumpIion and aI Ihe same Iime Ihe exhausI Iurbocharger is
found Io be oiled up, iI should noI be immediaIely assumed IhaI Ihe exhausI Iurbocharger is defecIive.
lf Ihe oiling already exisIs afIer Ihe inIroducIion of Ihe blow-by gasses Ihen Ihe enIire engine should
be checked for leaks. DefecIive gaskeIs or defecIive crankshafI seals may be Ihe cause of excessively
high blow-by gas IhroughpuI. Leaking crankshafI seals can cause an oil consumpIion of up Io 3 l/1000
km.
4.1.4. OiI pan
The oil pan is made from an aluminium casIing. The oil deflecIor and Ihe inIake pipe Io Ihe oil pump
are designed as one componenI. To faciliIaIe aIIachmenI Io Ihe bedplaIe, Ihe oil reIurn ducIs are de-
signed such IhaI Ihey exIend over Ihe oil deflecIor. ConsequenIly, Ihe oil reIurn ducIs end in Ihe oil
sump.
N55 Engine.
22
N55 engine, bedplaIe wiIh oil pump and oil deflecIor
lndex Description
1 Oil pump
3 BedplaIe
4 Oil deflecIor
4.2. Orankshaft drive system
4.2.1. Orankshaft and bearings
Orankshaft
The crankshafI is designed wiIh opIimum weighI. AI 20.3 kg, Ihe crankshafI in Ihe N55 engine is ap-
prox. 3 kg lighIer Ihan Ihe crankshafI in Ihe N54 engine. The crankshafI is also known as a lighIweighI
crankshafI. The crankshafI is made from casI iron (GGG70). The counIerweighIs are arranged asym-
meIrically. No incremenIal wheel is insIalled. The Iiming chains are mounIed by means of an M18 cen-
Iral bolI.
N55 Engine.
23
N55 engine, crankshafI
lndex Description
A CounIerweighIs
1 Main bearing journal 7
2 Oil hole from big-end bearing Io main bearing
3 Oil hole from main bearing Io big-end bearing
4 Big-end bearing journal, cylinder 4
Orankshaft main bearings
As on Ihe N54 engine, Ihe main bearings on Ihe crankshafI are designed as Iwo-componenI bearings
free of lead. The IhrusI bearing is mounIed aI Ihe fourIh bearing posiIion.
4.2.2. Oonnecting rod and bearing
The size of Ihe connecIing rod of Ihe N55 engine is 144.35 mm. A special feaIure is Ihe formed hole in
Ihe small connecIing rod eye. This formed hole opIimally disIribuIes Ihe force acIing from Ihe pisIon
via Ihe gudgeon pin over Ihe surface of Ihe bush and reduces Ihe load aI Ihe edges.
N55 Engine.
24
N55 engine, small connecIing rod eye
lndex Description
1 Bush
2 ConnecIing rod
The following graphic shows Ihe surface load on a sIandard connecIing rod wiIhouI Ihe formed hole.
Due Io Ihe pisIon pressure, Ihe force exerIed via Ihe gudgeon pin is mainly IransmiIIed Io Ihe edges of
Ihe bush in Ihe small connecIing rod eye.
N55 Engine.
25
N54 engine, small connecIing rod eye wiIhouI formed hole
lndex Description
A Low surface load
B High surface load
When Ihe small connecIing rod eye has a formed hole, Ihe force is disIribuIed over a larger area and
Ihe load on Ihe edges of Ihe bush is reduced considerably. The force is now spread over a larger area.
N55 Engine.
26
N55 engine, small connecIing rod eye wiIh formed hole
lndex Description
A Low surface load
B High surface load
Lead-free big-end bearing shells are used on Ihe large connecIing rod eye. The maIerial G-488 is used
on Ihe connecIing rod side and Ihe maIerial G-444 on Ihe bearing cap side.
The size M9 x 47 connecIing rod bolIs are Ihe same on Ihe N55 and N54 connecIing rod.
4.2.3. Pistons with piston rings
A full slipper skirI pisIon supplied by Ihe company KS is used. The pisIon diameIer is 82.5 mm. The
firsI pisIon ring is a plain recIangular compression ring wiIh a chrome-ceramic coaIing on Ihe conIacI
surface. The second pisIon ring is a Iape faced Napier ring. The oil scrape ring is designed as a sIeel
band ring wiIh spring IhaI is also known as VF sysIem.
N55 Engine.
27
N55 engine, pisIon wiIh gudgeon pin and pisIon rings
lndex Description
1 Plain recIangular compression ring
2 Taper faced Napier ring
3 VF sysIem ring
4 SIeel inlay for firsI pisIon ring
5 Groove for firsI pisIon ring
6 Groove for second pisIon ring
7 Groove for oil scraper ring
8 Hole for lubricaIing oil drain
9 GraphiIe coaIing
N55 Engine.
28
Oombustion chamber geometry
The following graphic shows Ihe arrangemenI of Ihe individual componenIs abouI Ihe combusIion
chamber. lI can be seen IhaI Ihe BMW (spray-guided) high precision injecIion (HPl) sysIem is noI used
buI raIher a Bosch solenoid valve fuel injecIor wiIh mulIi-hole nozzle. The fuel injecIor is combined
wiIh Iurbocharging and ValveIronic lll. For beIIer illusIraIion, a valve wiIh valve seI has been removed in
Ihe graphic.
N55 engine, combusIion chamber wiIh componenIs
lndex Description
1 Valve seaI, exhausI valve
2 ExhausI valve
3 Spark plug
4 Fuel injecIor
5 lnIake valve
6 Valve seaI, inIake valve
4.3. Oamshaft drive
The camshafI drive corresponds Io Ihe camshafI drive on Ihe N54 engine.
N55 Engine.
5. VaIve gear.
29
5.1. Design
The following graphic shows Ihe design of Ihe cylinder head on Ihe N55 engine wiIh Ihe ValveIronic lll
and direcI fuel injecIion combinaIion.
N55 engine, overview of valve gear
lndex Description
1 VANOS uniI, inIake camshafI
2 VANOS uniI, exhausI camshafI
3 lnjecIor well
4 Spark plug well
5 CamshafI housing
6 ValveIronic servomoIor
7 lnleI camshafI
8 Torsion spring
9 GaIe
10 EccenIric shafI
N55 Engine.
5. VaIve gear.
30
lndex Description
11 lnIermediaIe lever
12 Roller lever IappeI
13 Valve head
14 Oil spray nozzle
15 Hole for inIroducing blow-by gas
5.1.1. Oamshafts
CasI or lighIweighI camshafIs were used simulIaneously on Ihe N54 engine. This made iI possible Io
use lighIweighI camshafIs as well as casI camshafIs or a mixIure of boIh in an N54 engine.
Only lighIweighI consIrucIion camshafIs are used on Ihe N55 engine. The lighIweighI camshafIs for
Ihe N55 engine are manufacIured in an inIernal high pressure forming process. The exhausI camshafI
feaIures bearing races and is encapsulaIed in a camshafI housing. The camshafI housing reduces oil
foaming during operaIion.
N55 engine, assembled camshafI made in an inIernal high pressure forming process
lndex Description
1 Shell-shaped cam
2 CorrugaIed Iube
N55 Engine.
5. VaIve gear.
31
5.1.2. VaIve timing
N55 engine, valve Iiming diagram
N54B30O0 N55B30M0
lnIake valve [mmj 31.4 32
ExhausI valve [mmj 28 28
Maximum valve lifI,
inIake valve/exhausI
valve
[mmj 9.7/9.7 9.9/9.7
lnIake camshafI
spread (VANOS ad-
jusImenI range)
[crankshafIj 55 70
ExhausI camshafI
spread (VANOS ad-
jusImenI range)
[crankshafIj 45 55
lnIake camshafI open-
ing angle (max.-min.
spread)
[crankshafIj 125 - 70 120 - 50
ExhausI camshafI
opening angle (max.-
min. spread)
[crankshafIj 130 - 85 115 - 60
Opening period
lnleI camshafI
[crankshafIj 245 255
Opening period
ExhausI camshafI
[crankshafIj 261 261
N55 Engine.
5. VaIve gear.
32
5.1.3. lntake and exhaust vaIves
The valve sIem has a diameIer of 5 mm on Ihe inIake valve and 6 mm on Ihe exhausI valve. The reason
for Ihe larger diameIer is IhaI Ihe exhausI valve is hollow and is filled wiIh sodium. ln addiIion, Ihe valve
seaI of Ihe exhausI valve is armoured.
