02 B46 Engine

Technicaltraining.
Productinformation.
B46Engine
BMWService
Generalinformation
Symbolsused
Thefollowingsymbolisusedinthisdocumenttofacilitatebettercomprehensionortodrawattention
toveryimportantinformation:
Containsimportantsafetyinformationandinformationthatneedstobeobservedstrictlyinorderto
guaranteethesmoothoperationofthesystem.
Informationstatusandnational-marketversions
BMWGroupvehiclesmeettherequirementsofthehighestsafetyandqualitystandards.Changes
inrequirementsforenvironmentalprotection,customerbenefitsanddesignrendernecessary
continuousdevelopmentofsystemsandcomponents.Consequently,theremaybediscrepancies
betweenthecontentsofthisdocumentandthevehiclesavailableinthetrainingcourse.
ThisdocumentbasicallyrelatestotheEuropeanversionofleft-handdrivevehicles.Someoperating
elementsorcomponentsarearrangeddifferentlyinright-handdrivevehiclesthanshowninthe
graphicsinthisdocument.Furtherdifferencesmayariseasaresultoftheequipmentspecificationin
specificmarketsorcountries.
Additionalsourcesofinformation
Furtherinformationontheindividualtopicscanbefoundinthefollowing:
Owner'sHandbook
IntegratedServiceTechnicalApplication.
Contact:conceptinfo@bmw.de
2014BMWAG,Munich
ReprintsofthispublicationoritspartsrequirethewrittenapprovalofBMWAG,Munich
Theinformationcontainedinthisdocumentformsanintegralpartofthetechnicaltrainingofthe
BMWGroupandisintendedforthetrainerandparticipantsintheseminar.Refertothelatestrelevant
informationsystemsoftheBMWGroupforanychanges/additionstothetechnicaldata.
Contact:
SebastianRiedel
Tel.:+49(0)8938265044
E-mail:sebastian.rs.riedel@bmw.de
Informationstatus:June2014
BV-72/TechnicalTraining
B46Engine
Contents
1. Introduction............................................................................................................................................................................................................................................. 1
1.1. Enginedesignation............................................................................................................................................................................................. 1
1.2. Engineidentification......................................................................................................................................................................................... 2
1.2.1. 4-cylinderengine..................................................................................................................................................................2
1.3. Highlights............................................................................................................................................................................................................................ 3
1.3.1. Installationpositions........................................................................................................................................................ 3
1.3.2. Advantages..................................................................................................................................................................................... 4
1.3.3. Overviewoftechnicalfeatures........................................................................................................................4
1.4. Modulardesign..........................................................................................................................................................................................................5
1.4.1. TwinPowerTurbo..................................................................................................................................................................7
1.5. Technicaldata............................................................................................................................................................................................................. 7
1.5.1. Modeloverview........................................................................................................................................................................8
1.6. Engineacoustics.................................................................................................................................................................................................... 8
1.6.1. Comparison....................................................................................................................................................................................9
1.6.2. ActiveSoundDesign................................................................................................................................................. 12
2. EngineMechanical................................................................................................................................................................................................................ 14
2.1. Enginehousing..................................................................................................................................................................................................... 14
2.1.1. Cylinderheadcover..................................................................................................................................................... 15
2.1.2. Cylinderhead......................................................................................................................................................................... 22
2.1.3. Crankcase.....................................................................................................................................................................................24
2.1.4. Oilsump......................................................................................................................................................................................... 28
2.2. Crankshaftdrive................................................................................................................................................................................................... 33
2.2.1. Crankshaft....................................................................................................................................................................................33
2.2.2. Connectingrod.................................................................................................................................................................... 40
2.2.3. Piston...................................................................................................................................................................................................43
2.2.4. Counterbalanceshafts.............................................................................................................................................45
2.2.5. CounterbalanceshaftofB46engine............................................................................................... 52
2.2.6. Torsionalvibrationdamper................................................................................................................................55
2.2.7. Chaindrive.................................................................................................................................................................................. 57
2.3. Valvegear.......................................................................................................................................................................................................................60
2.3.1. Variants............................................................................................................................................................................................. 60
2.3.2. VANOS.............................................................................................................................................................................................. 61
2.3.3. Valvetronic................................................................................................................................................................................... 67
2.4. Beltdrive......................................................................................................................................................................................................................... 74
3. Oil Supply...............................................................................................................................................................................................................................................75
3.1. Oilcircuit......................................................................................................................................................................................................................... 75
3.2. Mapcontrol................................................................................................................................................................................................................. 77
3.3. Oilpump.......................................................................................................................................................................................................................... 78
3.3.1. Mapcontrolvalve............................................................................................................................................................. 81
B46Engine
Contents
3.3.2. Normaloperation.............................................................................................................................................................. 82
3.3.3. Emergencyoperation................................................................................................................................................ 83
3.4. Suctionpipe............................................................................................................................................................................................................... 84
3.5. Pressure-limitingvalve.............................................................................................................................................................................. 85
3.6. Oilfiltermodule.................................................................................................................................................................................................... 86