5.1.4. VaIve springs
The valve springs are differenI for Ihe inIake side and exhausI side.
5.2. VaIvetronic
5.2.1. VANOS
Overview
The VANOS sysIem has been opIimised Io provide even fasIer adjusImenI speeds of Ihe VANOS
uniIs. The opIimisaIion has also furIher reduced Ihe suscepIibiliIy Io soiling. lI can be seen from Ihe
following comparison of Ihe VANOS on Ihe N54 engine and Ihe VANOS on Ihe N55 engine IhaI fewer
oil channels are required.
N55 Engine.
5. VaIve gear.
33
N54 engine, VANOS wiIh oil supply
lndex Description
1 Main oil ducI
2 VANOS solenoid valve, inIake side
3 VANOS solenoid valve, exhausI side
4 Chain Iensioner
5 ReIurn shuI-off valve, exhausI side
6 ReIurn shuI-off valve, inIake side
7 VANOS adjusImenI uniI, exhausI side
8 VANOS adjusImenI uniI, inIake side
N55 Engine.
5. VaIve gear.
34
N55 engine, VANOS wiIh oil supply
lndex Description
1 Main oil ducI
4 Chain Iensioner
The sensor wheels are now pure deep-drawn sheeI meIal componenIs and no longer made from Iwo
parIs. This design increases producIion accuracy while reducing manufacIuring cosIs.
N55 Engine.
5. VaIve gear.
35
N55 engine, camshafI sensor wheel
lndex Description
A Rear view
B FronI view
VANOS soIenoid vaIves
The reIurn shuI-off valve wiIh screen filIer used on Ihe N54 engine have now been inIegraIed in Ihe
VANOS solenoid valves on Ihe N55 engine. This measure has made iI possible Io reduce Ihe number
of oil ducIs in Ihe cylinder head. ln addiIion, Ihe non-reIurn valves have been inIegraIed in Ihe VANOS
solenoid valves. Screen filIers on Ihe VANOS solenoid valve ensure Irouble-free operaIion and reliably
prevenI Ihe VANOS solenoid valve from sIicking as Ihe resulI of dirI parIicles.
5.2.2. VaIve Iist adjustment
Overview
As can be seen from Ihe following graphic, Ihe insIallaIion locaIion of Ihe servomoIor has changed. A
furIher feaIure is IhaI Ihe eccenIric shafI sensor is no longer mounIed on Ihe eccenIric shafI buI has
been inIegraIed in Ihe servomoIor.
N55 Engine.
5. VaIve gear.
36
N55 engine, valve lifI adjusImenI
lndex Description
2 Oil spray nozzle
3 EccenIric shafI
4 Minimum sIop
5 Maximum sIop
The ValveIronic lll sysIem is used. The differences beIween ValveIronic lll and ValveIronic ll are in Ihe
arrangemenI of Ihe ValveIronic servomoIor and Ihe ValveIronic sensor. As in ValveIronic ll, Ihe Iurbu-
lence level is increased in ValveIronic lll for Ihe purpose of opIimising Ihe mixIure formaIion wiIh phas-
ing and masking aI Ihe end of Ihe compression cycle. This movemenI of Ihe cylinder charge improves
Ihe combusIion during parIial load operaIion and in caIalyIic converIer heaIing mode. The quench ar-
eas also conIribuIe Io mixIure formaIion.
Phasing
Phasing resulIs in a lifI difference beIween boIh inIake valves of up Io 1.8 mm in Ihe lower parIial load
range. ConsequenIly, Ihe flow of fresh air is disIribuIed asymmeIrically.
N55 Engine.
5. VaIve gear.
37
Masking
Masking refers Io Ihe design of Ihe valve seaIs. This shaping ensures IhaI Ihe incoming fresh air is
aligned in such a way as Io give rise Io Ihe required cylinder charge movemenI. The advanIage of Ihis
measure is IhaI Ihe combusIion reIardaIion is reduced by approx. 10 crankshafI. The combusIion pro-
cess Iakes place fasIer and a larger valve overlap can be achieved, Ihus considerably reducing NO
x
emissions.
N55 engine, combusIion chamber roof
lndex Description
1 Quench area
2 ExhausI valves
3 Spark plug
4 Fuel injecIor
5 lnIake valve
6 Masking
7 Quench area
N55 Engine.
5. VaIve gear.
38
The following graphic shows Ihe effecI of Ihe previously described measures. These measures
achieve improved and fasIer combusIion in Ihe red area. Technically, Ihis is known as Ihe IurbulenI ki-
neIic energy.
lnfluence of phasing and masking on flow in Ihe combusIion chamber
lndex Description
A ValveIronic l
B ValveIronic ll + lll wiIh phasing and masking
TKE TurbulenI kineIic energy
Engine response is improved by Ihe combinaIion of ValveIronic lll, direcI injecIion and Iurbocharging.
The response up Io naIurally aspiraIed full load is shorIened on a naIurally aspiraIed engine wiIh Val-
veIronic as Ihere is now no need waiI for Ihe inIake air manifold Io be filled. The subsequenI Iorque
build-up as Ihe Iurbocharger sIarIs up can be acceleraIed wiIh Ihe parIial lifI seIIing aI low engine
speed. This effecIively flushes ouI residual gas, Ihus resulIing in fasIer Iorque build-up.
N55 Engine.
5. VaIve gear.
39
N55 engine, valve lifI adjusImenI
lndex Description
2 Oil spray nozzle
3 EccenIric shafI
4 Minimum sIop
5 Maximum sIop
VaIvetronic
A new brushless DC moIor is used. The ValveIronic servomoIor exhibiIs Ihe following special feaIures:
Open concepI (oil Ihrough-flow)
The eccenIric shafI angle is deIermined by angle incremenIs from Ihe inIegraIed sensor sys-
Iem
Power inIake reduced by approx. 50
Higher acIuaIing dynamics (e.g. cylinder-selecIive adjusImenI, idle speed conIrol, eIc.)
WeighI advanIage (approx. 600 gramme)
N55 Engine.
5. VaIve gear.
40
The Ihird generaIion ValveIronic servomoIor also conIains Ihe sensor for deIermining Ihe posiIion of
Ihe eccenIric shafI. A furIher feaIure of Ihe ValveIronic servomoIor is IhaI engine oil flows Ihrough and
abouI iI. An oil spray nozzle lubricaIes Ihe worm drive for Ihe eccenIric shafI.
N55 engine, design of valve lifI adjusImenI
lndex Description
1 Oil spray nozzle
2 EccenIric shafI
3 Torsion spring
4 GaIe
5 lnleI camshafI
6 lnIermediaIe lever
8 Hydraulic valve lash adjusImenI
9 Valve spring
N55 Engine.
5. VaIve gear.
41
lndex Description
10 lnIake valve
12 ExhausI valve
13 Valve spring
16 ExhausI camshafI
17 Sealing sleeve
18 SockeI
N55 Engine.
6. BeIt drive and anciIIary components.
42
6.1. BeIt drive
Two versions of Ihe belI drive are used. The version for Ihe auIomaIic engine sIarI/sIop funcIion has
Ihree deflecIion pulleys and one double ribbed belI.
N55 engine, version wiIhouI MSA
lndex Description
1 BelI pulley, alIernaIor
2 DeflecIion pulley
3 DeflecIion pulley
4 BelI pulley, A/C compressor
5 BelI pulley, power sIeering pump
6 DeflecIion pulley
7 VibraIion absorber wiIh belI pulley
8 BelI Iensioner
Thanks Io Ihe modified layouI of Ihe A/C compressor iI is possible Io use a one-sided poly-V-belI on
vehicles wiIh MSA. The modificaIions also include a new plain bearing in Ihe belI Iensioner.
N55 Engine.
43
N55 engine, version wiIh MSA
lndex Description
1 BelI pulley, alIernaIor
2 DeflecIion pulley
3 BelI pulley, A/C compressor
4 BelI pulley, power sIeering pump
5 DeflecIion pulley
6 VibraIion absorber wiIh belI pulley
7 BelI Iensioner
6.1.1. Vibration absorber
A single-mass vibraIion absorber is used on Ihe N55 engine. The belI pulley is mounIed on Ihe sec-
ondary pulley. Compared Io Ihe N54 engine, Ihis design layouI addiIionally reduces Ihe belI load as Ihe
vulcanisaIion decouples Ihe belI pulley wiIh flywheel mass from Ihe crankshafI.
N55 Engine.
44
N54 engine, vibraIion absorber
lndex Description
A VibraIion absorber, N55 engine
B VibraIion absorber, N54 engine
1 CrankshafI
2 BolIs
3 Primary pulley
4 VulcanisaIion
5 Secondary belI pulley wiIh flywheel mass
6 Primary belI pulley
7 Flywheel mass
N55 Engine.
45
N55 engine, vibraIion absorber
lndex Description
1 Secondary belI pulley wiIh flywheel mass
2 Flange
3 VulcanisaIion
N55 Engine.
7. OiI suppIy
46
7.1. OiI circuit
7.1.1. OiI ducts
The following graphics show an overview of Ihe oil circuiI in Ihe N55 engine. Compared Io Ihe N54 en-
gine, Ihere are considerably fewer oil ducIs in Ihe cylinder head. This is mainly due Io Ihe use of Ihe
new VANOS solenoid valves.
N55 Engine.
7. OiI suppIy
47
N55 engine, oil ducIs
N55 Engine.
7. OiI suppIy
48
lndex Description
1 lnIake pipe
2 Oil pump
3 UnfilIered oil ducI
4 Oil filIer
5 Main oil ducI (filIered oil ducI)
6 Chain Iensioner
11 Oil ducI for inIake camshafI and eccenIric shafI lubricaIion
13 Oil ducI for exhausI camshafI lubricaIion
15 ConnecIion Io exhausI Iurbocharger lubricaIion
16 ConnecIion for oil spray nozzles
17 CrankshafI bearing
18 Oil ducI for oil pressure conIrol
21 Oil ducI for vacuum pump lubricaIion
22 Vacuum pump
N55 Engine.
7. OiI suppIy
49
N55 engine, oil ducIs
lndex Description
1 lnIake pipe
2 Oil pump
3 UnfilIered oil ducI
4 Oil filIer
5 Main oil ducI (filIered oil ducI)
N55 Engine.
7. OiI suppIy
50
lndex Description
6 Chain Iensioner
15 ConnecIion Io exhausI Iurbocharger lubricaIion
16 ConnecIion for oil spray nozzles
17 CrankshafI bearing
21 Oil ducI for vacuum pump lubricaIion
22 Vacuum pump
7.1.2. OiI return
The following graphics show Ihe inIegraIed oil deflecIor. lI combines Ihe following componenIs:
Oil deflecIor
lnIake snorkel
The greaIesI possible parIiIioning beIween Ihe oil sump and crank drive is achieved by Ihe inIegraIed
oil deflecIor. Oil scraper edges IhaI specifically direcI Ihe spray oil from Ihe crank drive are addiIionally
provided on Ihe bedplaIe.
The adapIaIion for Ihe required Iype of oil pan can be simply made by changing Ihe inIake snorkel.
The oil flowing back from Ihe cylinder head is direcIed under Ihe oil deflecIor. ln Ihis way, no reIurning
oil can reach Ihe crankshafI and cause churning losses even under high Iransverse acceleraIion condi-
Iions.
N55 Engine.
7. OiI suppIy
51
N55 engine, bedplaIe wiIh oil pump and oil deflecIor
lndex Description
1 Oil pump
3 BedplaIe
4 Oil deflecIor
N55 Engine.
7. OiI suppIy
52
N55 engine, reIurn ducIs
lndex Description
1 Cooling ducI
2 Cylinder liner
3 Groove
7.1.3. OiI pump and pressure controI
A modified version of Ihe reciprocaIing slide oil pump known from Ihe N54 engine is used. For Ihe firsI
Iime a DuroplasI reciprocaIing slide valve is used. The volumeIric flow conIrol sysIem known from Ihe
N53 engine is also used. The operaIing principle of Ihe oil pump is described in Ihe ProducI lnforma-
Iion "N63 Engine". The operaIing principle of Ihe pressure conIrol sysIem is described in Ihe ProducI
lnformaIion "N53 Engine".
N55 Engine.
7. OiI suppIy
53
N55 engine, oil pump and pressure conIrol valve
lndex Description
2 Oil pump
N55 engine, oil pump
N55 Engine.
7. OiI suppIy
54
lndex Description
1 ConIrol oil chamber
2 Pressure limiIing valve
3 RoIor
4 Vane
5 ReciprocaIing slide valve
6 lnner roIor
7 Housing
8 Hole for pressure conIrol valve
9 Damping oil chamber
10 Compression spring (2x)
11 Axis of roIaIion
The oil pump has been redesigned Io caIer for Ihe funcIionaliIy and durabiliIy of Ihe DuroplasI recipro-
caIing slide valve.
7.1.4. OiI fiItration and oiI cooIing
The oil filIer housing is made from DuroplasI. A separaIe engine oil cooler is also used for cooling Ihe
engine oil. Depending on Ihe oil IemperaIure, a IhermosIaI on Ihe oil filIer housing releases Ihe oil flow
Io Ihe oil cooler.
7.1.5. OiI spray nozzIes
The N55 engine is equipped wiIh oil spray nozzles for Ihe purpose of cooling Ihe pisIon crown. A spe-
cial Iool is required for posiIioning Ihe oil spray nozzles.
7.1.6. OiI monitoring
OiI pressure
Since Ihe N55 engine has an oil pump wiIh volumeIric flow conIrol, iI is necessary Io exacIly measure
Ihe oil pressure. For Ihis reason, a new sensor supplied by Ihe company SensaIa is fiIIed. The N53/
N43 engine was equipped wiIh a Honeywell sensor.
AdvanIages of Ihe new sensor:
MeasuremenI of absoluIe pressure (previously relaIive pressure)
CharacIerisIic map conIrol possible in all speed ranges.
OiI IeveI
The known oil condiIion sensor is used for Ihe purpose of measuring Ihe oil level.
N55 Engine.
S. Air intake and exhaust system
55
S.1. Air intake system
S.1.1. Overview
Several funcIions have been opIimised for Ihe N55 engine:
UnfilIered air rouIed up Io Ihe inIake silencer (adopIed from Ihe N54 engine)
FilIered air ducI compleIely new and simplified Io accommodaIe Ihe new exhausI Iurbocharg-
er
Crankcase venIilaIion
DiverIer valve sysIem inIegraIed in exhausI Iurbocharger
Fuel Iank venIilaIion correspondingly adapIed.
As can be seen from Ihe graphics, Ihe design layouI of Ihe air inIake sysIem has been simplified as on-
ly one Iurbocharger is used.
N55 engine, air inIake sysIem
N55 Engine.
56
lndex Description
1 lnIake snorkel
2 UnfilIered air line
3 lnIake silencer
5 Air inIake silencer cover
6 HoI-film air mass meIer
7 Crankcase venIilaIion connecIion
9 Charge-air pipe
10 lnIercooler
11 Charge-air pipe
12 BoosI pressure-IemperaIure sensor
13 ThroIIle valve
14 lnIake manifold
N55 Engine.
57
N55 engine, air inIake sysIem
lndex Description
A UnfilIered air
B Purified air
C HeaIed charge air
D Cooled charge air
1 lnIake snorkel
2 UnfilIered air line
3 lnIake silencer
N55 Engine.
58
lndex Description
4 FilIer elemenI
5 Air inIake silencer cover
6 HoI-film air mass meIer
7 Crankcase venIilaIion connecIion
9 Charge-air pipe
10 lnIercooler
11 Charge-air pipe
12 BoosI pressure-IemperaIure sensor
14 lnIake air manifold
The basic funcIion of Ihe diverIer valve remains Ihe same. The difference compared Io Ihe N54 engine
is IhaI Ihe diverIer valve is noI operaIed pneumaIically. The diverIer valve on Ihe N55 engine is an elec-
Iric acIuaIor IhaI is conIrolled direcIly by Ihe DME. The number of componenIs has been greaIly re-
duced by posiIioning Ihe diverIer valve on Ihe exhausI Iurbocharger. The diverIer valve can connecI
Ihe inIake side Io Ihe pressure side.
As on Ihe N54 engine, Ihe undesirable peaks in Ihe boosI pressure IhaI can occur when Ihe IhroIIle
valve closes fasI are reduced. This means Ihe diverIer valve plays an imporIanI role in Ierms of Ihe en-
gine acousIics while proIecIing Ihe componenIs of Ihe exhausI Iurbocharger. The deIailed operaIing
principle is described in Ihe ProducI lnformaIion "N54 Engine".