3.6.1. Filterbypassvalve.......................................................................................................................................................... 88
3.6.2. Heatexchangerbypassvalve....................................................................................................................... 88
4. CoolingSystem........................................................................................................................................................................................................................... 89
4.1. Coolingcircuit,B46engine...............................................................................................................................................................89
4.1.1. Specialfeatures.................................................................................................................................................................. 90
4.2. Systemoverview,vehicle...................................................................................................................................................................... 91
4.3. Coolingmodule.................................................................................................................................................................................................... 92
4.4. Coolantpump.......................................................................................................................................................................................................... 93
4.5. Expansiontank...................................................................................................................................................................................................... 94
4.6. Coolant............................................................................................................................................................................................................................... 95
5. IntakeAirandExhaustSystem..................................................................................................................................................................... 96
5.1. Intakeairsystem.................................................................................................................................................................................................97
5.1.1. Intakesilencer....................................................................................................................................................................... 98
5.1.2. Chargeaircooling...........................................................................................................................................................99
5.2. Exhaustemissionsystem..................................................................................................................................................................... 99
5.2.1. Exhaustturbocharger................................................................................................................................................ 99
5.2.2. Blow-offvalve.................................................................................................................................................................... 100
5.2.3. Chargingpressurecontrol.............................................................................................................................100
5.2.4. Exhaustsystem ............................................................................................................................................................ 104
6. VacuumSupply....................................................................................................................................................................................................................... 109
6.1. Systemoverview............................................................................................................................................................................................ 109
6.2. Vacuumpump.....................................................................................................................................................................................................110
7. FuelSystem................................................................................................................................................................................................................................... 112
7.1. Fuelpumpcontrolmodule............................................................................................................................................................. 113
7.2. Electricfuelpump........................................................................................................................................................................................ 113
7.3. Fuelpreparation...............................................................................................................................................................................................115
7.3.1. Fuelhigh-pressurepump............................................................................................................................... 116
7.3.2. Directrail................................................................................................................................................................................... 119
7.3.3. Solenoidvalveinjector........................................................................................................................................ 121
8. EngineElectricalSystem..................................................................................................................................................................................... 129
8.1. DigitalMotorElectronics(DME)............................................................................................................................................ 129
B46Engine
Contents
8.2. Systemwiringdiagram,B46engine...............................................................................................................................130
8.3. Mapignition........................................................................................................................................................................................................... 132
8.3.1. Diagnosticfunctions............................................................................................................................................... 133
8.3.2. Ignitioncoils......................................................................................................................................................................... 135
8.3.3. Sparkplugs........................................................................................................................................................................... 138
8.4. Systemoverviewforengineelectricalsystem................................................................................................ 138
8.4.1. Transmissionside....................................................................................................................................................... 139
8.4.2. Sideview................................................................................................................................................................................... 140
8.4.3. Beltside......................................................................................................................................................................................141
B46Engine
1.Introduction
Thisdocumentdescribesthespecialfeaturesofthenew4-cylinderengineandservestosupport
thetechnicalservice.Duetothehugesimilarities,betweentheB38TopengineandB46,thetwo
enginesaredescribedinthisonedocument.Someimagesshownrelatetothe3-cylinderengine.
Thedifferencescomparedtothe4-cylinderengineareshownanddescribedseparately.However,the
similaritiesarenotrepeated.Theenginesaredistinguishedasfollowsinthisdocument:
B38=3-cylinderengine
B46=4-cylinderengine
Bx8=3and4-cylinderengine
1.1.Enginedesignation
Inthetechnicaldocumentation,theenginedesignationisusedtoensureunambiguousidentification
oftheengine.Frequently,onlyashortdesignationisused,whichisexplainedinthefollowingtable.
Position Meaning Index Explanation

1 Enginedeveloper B BMWGroupengine
2 Enginetype 3 3-cylinderin-lineengine
4 4-cylinderin-lineengine
3 Changetothebasic 6 SULEV/Turbo-ValvetronicDirectInjection(TVDI)
engineconcept 8 Turbo-ValvetronicDirectInjection(TVDI)
4 Workingmethodorfuel A Gasolineengine,transversalinstallation
andinstallationposition
5+6 Displacementin 15 1.5literdisplacement
1/10liter 20 2.0literdisplacement
7 Performanceclasses K Lowest
U Lower
M Middle
O Upper
T Top
S Super
8 Revisionrelevantto 0 Newdevelopment
approval 1 Firstrevision
2 Secondrevision
1
B46Engine
1.Introduction
1.2.Engineidentification
The7-digitengineidentificationisonthecrankcase.Thefirstsixdigitsoftheengineidentification
arederivedfromtheenginetype.Onlytheseventhdigitisdifferent.Theseventhdigitoftheengine
identificationisthetestnumberofthetypeapprovalcertification.
Theconsecutiveenginenumberisembossedabovetheengineidentification.Usingthesetwo
numberstheenginecanbeclearlyidentifiedbythemanufacturer.
1.2.1.4-cylinderengine
EngineidentificationforB46engine
Index Explanation
1 Enginenumber
2 Engineidentification
2
B46Engine
1.Introduction
1.3.Highlights
1.3.1.Installationpositions
Dependingonthedriveconcept,theinstallationpositionsofthenewenginesvaryinthedifferent
vehicles.
Transversemountingposition,B38Topengine
Index Explanation
1 Connectionforanti-rollbarlink
2 Compressoronintakeside,curved
3 Enginemount
4 Intakesysteminthedirectionofthetransmission
5 Oilfiltermodule,suspended
3
B46Engine
1.Introduction
Thisfollowingdriveandinstallationvariantsareavailable:
Transversemounting
Front-wheeldrives
Four-wheeldrives
Automatictransmission
1.3.2.Advantages
Benefitsduetolowernumberofcylinders:
lessweight
fewermovingmasses
lessspatialrequirement
reductionofinternalenginefriction
1
TheB46engineisbasedonthefamiliarN20engine.ThefamiliarTVDI technologyisusedinallnew
engines.Anoffsetoraxialoffset,asusedintheN20engine,isnotusedwiththenewB46engine.
Thenewenginegenerationismainlycharacterizedbylowerfuelconsumptionandfewerexhaust
emissions(ULEVII).Toachievelowfuelconsumption,amap-controlledoilpump,characteristicmap
thermostatandinjectionsystemwithdirect-railandelectricarcwire-sprayedcylinderbarrels,among
others,areused.Allenginesalsoreceiveanautomaticenginestart-stopfunctionandintelligent
alternatorcontrolasafurtherEfficientDynamicsmeasure.
1
TVDItechnologyconsistsof:
T=Turbocharger
V=Valvetronic
DI=Direct-Injection(directfuelinjection)
1.3.3.Overviewoftechnicalfeatures
B46A20
Map-controlledoilpump Yes
Electricarcwire-sprayedcylinderbarrels Yes
Twin-scrollexhaustturbocharger Yes
Electricallyadjustablewastegatevalve Yes
Directrail Yes
DoubleVANOS Yes
Valvetronic Yes
4
B46Engine
1.Introduction
1.4.Modulardesign
TheEfficientDynamicsstrategyoftheNenginegenerationhasresultedinalargenumberofdifferent
technologiesfindingtheirwayintotheBMWengineworld.Thestrategyforthesimplificationof
inspectionworkisalsopursuedwiththeBenginegeneration.
BMWEfficientDynamicsstrategyoftheBx8enginegeneration
Designation Explanation
BMWEfficientDynamics BMWEfficientDynamicsstrategy
Moreperformance Moreperformance
Lessfuelconsumption Lessfuelconsumption
FewerCO2emissions Lesscarbondioxideemissions
BMWEfficientDynamicsalsostandsformorepower,lessconsumptionandlesscarbondioxide
emissionsinthenewenginegeneration.Withtheadditionalmodularstrategy,otherobjectivessuch
aslowercosts,greaterproductionflexibility,aswellasenhancedcustomersatisfaction,arenowalso
beingpursued.
5
B46Engine
1.Introduction
ModularstrategyofBx8enginegeneration
Designation Explanation
Modular Modularstrategy
Enhancedcustomersatisfaction Enhancedcustomersatisfaction
Greaterflexibility Greaterflexibility
Lesscosts Lesscosts
Themodularstrategyaimsfordifferenteffectsthroughouttheproductdevelopmentprocessand
productlifecycle.Thisallowsdevelopmentandmanufacturingcosts,forexample,tobeloweredby
usinguniformprocesses.Inproduction,thecomplexityofthemanufacturingprocessplanningand
implementationisreduced.InService,thewarehousingissimplifiedasaresultofthereductionofpart
variety,andthesafehandlingofproductsisincreased.
6
B46Engine
1.Introduction
1.4.1.TwinPowerTurbo
AllB46enginesareequippedwiththeestablishedTwinPowerTurboTechnologies.
TwinPowerTurboTechnology,B46engine
TwinPowerTurbomeansthatthefollowingtechnologiesareused:
VANOS
Valvetronic
Directfuelinjection
Turbocharging
1.5.Technicaldata
B46A20M0
Poweroutputin[hp] 231
at[rpm] 47006000
Torquein[Nm] 350
at[rpm] 1250
Design/Numberofcylinders Row4
Displacementin[cm] 1998
Bore/strokein[mm] 82/94.6
Compressionratio 11:1
Valvespercylinder 4
Usedasof 07/2014
Model X1
7
B46Engine
1.Introduction
1.5.1.Modeloverview
ThetablebelowprovidesanoverviewoftheBMWmodelsinwhichthenewenginesareused:
BMWmodels Engine
X1 B46A20M0
1.6.Engineacoustics
Inordertounderstandtheoriginoftheacousticdifferences,wemusttakealookattheengine
mechanicsandcomparethedesignfeaturesoftheengine.Thefollowinggraphicsillustratetheorigin
ofthedifferentacoustics.
8
B46Engine
1.Introduction
1.6.1.Comparison
FiringintervalofB46engine
Index Explanation
1 Connectingrodbearingjournal,cylinder1
9
B46Engine
1.Introduction
Thegraphicshowsa4-cylinderin-lineenginewithafiringintervalof180andafiringorderof134
2.Onecrankshaftrevolution(360)resultsintwoworkcyclesforthe4-cylinderin-lineengine.
Theacousticdifferencesthereforehavetheirorigininthedifferentfiringintervals.
AcousticoscillationsoftheBx8engines
Index Explanation
A Acousticoscillationofthe4-cylinderin-lineengine
B Acousticoscillationofthe3-cylinderin-lineengine
Ifonecomparestheacousticoscillationsofthetwoenginesasaresultoftheignitionprocess,
therearetwodifferentenginesounds.Thesoundofthe4-cylinderin-lineengineisperceivedas
harmoniousandsmooth.
10
B46Engine
1.Introduction
Acousticdiagramshowingcomparisonbetween3,4and6-cylinderengine
Index Explanation
A 6-cylinderin-lineengine
B 4-cylinderin-lineengine
C 3-cylinderin-lineengine
Hz Dominantfiringfrequency[f]
rpm Revolutionsperminute
Thedominantfiringfrequencies[f]canbecalculatedasfollows:
6-cylinderin-lineengine(firingorder3)
f=Enginespeed:603
4-cylinderin-lineengine(firingorder2)
f=Enginespeed:602
3-cylinderin-lineengine(firingorder1.5)
f=Enginespeed:601.5.