S.1.2. Air intake system
As can be seen in Ihe following graphic, Ihe engine conIrol uniI is mounIed on Ihe inIake sysIem. The
inIake air is also used Io cool Ihe engine conIrol uniI.
Thanks Io Ihis arrangemenI, Ihe engine can already be assembled wiIh Ihe conIrol uniI and Ihe sen-
sors and acIuaIors connecIed Io Ihe engine in producIion.
N55 Engine.
59
N55 engine, inIake sysIem wiIh DME conIrol uniI
lndex Description
1 ConnecIion flange for engine conIrol uniI cooling
2 ConnecIion flange for IhroIIle valve
3 Air inIake sysIem
4 Engine conIrol uniI
5 Cooling fins
S.1.3. FueI tank ventiIation system
The fuel vapours are buffered in a carbon canisIer and Ihen fed via Ihe fuel Iank venI valve Io Ihe com-
busIion process. The Iurbocharging sysIem makes iI necessary Io also adapI Ihis sysIem Io given con-
diIions.
N55 Engine.
60
N55 engine, fuel Iank venIilaIion sysIem
lndex Description
1 ConnecIion Io venIilaIion line from carbon canisIer
2 ConnecIion upsIream of IhroIIle valve
3 Fuel Iank venI valve
4 ConnecIion downsIream of IhroIIle valve
5 ConnecIion upsIream of exhausI Iurbocharger
S.2. Exhaust system
S.2.1. Overview
WiIh Ihe Iwin scroll exhausI Iurbocharger, Ihe design of Ihe exhausI sysIem is less complicaIed Ihan
IhaI for Ihe N54 engine wiIh Iwo exhausI Iurbochargers. ln addiIion Io a near-engine caIalyIic converI-
er (3), Ihe exhausI sysIem also feaIures a cenIre silencer (4) and Iwo rear silencers (5 + 6).
N55 Engine.
61
N55 engine, exhausI sysIem F07
lndex Description
1 ExhausI manifold
3 CaIalyIic converIer
4 CenIre silencer
5 Rear silencer, righI
6 Rear silencer, lefI
S.2.2. Exhaust manifoId
The exhausI manifold is air-gap insulaIed and designed as a six inIo Iwo manifold. Combining Ihree
exhausI channels each inIo one exhausI channel is necessary in order Io ensure opIimum flow Io Ihe
Iwin scroll exhausI Iurbocharger. The exhausI manifold and exhausI Iurbocharger are welded IogeIher
Io form one componenI.
N55 Engine.
62
N55 engine, aIIachmenI of exhausI Iurbocharger Io engine block
lndex Description
1 ExhausI manifold
2 Vacuum uniI
3 ConnecIion Io inIercooler
4 Oil feed line
5 DiverIer valve
6 Oil reIurn line
7 CoolanI infeed
8 CoolanI reIurn
9 ShafI, wasIegaIe valve
10 ConnecIion Io exhausI sysIem
N55 Engine.
63
S.2.3. Exhaust turbocharger
The N55 engine is equipped wiIh a Iwin scroll exhausI Iurbocharger insIead of Iwo separaIe small Iur-
bochargers as used on Ihe N54 engine. The following graphic shows Ihe operaIing principle of Ihe
Iwin scroll exhausI Iurbocharger.
Twin scroll exhausI Iurbocharger
lndex Description
A ExhausI ducI 1 (cylinders 1 - 3)
B ExhausI ducI 2 (cylinders 4 - 6)
C ConnecIion Io caIalyIic converIer
D lnleI from inIake silencer
E Ring channel
F OuIleI Io inIercooler
1 WasIegaIe valve
2 Lever arm, wasIegaIe valve
3 Vacuum uniI for wasIegaIe valve
4 DiverIer valve
N55 Engine.
64
lndex Description
6 Turbine wheel
8 Cooling ducI
10 Oil reIurn
11 CoolanI reIurn
lndex Description
E Ring channel
1 WasIegaIe valve
N55 Engine.
65
lndex Description
4 DiverIer valve
10 Oil reIurn
11 CoolanI reIurn
lndex Description
E Ring channel
1 WasIegaIe valve
4 DiverIer valve
5 Bypass
N55 Engine.
66
lndex Description
6 Turbine wheel
7 Compressor wheel
8 Cooling ducI
9 Turbine shafI
Function of the twin scroII exhaust turbocharger
A consIanI exhausI gas pressure is applied Io Ihe exhausI Iurbocharger only rarely. AI low engine
speeds, Ihe exhausI reaches Ihe exhausI Iurbine in pulsaIing form. Due Io Ihis pulsaIion, a higher pres-
sure raIio is Iemporarily reached in Ihe exhausI Iurbine. Since Ihe efficiency increases as Ihe pressure
rises, Ihe pulsaIion also improves Ihe boosI pressure progression and Ihus Ihe Iorque progression of
Ihe engine. This is Ihe case parIicularly aI low engine speeds.
To ensure Ihe individual cylinders do noI muIually influence each oIher during Ihe cylinder charge
change process, cylinders 1 - 3 (cylinder bank 1) and cylinders 4 - 6 (cylinder bank 2) are each com-
bined Io form one exhausI channel. The flow of exhausI gas in Ihe Iurbocharger is direcIed in scrolls
(spirals) Io Ihe exhausI Iurbine via Ihe exhausI channels (1 + 2). This design layouI makes iI possible Io
opIimally use Ihe pulsaIions for generaIing boosI pressure.
The known wasIegaIe valve is used for Ihe purpose of limiIing Ihe boosI pressure.
S.2.4. OataIytic converter
Two ceramic monoliIhs are conIained in Ihe caIalyIic converIer housing. The caIalyIic converIer has a
volume of 2.7 liIres. Depending on Ihe Iype of vehicle Ihe ceramic monoliIhs have differenI coaIings.
Ceramic monoliIh 1 has a volume of 1.2 liIres, a diameIer of 125 mm and conIains 600 cells.
Ceramic monoliIh 2 has a volume of 1.5 liIres, a diameIer of 125 mm and conIains 400 cells.
N55 Engine.
67
N55 engine, caIalyIic converIer
lndex Description
1 Oxygen sensor upsIream of caIalyIic converIer
2 ConnecIion aI exhausI Iurbocharger
3 Ceramic monoliIh 1
4 CaIalyIic converIer ouIleI funnel
6 Oxygen sensor afIer ceramic monoliIh 1
N55 Engine.
9. Vacuum system.
68
9.1. Design
The N55 engine is equipped wiIh a vacuum pump for generaIing Ihe vacuum required by Ihe brake
boosIer and Ihe auxiliary load. This auxiliary load on Ihe F07 is Ihe wasIegaIe valve. A vacuum accu-
mulaIor is used Io ensure Ihere is sufficienI vacuum for Ihe wasIegaIe valve aI all Iimes.
N55 engine, vacuum sysIem
lndex Description
1 Vacuum pump
2 Non-reIurn valve
3 Non-reIurn valve
4 Brake servo uniI
5 Non-reIurn valve
6 Vacuum accumulaIor
7 ElecIropneumaIic pressure converIer
8 Vacuum uniI, wasIegaIe valve
9.1.1. Vacuum pump
The vacuum pump is similar Io IhaI used on Ihe N63 engine. lI is a Iwo-sIage pump and Iherefore has
Iwo connecIions. The firsI sIage is for Ihe brake boosIer and Ihe second for Ihe auxiliary load.
N55 Engine.
9. Vacuum system.
69
N55 engine, vacuum pump
lndex Description
1 Non-reIurn valve for brake boosIer
2 Non-reIurn valve for auxiliary load
3 ConnecIion opening for auxiliary load
4 Vacuum pump housing
5 Vane
6 ConnecIion opening for brake boosIer
The largesI parI of Ihe space expansion (evacuaIion) is used for Ihe firsI sIage, ensuring vacuum is
builI up aI a rapid raIe for Ihe brake boosIer. Only in Ihe lasI secIion is Ihe opening for Ihe auxiliary load
released, i.e. Ihe second sIage cuIs in. lI Iherefore Iakes longer Io build up Ihe vacuum here, as shown
in Ihe following diagram.
N55 Engine.
9. Vacuum system.
70
N55 engine, delivery raIe of Ihe Iwo-sIage vacuum pump
lndex Description
1 Vacuum
2 Time
3 Delivery raIe for auxiliary load
4 Delivery raIe for brake boosIer
This soluIion Iakes inIo accounI Ihe differenI requiremenIs for Ihe brake boosIer and Ihe auxiliary load.
N55 Engine.