Overviewoffiringinterval
Engine Numberofcylinders Firingorder Firinginterval

4-cylinderengine 4 1342 180
(B46)
11
B46Engine
1.Introduction
1.6.2.ActiveSoundDesign
Theacousticsoftheenginecanbeadaptedusingthehi-fisystem.Withthehelpoftheaudiosystem
installedinthevehicle,thevehiclesoundpatternissupportedbytheuseoftheActiveSound
Design.Thesoundpatternisachievedwiththereinforcementoftheacousticcomponents,whichare
generatedbytheengine.
Thefollowinggraphicprovidesasystemoverview.
BusstructureofActiveSoundDesign
Index Explanation
1 Enginespeed
2 Load
3 AudiosignaloftheActiveSoundDesign(ASD)
4 Speaker
5 Audiosignaloftheheadunit
ASD ActiveSoundDesign
BDC BodyDomainController
DME DigitalMotorElectronics
Headunit Controlunitforentertainmentandinfotainmentfunctions
K-CAN/K-CAN2 Bodycontrollerareanetwork(2)
PT-CAN Powertraincontrollerareanetwork
12
B46Engine
1.Introduction
TheDigitalMotorElectronics(DME)enginecontrolunitsendsinformationabouttheenginespeed
andloadviathePT-CANtotheBodyDomainController(BDC).TheBodyDomainController(BDC)
transmitsthisinformationfromthePT-CANtotheK-CAN/K-CAN2.ViatheK-CAN/KCAN2the
informationreachestheActiveSoundDesign(ASD)controlunit.TheActiveSoundDesign(ASD)
controlunitgeneratesanaudiosignalwiththisinformation.Thisaudiosignalismodulatedtotheaudio
signaloftheheadunitandforwardedtotheloudspeakers.Anenginesoundcorrespondingtothe
drivingconditionisoutputtothedriverviathespeaker.
TheActiveSoundDesign(ASD)canbemuteduptothenextterminalchangeviatheISTAdiagnosis
system.ItisnotpossibletodeactivatetheActiveSoundDesignpermanently.
13
B46Engine
2.EngineMechanical
2.1.Enginehousing
EnginehousingofB38engine
Index Explanation
1 Cylinderheadcover
2 Cylinderhead
3 Cylinderheadgasket
4 Crankcase
5 Oilsump
14
B46Engine
2.EngineMechanical
2.1.1.Cylinderheadcover
CylinderheadcoverB38engine
Index Explanation
1 Mountingsofcamshaftsensors
2 Oilfillerneck
3 Recessesforinjectors
4 Mountingsforignitioncoils
5 Blow-bychannel,turbochargedoperation
6 Oilseparator,turbochargedoperation
7 Mountingforhighpressurepump
15
B46Engine
2.EngineMechanical
Index Explanation
8 MountingsofVANOSsolenoidvalveactuators
9 Oilseparator,naturallyaspiratedengineoperation
10 Blow-bychannel,naturallyaspiratedengineoperation
11 Bayonetfittingwithretainingclips
AsisthecasewiththeexistingN20engine,theB46enginealsohasarecessformountingtheVANOS
solenoidvalveactuatorsinthecylinderheadcover.IncontrasttotheN20engine,theVANOSsolenoid
valveactuatorsarenotscrewedon,andinsteadarefastenedusingabayonetfittingandretainingclips.
Tasksofcrankcaseventilation:
Regulationoftheinternalenginepressure.
Cleaningtheblow-bygasestoremoveengineoil.
Recirculationofthecleanedblow-bygasesintheintakearea.
Whentheengineisinoperation,gases(referredtoas"blow-bygases")fromthecombustionchamber
passthroughthecylinderwallsandenterthecrankcase.Theseblow-bygasescontainunburnedfuel
andallelementsoftheexhaustgas.Inthecrankcasetheyaremixedwithengineoilwhichisavailable
thereintheformofoilmist.
Thevolumeoftheblow-bygasesisdependentontheenginespeedandtheload.Withoutcrankcase
ventilationexcesspressurewouldariseinthecrankcase.Thisexcesspressurewouldbepresentinall
cavitiesconnectedtothecrankcase(e.g.oilreturnduct,chainshaft,etc.)andleadtooilleakageatthe
seals.
Thecrankcaseventilationpreventsthis.Itroutestheextensivelyengineoil-freeblow-bygasesto
thecleanairpipeandtheseparateddropletsofoilflowbacktotheoilsumpviaanoilreturnpipe.
Inaddition,thecrankcaseventilation,incombinationwithapressurecontrolvalve,ensuresalow
vacuuminthecrankcase.
16
B46Engine
2.EngineMechanical
Crankcaseventilation,B38engine
17
B46Engine
2.EngineMechanical
Index Explanation
A Cylinderheadcover,viewfrombelow
1 Blow-bychannelintocleanairpipe(turbochargedoperation)
2 Blow-bychannelupstreamoftheintakevalves
(naturallyaspiratedengineoperation)
3 Cylinderheadcover
4 Intakeports
5 Oilreturn
6 Oilseparator(turbochargedoperation)
7 Oilseparator(naturallyaspiratedengineoperation)
8 Exhaustturbocharger
ThecrankcaseventilationinB46enginehasatwo-stagedesign.Thismeansthat,dependingonthe
loadcondition,theblow-bygasesareroutedviadifferentchannels.
Naturallyaspiratedengineoperation
Duringnaturally-aspiratedengineoperation,theblow-bygasesupstreamoftheintakevalvesare
routedtotheintakeport.