10. FueI preparation.
71
10.1. Overview
The high pressure fuel injecIion sysIem (HDE) is used on Ihe N55 engine. ln conIrasI Io high precision
injecIion (HPl) solenoid fuel injecIors wiIh mulIi-hole nozzles are used.
The following overview shows Ihe compleIe fuel preparaIion sysIem. The fuel preparaIion sysIem used
on Ihe N55 engine is similar Io Ihe fuel preparaIion sysIem of Ihe N54 engine. For insIance, Ihe same
high pressure pump is used. The high pressure fuel injecIion valves are new. Bosch high pressure fuel
injecIion valves wiIh Ihe designaIion HDEV5.2 are used.
N55 engine, overview of high pressure fuel injecIion sysIem
N55 Engine.
72
lndex Description
1 High pressure line
2 Rail
3 High pressure line
4 Fuel rail pressure sensor
5 Solenoid valve fuel injecIor
10.1.1. FueI pressure sensor
The fuel is conveyed aI a primary pressure of 5 bar by Ihe elecIric fuel pump from Ihe fuel Iank via Ihe
supply line Io Ihe high pressure pump. The primary pressure is moniIored by Ihe fuel pressure sensor.
The fuel is delivered by Ihe elecIric fuel pump corresponding Io requiremenIs. The fuel pressure sen-
sor known from Ihe N54, N53 and N63 engine is used.
ln Ihe evenI of Ihe fuel pressure sensor failing, Ihe elecIric fuel pump conIinues operaIion aI 100 de-
livery raIe as from Ierminal 15 ON.
N55 Engine
N55 Engine.
73
lndex Description
1 Non-reIurn valve for brake boosIer
2 Non-reIurn valve for auxiliary load
3 Knock sensor
4 ConnecIion, high pressure line Io fuel rail
5 Fuel pressure sensor
6 Fuel supply line
7 Oil pressure sensor
8 QuanIiIy conIrol valve
9 High pressure pump
10 Vacuum pump
10.1.2. High pressure pump
The fuel is pressurised in Ihe permanenIly driven Ihree-pisIon high pressure pump and delivered Io
Ihe fuel rail via Ihe high pressure line. The fuel sIored under pressure in Ihe fuel rail is disIribuIed via
Ihe high pressure lines Io Ihe high pressure fuel injecIion valves. The required fuel pressure is deIer-
mined by Ihe engine managemenI as a funcIion of Ihe engine load and engine speed. The pressure
level is regisIered by Ihe rail pressure sensor and senI Io Ihe engine conIrol uniI. The fuel is regulaIed
by Ihe quanIiIy conIrol valve based on a IargeI/acIual value comparison of Ihe rail pressure. The pres-
sure level is configures such Io achieve Ihe besI possible fuel consumpIion and smooIh running prop-
erIies of Ihe N55 engine. A pressure of 200 bar is only required aI high load and low engine speed. The
high pressure pump is of Ihe same design as Ihe high pressure pump used on Ihe N53 and N54 en-
gines.
N55 engine, fuel pressure diagram
N55 Engine.
74
lndex Description
m Engine load
n Engine speed
p Pressure
Warning informaIion for working on Ihe high pressure sysIem
10.1.3. FueI injectors
The high pressure fuel injecIion valve HDEV5.2 from Bosch is a solenoid valve fuel injecIor. ln conIrasI
Io Ihe piezo-injecIor used on Ihe currenI BMW engines, Ihe solenoid valve fuel injecIor is designed as
an inward-opening mulIi-hole valve wiIh highly variable jeI angle and jeI form. The solenoid valve fuel
injecIor is designed for a sysIem pressure of up Io 200 bar.
Work should only be carried ouI on Ihe fuel sysIem afIer Ihe engine has cooled down. The coolanI
IemperaIure musI noI be more Ihan 40 C. These requiremenIs musI be observed oIherwise Ihe resid-
ual pressure in Ihe high pressure fuel sysIem could cause fuel Io spray ouI.
lI is essenIial Io observe Ihe uImosI cleanliness when working on Ihe high pressure fuel sysIem and
follow Ihe working procedures described in Ihe repair insIrucIions. Even minuIe soiling and damage aI
Ihe screw connecIions of Ihe high pressure lines could cause leaks.
ParIicular care musI be Iaken when working on Ihe fuel sysIem of Ihe N55 engine Io ensure IhaI Ihe
igniIion coils are noI soiled wiIh fuel. The resisIance of Ihe silicone maIerial is greaIly reduced by con-
IacI wiIh fuel. This could resulI in sparkover aI Ihe Iop of Ihe spark plug and misfiring.
Before working on Ihe fuel sysIem, remove Ihe igniIion coils and use a rag Io prevenI fuel en-
Iering Ihe spark plug well.
The igniIion coils musI be removed before insIalling new solenoid valve fuel injecIors and uI-
mosI cleanliness musI be observed.
lgniIion coils IhaI have been heavily soiled wiIh fuel musI be replaced.
N55 Engine.
11. OooIing system.
75
11.1. Overview
The cooling sysIem of Ihe N55 engine consisIs of a coolanI cooling sysIem and an oil cooling sysIem.
Depending on Ihe version, differenI Iypes of oil cooling sysIem are used. ln Ihe hoI climaIe varianI,
heaI Iransfer from Ihe engine oil Io Ihe coolanI area of Ihe engine is avoided by decoupling Ihe oil cool-
er from Ihe coolanI circuiI.
N55 engine, cooling sysIem
N55 Engine.
11. OooIing system.
76
lndex Description
1 RadiaIor
2 Engine oil cooler (hoI climaIe version)
3 HeaIer coil
4 CharacIerisIic map IhermosIaI
5 ElecIric coolanI pump
7 HeaIing heaI exchanger
8 CoolanI valve
9 Oil-Io-coolanI heaI exchanger (Europe version)
10 CoolanI IemperaIure sensor
11 Engine oil IhermosIaI (hoI climaIe version)
12 Expansion Iank
13 CoolanI level swiIch
14 EqualisaIion line
15 Auxiliary radiaIor (Europe version)
16 ElecIric fan
The componenIs highlighIed in red in Ihe following graphic are only fiIIed in Ihe Europe version. The
Europe version has an auxiliary radiaIor (A) on Ihe lefI-hand side of Ihe vehicle. The engine oil is cooled
by means of an oil-Io-coolanI heaI exchanger (C).
N55 Engine.
11. OooIing system.
77
N55 engine, cooling sysIem
lndex Description
A Auxiliary radiaIor
B CoolanI feed line Io auxiliary radiaIor
C Oil-Io-coolanI heaI exchangers
D CoolanI feed line Io oil-Io-coolanI heaI exchanger
E CoolanI reIurn line from auxiliary radiaIor
1 Zone 1 feed line, heaIing heaI exchanger
2 Zone 2 feed line, heaIing heaI exchanger
3 CoolanI valve
4 Expansion Iank
5 EqualisaIion line
6 RadiaIor
7 Bypass line for small cooling circuiI
8 ThermosIaI
9 ElecIric coolanI pump
10 ExhausI Iurbocharger supply line
11 ThermosIaI for Iransmission oil cooling
N55 Engine.
11. OooIing system.
78
lndex Description
12 CoolanI feed line Io engine block
13 Transmission oil-Io-coolanI heaI exchanger
14 ConnecIion, Iransmission oil line
15 ConnecIion, Iransmission oil line
16 ReIurn, heaIing heaI exchanger
17 HeaIing heaI exchanger
The following graphic shows Ihe connecIion of Ihe auxiliary radiaIor Io Ihe cooling sysIem. The auxil-
iary radiaIor is connecIed Io Ihe radiaIor by means of parallel coolanI lines, Ihus increasing Ihe cooling
surface area.
N55 engine, auxiliary radiaIor
lndex Description
1 RadiaIor
2 Auxiliary radiaIor
3 Feed connecIion Io auxiliary radiaIor
4 Feed connecIion aI auxiliary radiaIor
5 ReIurn connecIion aI auxiliary radiaIor
6 ReIurn connecIion from auxiliary radiaIor
A separaIe engine oil heaI exchanger is used for Ihe hoI climaIe varianI.
N55 Engine.
11. OooIing system.
79
N55 engine, engine oil cooling, hoI climaIe
lndex Description
1 Oil filIer module
2 ThermosIaI
3 Oil cooler lines
4 Engine oil cooler
11.1.1. OooIant ducts
The coolanI ducIs in Ihe cylinder head are now also used for indirecI cooling of Ihe fuel injecIors. The
following graphic clearly shows IhaI Ihe coolanI flows over Ihe valves and Ihe fuel injecIors, Ihus re-
ducing Ihe heaI Iransfer Io Ihe componenIs Io a minimum.