18
B46Engine
2.EngineMechanical
Crankcaseventilation,naturallyaspiratedoperationofBx8engine
Index Explanation
B Ambientpressure
C Vacuum
D Exhaustgas
E Oil
F Blow-bygas
1 Airfilter
2 Intakemanifold
19
B46Engine
2.EngineMechanical
Index Explanation
3 Separator
5 Blow-bychannelupstreamofcrankcase
6 Purgeairline
7 Non-returnvalve
8 Crankchamber
9 Oilsump
10 Oilreturn
12 Non-returnvalve,oilreturn
13 Cleanairpipe
14 Hosetocleanairpipe
15 Non-returnvalvewithrestrictor
16 Throttlevalve
17 Pressurecontrolvalve
Thefineoilmistisseparatedfromtheblow-bygaseswiththeassistanceofaseparatorandtheoil
dropletsformedareroutedbacktotheoilsumpviatheoilreturn.
Thethrottlevalveisclosedduringnaturally-aspiratedengineoperation.Thisproducesavacuumin
theintakesystem.whichdrawsintheblow-bygasesviablow-bychannelscastintothecylinderhead
directlyupstreamoftheintakevalves.InsystemscontrolledbyValvetronic,thethrottlevalveisalso
lightlyshutintheseoperatingconditionstoguaranteetheengineventilationfunction.
Apurgeairline,whichisconnectedtothecleanairpipeaheadoftheexhaustturbochargerandtothe
crankcase,routesfreshairviaanon-returnvalvedirectlyintothecrankcasechamber.Thebiggerthe
vacuuminthecrankcase,thebiggertheairmassintroducedintothecrankcase.Thispurgingprevents
thepressurecontrolvalvefromicingup.
Chargedoperation
Asasignificantoverpressureprevailsintheintakepipeduringturbochargedoperation,theblow-by
gasescannotbeintroducedupstreamoftheintakevalvesintheintakeport.Theblow-bygasesare
thereforeintroducedintothecleanairpipeinthisoperatingcondition.
20
B46Engine
2.EngineMechanical
CrankcaseventilationwithturbochargedoperationofB46engine
Index Explanation
A Chargingpressure
C Vacuum
D Exhaustgas
E Oil
F Oilandblow-byfuel-airmixture
1 Airfilter
2 Intakemanifold
21
B46Engine
2.EngineMechanical
Index Explanation
3 Separator
5 Blow-bychannelupstreamofcrankcase
6 Purgeairline
7 Non-returnvalve
8 Crankchamber
9 Oilsump
10 Oilreturn
12 Non-returnvalve,oilreturn
13 Cleanairpipe
14 Hosetocleanairpipe
16 Throttlevalve
17 Pressurecontrolvalve
Thefineoilmistisseparatedfromtheblow-bygaseswiththeassistanceofaseparatorandtheoil
dropletsformedareroutedbacktotheoilsumpviatheoilreturn.
Thecylinderheadcoverisconnectedtothecleanairpipebyahose.Duringturbochargedoperation,
avacuumisproducedinthecleanairpipe.Thisvacuumdrawstheblow-bygasesintothecleanair
pipeviathehose.
Alwaysensureabsolutecleanlinesswhenfillingtheenginewithengineoil.Cleantheoilfillerneck
beforeyouscrewonthesealingcap.Engineoilresidueatthesealingcapmayleadtomisdiagnosis
atthecrankcaseventilation.
2.1.2.Cylinderhead
Technicalfeatures:
Material:AlSi7MgCU0.5
Coolantcoolingaccordingtothecross-flowprinciple
Fourvalvespercylinder
Mountingofthevalvegear
MountingoftheValvetronicandtheValvetronicservomotor
Mountingofthehighpressurepump
22
B46Engine
2.EngineMechanical
CylinderheadofB38engine
Index Explanation
1 Cylinderhead
2 Mounting,highpressurepump
3 Axialbearing,exhaustcamshaft
4 Axialbearing,intakecamshaft
5 Intakeports
6 Mounting,Valvetronicservomotor
Coolingconceptofcylinderhead
TheB46enginehasacylinderheadwithcross-flowcooling.Inthecaseofcross-flowcooling,the
coolantflowsfromthehotexhaustsidetothecoolerintakeside.Thishastheadvantageofproviding
uniformheatdistributionintheoverallcylinderhead.Lossofpressureinthecoolingcircuitisalso
prevented.
Cylinderheadgasket
InordertosatisfythehighdemandsoftheB46engine,atriple-layerspringsteelgasketisusedasthe
cylinderheadgasket.
23
B46Engine
2.EngineMechanical
CylinderheadgasketinB38engine
Index Explanation
1 Springsteelgasket
2 Sealingareaofthechainshaft
3 Sealingarea,combustionchamber,cylinder3
Thecylinderheadgasketisproducedintwodifferentthicknesses.Thethicknessofthegasketcan
onlybecheckedviathepartnumber.
Ifacylinderheadgaskethasalreadybeenuseditmustnotbeusedagain.