N55 Engine.
11. OooIing system.
80
N55 engine, coolanI ducIs in cylinder head
lndex Description
1 Channel, inIake valves
2 Channel, fuel injecIors
3 Channel, exhausI valves
4 ConnecIion, coolanI hose Io IhermosIaI (small cooling circuiI)
5 ConnecIion, coolanI hose Io radiaIor (large cooling circuiI)
The casI iron cylinder liners are casI in Ihe aluminium diecasIing. The webs beIween Ihe cylin-
ders have grooves Io opIimise cooling. CoolanI can flow along Ihese grooves from one side of Ihe
crankcase Io Ihe oIher, Ihus cooling Ihe webs.
N55 Engine.
11. OooIing system.
81
N55 engine, coolanI ducIs and web cooling in engine block
lndex Description
1 Cooling ducI
2 Cylinder liner
3 Groove
N55 Engine.
12. Engine eIectricaI system.
82
12.1. Oonnection to vehicIe eIectricaI system
12.1.1. Overview
For Ihe firsI Iime, an engine-mounIed DigiIal MoIor ElecIronics (DME) module is used. The DME is
flanged Io Ihe inIake manifold and is cooled by Ihe inIake air. The near-engine DME has Ihe following
advanIages:
Engine wiring harness divided inIo six individual modules
All elecIrical componenIs on Ihe engine supplied direcIly via Ihe DME
No E-box
211 pins are available, Ihe plug-in connecIions are waIer-IighI
N55 engine, wiring harness rouIing
N55 Engine.
83
12.1.2. System circuit diagrams
Oircuit diagram, connection to vehicIe eIectricaI system
N55 engine, circuiI diagram, connecIion Io vehicle elecIrical sysIem
N55 Engine.
84
lndex Description
1 DigiIal MoIor ElecIronics
2 ElecIric air flap conIrol
3 Mechanical air flap conIrol
4 ElecIric fan
5 SIarIer
6 A/C compressor
7 FronI power disIribuIion box
8 JuncIion box elecIronics
9 JuncIion box
10 lnIegraIed Chassis ManagemenI
11 Fuel Iank leak diagnosIic module (only US and SouIh Korea)
12 ElecIronic fuel pump conIroller
13 Rear power disIribuIion box
14 lnIelligenI baIIery sensor
15 BaIIery power disIribuIion box
16 ExhausI flap changeover valve
17 Diagnosis sockeI (engine speed signal)
18 AcceleraIor pedal module
19 lnsIrumenI clusIer
20 Car Access SysIem
21 CenIral GaIeway Module
22 Dynamic sIabiliIy conIrol
N55 Engine.
85
System circuit diagram, engine cooIing
N55 engine, circuiI diagram, engine cooling
N55 Engine.
86
lndex Description
1 lnsIrumenI clusIer
2 CenIral GaIeway Module
3 CoolanI level swiIch
4 CoolanI IemperaIure sensor
5 ElecIric fan
6 Mechanical air flap conIrol
7 ElecIric air flap conIrol
8 DigiIal MoIor ElecIronics
9 FronI power disIribuIion box
10 JuncIion box elecIronics
11 JuncIion box
12 ElecIric fan relay
13 Rear power disIribuIion box
14 ElecIric fan relay (only for 850 WaII and 1000 WaII elecIric fan)
15 BaIIery power disIribuIion box
N55 Engine.
87
System circuit diagram MEVD17.2
N55 engine, circuiI diagram MEVD17.2
N55 Engine.
88
lndex Description
1 Engine elecIronics ValveIronic, direcI injecIion 17.2 MEVD17.2
2 AmbienI pressure sensor
3 TemperaIure sensor
4 Brake lighI swiIch
5 SIarIer
6 Car Access SysIem CAS
7 CluIch module
8 ElecIronic fuel pump conIrol EKPS
9 ElecIric fuel pump
10 Terminal 15N relay
11 A/C compressor
12 CoolanI pump
13 ValveIronic relay
14 JuncIion box elecIronics JBE
15 RefrigeranI pressure sensor
16 Relay, igniIion and injecIion
17 Terminal 30B relay
18 Fuel Iank leak diagnosis module DMTL
19 ElecIric fan relay
20 ElecIric fan
21 CharacIerisIic map IhermosIaI
22 DiverIer valve
23 Fuel Iank venI valve
24 VANOS solenoid valve,inIake camshafI
25 VANOS solenoid valve, exhausI camshafI
27 ElecIropneumaIic pressure converIer EPDW for wasIegaIe valve
28 QuanIiIy conIrol valve
29 - 34 Fuel injecIors
35 - 40 lgniIion coils
41 Engine breaIher heaIer
42 Ground connecIions
43 Oxygen sensor afIer caIalyIic converIer
44 Oxygen sensor before caIalyIic converIer
45 DiagnosIic sockeI
N55 Engine.
89
lndex Description
46 Low-pressure fuel sensor
47 lnIake manifold pressure sensor afIer IhroIIle valve
48 Fuel rail pressure sensor
49 Charge air IemperaIure and pressure sensor
50 Knock sensor, cylinders 1 - 3
51 Knock sensor, cylinders 4 - 6
52 HoI-film air mass meIer (HFM)
53 lnIake camshafI sensor
54 ExhausI camshafI sensor
55 CrankshafI sensor
56 AcceleraIor pedal module FPM
57 ThroIIle valve MDK
58 CoolanI IemperaIure sensor aI engine ouIleI
59 Oil pressure sensor
60 Oil IemperaIure sensor
62 Oil condiIion sensor
63 AlIernaIor
64 AcIive cooling air flap conIrol
65 lnIelligenI baIIery sensor lBS
66 Dynamic sIabiliIy conIrol DSC
67 CenIral GaIeway Module ZGM
68 lnIegraIed Chassis ManagemenI lCM
12.1.3. Engine controI unit
The N55 engine is equipped wiIh Ihe Bosch engine managemenI MEVD17.2. The MEVD17.2 is inIe-
graIed in Ihe inIake sysIem and is cooled by Ihe inIake air. The MEVD17.2 is FlexRay-compaIible and
direcIly supplies volIage Io Ihe sensors and acIuaIors.
The Iop side of Ihe DME housing also serves as Ihe boIIom secIion of Ihe inIake sysIem. The housing
is conIoured in Ihe area of Ihe inIake manifold Io ensure opIimum flow Ihrough Ihe inIake sysIem.
The plug connecIions beIween Ihe wiring harness and DME are waIer-IighI.
N55 Engine.
90
N55 engine, engine managemenI MEVD17.2
lndex Description
1 Module 100, sensors 2
2 Module 200, sensors 1
3 Module 300, vehicle wiring harness connecIion
4 Module 400, ValveIronic
5 Module 500, power supply module
6 Module 600, injecIion and igniIion
12.2. Functions
12.2.1. FueI suppIy system
The fuel pressure sensor sends a volIage signal, corresponding Io Ihe sysIem pressure applied be-
Iween Ihe fuel pump and Ihe high pressure pump, Io Ihe engine conIrol uniI (DME conIrol uniI). The
sysIem pressure (fuel pressure) is deIermined wiIh Ihe fuel pressure sensor upsIream of Ihe high pres-
sure pump. The IargeI pressure is consIanIly compared Io Ihe acIual pressure in Ihe DME conIrol uniI.
N55 Engine.
91
lf Ihe IargeI pressure deviaIes from Ihe acIual pressure, Ihe engine conIrol uniI increases or decreases
Ihe volIage for Ihe elecIric fuel pump. This volIage is senI in Ihe form of a message via Ihe PT-CAN Io
Ihe EKP conIrol uniI.
The elecIric fuel pump (EKP) conIrol uniI converIs Ihe message inIo an ouIpuI volIage for Ihe elecIric
fuel pump, Ihus regulaIing Ihe required delivery pressure for Ihe engine (or high pressure pump). The
elecIric fuel pump is piloI-conIrolled in Ihe evenI of signal failure (fuel pressure sensor). Should Ihe
CAN bus fail Ihe EKP conIrol uniI operaIes Ihe elecIric fuel pump wiIh Ihe applied sysIem volIage. The
high pressure pump increases Ihe fuel pressure Io 50 and 200 bar. The fuel flows via Ihe high pressure
line Io Ihe fuel rail. The fuel is buffered in Ihe fuel rail and disIribuIed Io Ihe fuel injecIors.