2.1.3.Crankcase
Overview
Unit B46A20M0
Displacement [cm] 1998
Hole [mm] 82
Stroke [mm] 94.6
Singlecylindervolumes [cm] 499.6
Compressionratio 11:1
Distancebetweencylinders [mm] 91
24
B46Engine
2.EngineMechanical
Overview
Sideviewofcrankcase,B46engine
Index Explanation
A CrankcaseofB46engine
C Beltdriveside
D Transmissionside
1 ClosedDeck
2 Sealingsurface,coolantpump(transverseinstallation)
3 Cylinderbarrels(LDS=electricarcwiresprayed)
4 Coolantoutlet
5 Boreholeforoilpressuresensor
6 Boreholeforvacuumduct
7 Borehole,solenoidvalve
8 Sealingsurface,oilfiltermodule
Characteristicsofcrankcase:
Heat-treatedallaluminiumcrankcasemadefromAlSiMgCu0.5
Electricarcwire-sprayedcylinderbarrels
Weight-optimizedmainbearingcapofcrankshaftwithembossingteeth
Closed-deckdesign
DeepSkirt
Oilductsfortheuseofamap-controlledoilpump
Supportofcounterbalanceshaft(s)incoredtunnel
25
B46Engine
2.EngineMechanical
Electricarcwirespraying(LDS)
Electricarcwiresprayingmethod,Bx8engine
ThecylinderbarrelsoftheB46enginearecoatedbymeansofanelectricarcwiresprayingprocess.
Inthisprocedureaconductivemetalwireisheateduntilitmelts.Themeltisthensprayedontothe
cylinderbarrelsathighpressure.Thislayerofferrousmaterialisroughly0.3mmthick,extremelywear-
resistantandfacilitatesanefficienttransferofheatfromthecombustionchamberstothecrankcase,
andfromtheretothecoolantducts.
Advantages:
Lowerweight
Highwearresistance
Goodheatdissipationtothecrankcase
Lowerinternalenginefrictionthankstoexcellentslidingproperties
Duetothethinmaterialapplicationduringtheelectricarcwire-sprayingprocedure,subsequent
processingofthecylinderbarrelsisnotpossible.
26
B46Engine
2.EngineMechanical
Bearing,counterbalanceshaft
Crankcasefrombelow,Bx8engine
Index Explanation
A CrankcaseofB46engine
1 Positionofcounterbalanceshaft1
2 Cylinderbarrel(coatedbyelectricarcwirespraying)
3 Embossedmainbearingcap
4 Mainbearingseat
5 Ventilationholes
6 Positionofcounterbalanceshaft2
Inthe4-cylinderengine,theseforcesarereducedbytwocounter-rotatingcounterbalanceshafts.For
moreinformation,refertothechapteronCounterbalanceshafts.
ClosedDeck
Withtheclosed-deckdesign,thecoolantductsaroundthecylinderareclosedfromaboveand
providedwithcoolantboreholes.
27
B46Engine
2.EngineMechanical
DeepSkirt
Withthe"deepskirt"concept,thesidewallsextendfardownwards.Thislendsthecrankcaseahigh
degreeofstabilityandconsiderableflexibilityintermsofthepistonstrokelength.
Embossedcrankshaftbearingcap
TheweightofthemainbearingcapofthecrankshafthasbeenfurtheroptimizedforthenewB46
engine.Whentheimpressionconnectionismadethemainbearingcapisdesignedwithaprofile.
Whenthemainbearingboltsaretightenedforthefirsttime,thisprofilepushesintothesurfaceof
thebearingblockonthecrankcaseside.
Exchangeofthemainbearingcap,orpositioninginanotherbearingpositiononthecrankshaft,
isnotpermittedandwillleadtoenginedamage.
Ventilationholes
Thecombustionchambersareconnectedviaventilationboreholesatthebottomendofthecylinder
barrels.Theairflows,whichariseasaresultoftheupwardanddownwardmovementofthepistons,
canthusescapeeasierviatheventilationboreholes.Inaddition,asthedisplacementofairvolumehas
beensimplifiedbyusingtheventilationboreholes,thepistoncanmoveupanddownmoreeasily.
Thisreducestheinternalfrictionoftheengineandensurestheengineoperatesmoreefficiently.
2.1.4.Oilsump
Theoilsumpismanufacturedfromdie-castaluminium.
Tasks:
Collectingvesselforengineoil.
Collectionareaforreturningengineoil.
Reinforcingcomponentintheengine-transmissioncombination.
Fixturefortheoil-levelsensorandoildrainplug.
Connectionoftheanti-rollbarlinkfortransversemounting.
28
B46Engine
2.EngineMechanical
SideviewofB38engine
Index Explanation
1 Attachmentpoints,crankcaseattransmission
2 Timingcasecover
3 Sealplugforboreholeoftheholdingfixture
4 Attachmentpoints,oilsumpattransmission
5 Oilsump
6 Anti-rollbarlink(onlyfortransversemounting)
7 Oillevelsensor
Theenginecanbedisconnectedviaaboreholeintheoilsumpforadjustingthetiming.When
installingtheoilsumpwiththetransmissionremoved,makesurethatthetransmissioncontactsurface
oftheoilsumpandthetimingcasecoverareinoneplane.Alwaysusethecorrespondingspecial
tool.Ifagaparisesbetweenthetwoareaswhentighteningthemountingboltsofthetransmission,it
causesdamagetotheoilsump.
29
B46Engine
2.EngineMechanical
OilsumpofB38engine
Index Explanation
1 Anti-rollbarlink(onlyfortransversemounting)
2 Oildrainplug
3 Oilsump
4 Oillevelsensor
5 Reinforcingribs
6 Connectionofanti-rollbarlinkatoilsump
7 Oilreturntooilsump
8 Crankcaseendcover(beltside)
Theengineoilflowsfromtheoilcircuitbacktotheoilsumpviathereturnlineoftheexhaust
turbocharger.
TheB46enginedoesnothaveanoildipstick.Theoillevelismonitoredelectronicallyatalltimes
withtheassistanceoftheoil-levelsensorandcanberequestedviatheon-boardcomputer.