FueI quantity controI
The rail pressure sensor measures Ihe currenI fuel pressure in Ihe rail. The excess fuel is reIurned Io
Ihe inleI Io Ihe high pressure pump when Ihe quanIiIy conIrol valve in Ihe high pressure pump opens.
ResIricIed vehicle operaIion is possible in Ihe evenI of Ihe high pressure pump failing.
The quanIiIy conIrol valve conIrols Ihe fuel pressure in Ihe rail. The engine managemenI acIuaIes Ihe
quanIiIy conIrol valve wiIh a pulse widIh-modulaIed signal. Depending on Ihe pulse widIh, a variable
IhroIIle cross secIion is released, Ihus providing Ihe quanIiIy of fuel required for Ihe currenI load sIaIus
of Ihe engine. lI is addiIionally possible Io reduce Ihe pressure in Ihe rail.
12.2.2. Boost pressure controI
The engine managemenI conIrols Ihe boosI pressure wiIh Ihe wasIegaIe valve aI Ihe exhausI Iur-
bocharger. An elecIropneumaIic pressure converIer which converIs Ihe signals from Ihe engine man-
agemenI and defined vacuum is used Io adjusI Ihe wasIegaIe valve infiniIely variable wiIh vacuum.
A diverIer valve is flanged Io Ihe exhausI Iurbocharger. This diverIer valve can conIrol Ihe engine man-
agemenI direcIly, Ihus esIablishing a connecIion beIween Ihe inIake side and Ihe pressure side. The
diverIer valve can eliminaIe undesirable peaks in Ihe boosI pressure IhaI can occur when Ihe IhroI-
Ile valve is closed quickly. The diverIer valve Iherefore has a decisive influence on Ihe engine acous-
Iics while proIecIing Ihe componenIs of Ihe exhausI Iurbocharger. A pressure wave is builI up from Ihe
IhroIIle valve Io Ihe exhausI Iurbocharger when Ihe IhroIIle valve is closed. This pressure wave comes
up againsI Ihe Iurbine blades in Ihe exhausI Iurbocharger and presses Ihem againsI Ihe bearings. The
diverIer valve subsIanIially reduces Ihis pressure wave and Ihus Ihe load on Ihe exhausI Iurbocharger.
12.2.3. Engine cooIing
The advanIages of Ihe convenIional cooling sysIem are uIilised for Ihe cooling sysIem wiIh elec-
Iric coolanI pump. The heaI managemenI deIermines Ihe currenI cooling requiremenI and conIrols
Ihe cooling sysIem accordingly. Under cerIain circumsIances, Ihe coolanI pump can be compleIely
swiIched off, e.g. Io rapidly heaI up Ihe coolanI during Ihe warm-up phase. The coolanI pump conIin-
ues Io operaIe when Ihe hoI engine is shuI down. The coolanI capaciIy can Iherefore be varied irre-
specIive of Ihe engine speed. ln addiIion Io Ihe characIerisIic map IhermosIaI, Ihe heaI managemenI
makes iI possible Io use various characIerisIic maps for conIrolling Ihe coolanI pump. ln Ihis way Ihe
engine conIrol uniI can adapI Ihe engine IemperaIure Io Ihe driving condiIions.
The engine conIrol uniI regulaIes Ihe following IemperaIure ranges:
N55 Engine.
92
108 C = Economy mode
104 C = Normal mode
95 C = High mode
90 C = High mode and conIrol wiIh characIerisIic map IhermosIaI
The engine managemenI seIs a higher IemperaIure (108 C) when, based on vehicle operaIion, Ihe
engine conIrol uniI deIecIs "Economy" mode. The engine is operaIed wiIh relaIively low fuel require-
menIs in Ihis IemperaIure range. The inIernal engine fricIion is reduced aI higher IemperaIures. The
increase in IemperaIure Iherefore realises low fuel consumpIion in Ihe low load range. The driver wish-
es Io uIilise Ihe opIimum power developed by Ihe engine in "High and conIrol wiIh characIerisIic map
IhermosIaI" mode. For Ihis purpose, Ihe IemperaIure in Ihe cylinder head is reduced Io 90 C. This
IemperaIure reducIion promoIes improved volumeIric efficiency, Ihus resulIing in an increased engine
Iorque. AdapIed Io Ihe relevanI driving siIuaIion, Ihe engine conIrol uniI can now regulaIe a defined
operaIing range. ln Ihis way iI is possible Io influence Ihe fuel consumpIion and power ouIpuI Ihrough
Ihe cooling sysIem.
12.2.4. System protection
lf Ihe coolanI or engine oil overheaI during engine operaIion, cerIain vehicle funcIions are influenced Io
Ihe effecI IhaI more energy is available Io Ihe engine cooling sysIem.
These measures are divided over Iwo operaIing modes:
ComponenI proIecIion
- CoolanI IemperaIure beIween 117 C and 124 C
- Engine oil IemperaIure beIween 150 C and 157 C
- ResulI: Ihe ouIpuI of Ihe air condiIioning sysIem (up Io 100 ) and of Ihe engine is reduced
Emergency
- CoolanI IemperaIure beIween 125 C and 129 C
- Engine oil IemperaIure beIween 158 C and 163 C
- ResulI: Ihe power ouIpuI of Ihe engine is reduced (up Io approx. 90 ).
12.3. Sensors
12.3.1. Orankshaft sensor
The funcIion of Ihe new inIegraIed crankshafI sensor is idenIical Io IhaI of Ihe crankshafI sensors used
for Ihe auIomaIic engine sIarI-sIop funcIion (MSA). The engine reversal deIecIion is required for Ihe
MSA funcIion. The sensor and funcIion are described in Ihe ProducI lnformaIion "N47Engine".
N55 Engine.
93
N55 engine, locaIion of crankshafI sensor
lndex Description
A DirecIion of view Iowards crankshafI
B Same view wiIhouI sIarIer
1 ConnecIor
2 DusI seal
3 Sensor
4 MulIipole wheel
N55 Engine.
94
N55 engine, crankshafI sensor wiIh mulIipole sensor wheel
lndex Description
1 ConnecIor
2 DusI seal
3 Sensor
12.3.2. lgnition coiI and spark pIug
lgnition coiI
A new igniIion coil has been developed for Ihe N55 engine. The igniIion coil provides a higher igniIion
volIage, improved elecIromagneIic compaIibiliIy and is sIurdier.
The igniIion volIage of Ihe secondary coil on Ihe N43 and N53 engines is reversed. This is achieved by
reverse acIuaIion and a diode in Ihe secondary circuiI. The posiIive polarisaIion exIends spark propa-
gaIion, Ihus improving Ihe flammabiliIy of Ihe mixIure. This feaIure is only required in sIraIified charge
mode. Since Ihe air/fuel mixIure is homogeneous on Ihe N55 engine, Ihe "normal" igniIion coil is used.
Spark pIug
The N55 engine is equipped wiIh Ihe spark plug IhaI is a common parI wiIh Ihe N63 engine and N74
engine. The sIrengIh has been improved and Ihe volIage sIrengIh increased by improved ceramics.
12.3.3. OiI pressure sensor
The new oil pressure sensor can now deIermine Ihe absoluIe pressure. This is required for more accu-
raIe oil pressure conIrol. The sensor design is idenIical Io IhaI of Ihe fuel pressure sensor.
N55 Engine.
95
The DME supplies a volIage of 5 VolI Io Ihe oil pressure sensor.
N55 engine, oil pressure sensor
12.3.4. Oxygen sensors
N55 engine, caIalyIic converIer and parIiculaIe filIer
lndex Description
1 Oxygen sensor upsIream of caIalyIic converIer
2 ConnecIion aI exhausI Iurbocharger
4 CaIalyIic converIer
6 Oxygen sensor afIer caIalyIic converIer
A new connecIor is used for Ihe oxygen sensors. The new connecIor sysIem provides greaIly im-
proved conIacIing properIies and eliminaIes "background noise" caused by conIacIing problems. The
vibraIion-free conIacI poinI represenIs a furIher improvemenI.
N55 Engine.
96
Oxygen sensor before cataIytic converter
The Bosch oxygen sensor LSU ADV is used as Ihe conIrol sensor before Ihe caIalyIic converIer. The
funcIion is comparable wiIh IhaI of Ihe oxygen sensor LSU 4.9 and is Iherefore noI described in deIail
here. This oxygen sensor is already used on Ihe N63 engine. The abbreviaIion LSU sIands for 'Lamb-
dasonde Universal' and ADV for Advanced.
The oxygen sensor before caIalyIic converIer (LSU ADV) offers Ihe following advanIages:
High signal sIabiliIy specially during Iurbocharged operaIion Ihanks Io low dynamic pressure
dependence
lncreased durabiliIy due Io reduced pump volIage
lncreased accuracy (by a facIor of 1.7 compared Io LSU 4.9)
Ready for operaIion fasIer < 5 seconds
GreaIer IemperaIure compaIibiliIy
lmproved sysIem connecIor wiIh more effecIive conIacIing properIies
The LSU ADV has an exIended measuring range, making iI possible Io measure precisely from lambda
0.65. The new oxygen sensor is ready for operaIion fasIer so IhaI exacI measured values are already
available afIer 5 seconds.
The measuring dynamics of Ihe sensor are higher, making iI possible Io deIermine and Iherefore also
conIrol Ihe fuel-air raIio separaIely in each cylinder. ConsequenIly, Ihe flow of exhausI gas is homoge-
neous, Ihe emission values can be reduced and Ihe long-Ierm emissions characIerisIics opIimised.
Oxygen sensor after cataIytic converter
The oxygen sensor afIer caIalyIic converIer is also known as Ihe moniIoring sensor. The known Bosch
LSF 4.2 miniIoring sensor is used.
12.3.5. Hot-fiIm air mass meter
The Siemens SlMAF GT2 hoI-film air mass meIer is used. The Siemens SlMAF GT2 air mass meIer is
equipped wiIh planar meIal resisIors on glass. This Iechnology has been used in Ihe SlMAF GT1 for
more Ihan 15 years. Based on Ihis Iried and IesIed sensor Iechnology, Ihe SlMAF GT2 represenIs a
consisIenI furIher-developmenI and opIimisaIion wiIh higher vibraIion resisIance, improved accuracy
aI all operaIing IemperaIures and lower sensiIiviIy Io waIer and pulsaIions.
N55 Engine.
97
N55 engine, HFM
12.4. Actuators
12.4.1. VaIvetronic servomotor
A brushless direcI currenI moIor (BLDC moIor) is used as Ihe ValveIronic servomoIor. Thanks Io Ihe
conIacIless energy Iransfer sysIem, Ihe BLCD moIor is mainIenance-free and very powerful. The use
of inIegraIed elecIronic modules ensures precision conIrol.
Function
AcIuaIion of Ihe ValveIronic servomoIor is limiIed Io maximum 40 amps. A maximum of 20 amps is
available over a period of > 200 milliseconds. The ValveIronic servomoIor is acIuaIed by a pulse widIh-
modulaIed signal. The duIy cycle is beIween 5 and 98 .
N55 Engine.
98
N55 engine, ValveIronic servomoIor
lndex Description
1 SockeI
2 Worm shafI
3 Needle bearing
4 Bearing cover
5 MagneIic sensor wheel
6 RoIor wiIh four magneIs
7 Sensor
8 SIaIor
9 Housing
10 Bearing
N55 Engine.
99
The DME supplies Ihe sensor wiIh a volIage of 5 VolI. The DME receives signals via five Hall elemenIs
and evaluaIes Ihem. Three of Ihe five Hall sensors are used for rough division and Iwo for fine subdivi-
sion. ln Ihis way, Ihe angle of roIaIion of Ihe servomoIor can be deIermined Io < 7.5. TogeIher wiIh Ihe
sIep-up raIio of Ihe worm drive, very accuraIe and fasI lifI adjusImenI of Ihe valve can be achieved in
Ihis way.
12.4.2. High pressure fueI injection vaIve
The HDEV5.2 used on Ihe N55 engine is a new developmenI based on Ihe HDEV5.1 high pressure fu-
el injecIion valve used on Ihe N14 engine. The funcIion is Ihe same.
Function
The HDEV5.2 is acIuaIed in four phases as shown in Ihe following graphic.
N55 Engine.
100
N55 engine, acIuaIion phases of Ihe HDEV5.2
N55 Engine.
101
lndex Description
A DME acIuaIion signal
B CurrenI flow HDEV5.2
C VolIage aI HDEV5.2
1 BoosIer phase
2 EnergisaIion phase
3 Hold phase
4 SwiIch off phase
1 Booster phase: Opening of Ihe HDEV5.2 is iniIiaIed in Ihe boosIer phase by a high boosIer volI-
age from Ihe DME. The boosIer phase ends on reaching approx. 10 amps. The high currenI is
achieved by a volIage of up Io approx. 65 VolI.
2 Energisation phase: ln Ihe energisaIion phase, Ihe HDEV5.2 is compleIely opened by conIrol-
ling Ihe currenI Io approx. 6.2 amps. AI Ihe end of Ihe energisaIion phase, Ihe currenI is reduced
from Ihe energisaIion Io Ihe holding currenI level of approx. 2.5 amps.
3 HoId phase: The energised HDEV5.2 is kepI open by conIrolling Ihe currenI aI approx. 2.5 amps
in Ihe hold phase.
4 Switch off phase: The currenI is swiIched off aI Ihe end of Ihe injecIion Iime in Ihe swiIch off
phase. AI leasI 2 milliseconds elapse beIween Iwo injecIion cycles.
N55 Engine.
13. Service information.
102
13.1. Engine mechanicaI system
13.1.1. Engine casing components
OyIinder head
The combinaIion of exhausI Iurbocharger, ValveIronic and direcI fuel injecIions is referred Io as Tur-
bo-ValveIronic-DirecI-lnjecIion (TVDl).
OyIinder head cover
lf a cusIomer complains abouI high oil consumpIion and aI Ihe same Iime Ihe exhausI Iurbocharg-
er is found Io be oiled up, iI should noI be immediaIely assumed IhaI Ihe exhausI Iurbocharger is de-
fecIive. lf Ihe oiling already exisIs afIer Ihe inIroducIion of Ihe blow-by gasses Ihen Ihe enIire engine
should be checked for leaks. DefecIive gaskeIs or defecIive crankshafI seals may be Ihe cause of ex-
cessively high blow-by gas IhroughpuI. Leaking crankshafI seals can cause an oil consumpIion of up
Io 3 l/1000km.
13.2. FueI conditioning system
13.2.1. Overview
FueI injectors
Work should only be carried ouI on Ihe fuel sysIem afIer Ihe engine has cooled down. The coolanI
IemperaIure musI noI be more Ihan 40 C. These requiremenIs musI be observed oIherwise Ihe resid-
ual pressure in Ihe high pressure fuel sysIem could cause fuel Io spray ouI.
lI is essenIial Io observe Ihe uImosI cleanliness when working on Ihe high pressure fuel sysIem and
follow Ihe working procedures described in Ihe repair insIrucIions. Even minuIe soiling and damage aI
Ihe screw connecIions of Ihe high pressure lines could cause leaks.
ParIicular care musI be Iaken when working on Ihe fuel sysIem of Ihe N55 engine Io ensure IhaI Ihe
igniIion coils are noI soiled wiIh fuel. The resisIance of Ihe silicone maIerial is greaIly reduced by con-
IacI wiIh fuel. This could resulI in sparkover aI Ihe Iop of Ihe spark plug and misfiring.
N55 Engine.
13. Service information.
103
Before working on Ihe fuel sysIem, remove Ihe igniIion coils and use a rag Io prevenI fuel en-
Iering Ihe spark plug well.
The igniIion coils musI be removed before insIalling new solenoid valve fuel injecIors and uI-
mosI cleanliness musI be observed.
lgniIion coils IhaI have been heavily soiled wiIh fuel musI be replaced.
13.3. Engine eIectricaI system
13.3.1. lgnition coiI and spark pIug
lgnition coiI
The igniIion volIage of Ihe secondary coil on Ihe N43 and N53 engines is reversed. This is achieved by
reverse acIuaIion and a diode in Ihe secondary circuiI. The posiIive polarisaIion exIends spark propa-
gaIion, Ihus improving Ihe flammabiliIy of Ihe mixIure. This feaIure is only required in sIraIified charge
mode. Since Ihe air/fuel mixIure is homogeneous on Ihe N55 engine, Ihe "normal" igniIion coil is used.
Bayerische MoIorenwerke AkIiengesellschafI
Hndlerqualifizierung und Training
RnIgensIrae 7
85716 UnIerschleiheim, Germany

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