30
B46Engine
2.EngineMechanical
SealingB46engine
OilsumpgasketB46engine
Index Explanation
1 Radialshaftseal
2 Oilsump
3 Siliconebead
4 Sealingsurface,oilsump
31
B46Engine
2.EngineMechanical
AcrankcaseendcoverisnotrequiredwiththeB46engine.Thesiliconebeadmustbeappliedaround
theentiresealingsurfaceareaoftheoilsump.
Schematicdiagramforoilsumpsealing
Index Explanation
A Componentswithoutsiliconebead
B Componentswithsiliconebead
C Componentsboltedwithsiliconebead
1 Crankcase
2 Siliconebead
3 Oilsumpwithbevel
4 Siliconedischarge
Inordertosealwithsealant,abevelisrequiredaroundtheinneredgeoftheflange.Excesssealing
compoundcanbedischargedinacontrolledmannerintothespaceprovidedwhenscrewing.
Removalofthesealingcompoundbyoilsplashesisthusprevented.
32
B46Engine
2.EngineMechanical
2.2.Crankshaftdrive
2.2.1.Crankshaft
OverviewofcrankshaftofB46engine
CrankshaftofB46engine
Index Explanation
K Transmissionside,crankshaft
1 Camshaftsprocket,intermediateshaft
2 Gear,counterbalanceshaft1
3 Crankshaftgear
33
B46Engine
2.EngineMechanical
Index Explanation
4 Gear,counterbalanceshaft2
5 Intermediategear(changeindirectionofrotationofcounterbalanceshaft2)
6 Oilandvacuumpump
7 Oilpumpsprocket
IntheB46engineboththetimingchainandthedriveforthecounterbalanceshaftsarelocatedonthe
transmissionsideofthecrankshaft.
Technicaldata,crankshaft
Characteristics Unit B46engine

Material C38+N2
Manufacture Forged
Diameterofthemain [mm] 50
bearingjournal
Widthofthemain [mm] 25
bearingjournal
Diameteroftheconnecting [mm] 50
rodbearingjournal
Widthofconnectingrod [mm] 24
bearingjournal
Strokeoftheconnecting [mm] 94.6
rodbearingjournal
Throwangle [] 180
Numberofcounterweights 4
Numberofmainbearing 5
positions
Positionofthethrustbearing Bearing3
34
B46Engine
2.EngineMechanical
CrankshaftbearinginB38engine
OverviewofbearingshellsattheB38engine
Index Explanation
A Bearingshellinmainbearingseat
B Bearingshellsinmainbearingcap
C Axialguidebearing
K Transmissionside
1 Crankshafts,mainbearing
2 Connectingrodbearingjournal
3 Counterweights
4 Mainbearingseat
5 Mainbearingcap
Thecrankshaftismountedusingdifferentbearingshells.Thebearingshellsinthelow-loadzoneof
thebearingseathaveoilholesandaperipheralgrooveforfreshoilsupply.Thehighlystressedbearing
shellsintheareaofthemainbearingcaphavenooilholesorgrooves.
35
B46Engine
2.EngineMechanical
Duetotheverylowtolerances,specialattentionmustbepaidtocleanlinesswhenhandlingbearing
shells.
Theaxialguidebearingislocatedinthecenterbearingareaofthecrankshaft.Thisbearingholdsthe
crankshaftintheaxialdirectionandmustabsorbforcesinthelongitudinaldirectionwhich,forexample,
canariseduringtheoperationtheclutch.
Beforethecompletionoftheengine,checkthesideclearanceinaccordancewiththerepair
instructions.Excessivesideclearancemaycauseelectricalfaultsordamagetothecomponents.
Identifyingthebearingshells
Sothatthecrankshaftcancarryoutitsmaintaskeffectively,incorporationoftheliftingmovementand
conversiontoarotationalmovement,itmustbepositionedcorrectly.Thedimensiontobeadjusted
canalsobecalledafitandisgeneratedusingcrankshaftbearingshellswithvaryingdegreesof
thickness.
CrankshaftbearinginB38engine
Index Explanation
1 Hole
2 Shaft
Adistinctionismadebetweenthreetypesoffitinthedesign:
Clearancefit
Transitionfit
Interferencefit
36
B46Engine
2.EngineMechanical
Thefitisviewedasanaccuraterelationshipbetweentheboreholeandtheshaft.Thecrankcase
representstheboreholeandthecrankshaftrepresentstheshaft.Thisiswhythenumbersforthe
classificationofthebearingshellsarelocatedonthecrankcaseandthecrankshaft.Inthecaseofa
dimensionbeingadjusted,thisisaso-calledclearancefit.Aclearancefitischaracterizedbythefact
thatineachcasetheminimumdimensionoftheboreholeisgreaterthanthemaximumdimensionof
theshaft.Thiscreatesthenecessaryplaybetweentheshaftandtheborehole,whichisneededfor
thebearingofthecrankshaft.
Bearingshellclassificationonthebearingseat
Bearingshellclassificationonthebearingseat,B38engine
Index Explanation
I Bearingseat1
II Bearingseat2
III Bearingseat3
IV Bearingseat4
K Transmissionside
R Beltside
1 Crankcase
2 Stampedletters
Thestampedlettersonthecrankcaseareusedtodeterminethebearingshellsizesofthebearing
seat.
37
B46Engine
2.EngineMechanical
Thefollowinglettersareusedfortheclassification:
A=highestpossibleplay(thinnestbearingshell)
B=mediumplay(mediumbearingshell)
C=lowestpossibleplay(thickestbearingshell).
TheletterKstandsforthetransmissionsideofthecrankcase.Italsospecifiesthecountingorderfor
theassignment.
IfthereisaKbeforethestampedletters,thenthefirstletterofthecodereferstothebearingshellof
bearingseat4,whichislocatedonthetransmissionside.Thesubsequentletters,readfromleftto
right,refertothebearingseat3,2and1.Thepositionsmarkedwith"0"areplaceholdersforlarger
enginesandaresimplyomitted.
Usingthepreviousgraphicforreference,thefollowingcombinationisobtained:
Assignment:
Transmissionside=K
Bearingseat4=C
Bearingseat3=B
Bearingseat2=B
Bearingseat1=A.
Ifthestampedlettersarenotprecededby"K",thenthefirstletterofthecodereferstothebearing
shellofbearingseat1,whichislocatedoppositethetransmissionsideonthebeltside.The
subsequentletters,readfromlefttoright,refertobearingseat2,3and4.
Whenassigningtheletterswithout"K",thefollowingcombinationisobtained:
Assignment:
Bearingseat1=C
Bearingseat2=B
Bearingseat3=B
Bearingseat4=A.
38
B46Engine
2.EngineMechanical
Bearingshellclassificationonmainbearingcap
Bearingshellclassificationonmainbearingcap,B38engine
Index Explanation
I Mainbearingcap1
II Mainbearingcap2
III Mainbearingcap3
IV Mainbearingcap4
K Transmissionside
R Beltside
1 Crankshaft
2 Stampeddigits
Thestampeddigitonthecrankshaftdeterminesthebearingshellsizesofthemainbearingcap.
Thefollowingnumbersareusedfortheclassification:
1=highestpossibleplay(thinnestbearingshell)
2=mediumplay(mediumbearingshell)
3=lowestpossibleplay(thickestbearingshell).
39
B46Engine
2.EngineMechanical
Inthecaseofthecrankshaft,theletterKalsodefinestheassignmentofthebearingposition.
ThedigitnexttotheKistobeassignedtothemainbearingcap4whichisonthetransmissionside.
Thesubsequentdigits,readfromlefttoright,refertothemainbearingcap3,2and1.
Usingthepreviousgraphicforreference,thefollowingcombinationisobtained:
Assignment:
Mainbearingcap1=1
Mainbearingcap2=2
Mainbearingcap3=3
Mainbearingcap4=2
Transmissionside=K.
Decipheringthecombinationoflettersanddigits
Theletteranddigitcombinationofthemainbearingshellscanbedecryptedusingatableintherepair
instructions.Thecorrectbearingshellsizesaredeterminedwithhelpofthecolorcodes.
2.2.2.Connectingrod
ConnectingrodofB46engine
40
B46Engine
2.EngineMechanical
Index Explanation
1 Piston
2 Force-transmittingsurface
3 Wristpin
4 Connectingrodbearingbushwithshapedborehole
5 Connectingrod
6 Connectingrodbush
7 Smallconnectingrodeye(trapezoidalshape)
8 Largeconnectingrodeye(cracked)
9 Connectingrodboltsoftheconnectingrodbearingcap
10 Connectingrodbearingshelloftheconnectingrodbearingcap
11 Connectingrodbearingshelloftheconnectingrod(IROX-coated)
Thefamiliardrop-forgedcrackedconnectingrodsareused.
Ifaconnectingrodbearingcapismountedthewrongwayroundoronanotherconnectingrod,the
fracturestructureofbothpartsisdestroyedandtheconnectingrodbearingcapisnotcenterd.Inthis
eventtheentireconnectingrodsetmustbereplacedwithnewparts.InServicepleaseobservethe
specifiedjointingtorquesandangleofrotationspecificationsintherepairinstructions.
Weightclassification
Toguaranteesmoothenginerunning,theconnectingrodsaredividedintoweightclasses.Thelarge
andsmallconnectingrodeyesareweighedseparatelyanddividedintovariousclassesaccordingto
theirweight.
InServiceonlyconnectingrodsofthesameweightclasscanbeused.Thisiswhyonlyafullsetof
connectingrodsisavailableintheeventofareplacement.Thissetcomprisesthecorresponding
numberofconnectingrodsofaweightclassification.
Irox-coating
Inordertocomplywiththeincreasinglystringentexhaustemissionregulations,mostcombustion
enginesnowadaysareequippedwithanautomaticenginestart-stopfunction.Thishasledtoahuge
increaseinstartingcycles.
Toensuretheenginerunssmoothly,itisimportantthatsufficientlubricatingoilissuppliedtothe
bearingpositionsofthecrankshaft.Iftheoilsupplycanbeensured,solidbodycontactwillnot
occurbetweentheconnectingrodbearingjournalandconnectingrodbearingshellduetothethin
lubricatingfilm.
41
B46Engine
2.EngineMechanical
Iftheengineisnowstopped,itwillnotbepossibleforthemechanically-drivenoilpumptomaintain
theoilsupply.Theoilfilmbetweenthebearingpositionsflowsoff.Solidbodycontactoccursbetween
theconnectingrodbearingjournalandconnectingrodbearingshell.Oncetheengineisrestarted,
ittakesacertainamountoftimeforthelubricatingfilmtofullyre-establishitself.Theconnecting
rodbearingshellmaybesubjecttowearinthisshortperiod.TheIrox-coatingreducesthisweartoa
minimum.
TheIROX-coatedbearingshellsareonlylocatedontheconnectingrodsideasheretheloadacts
mainlyonthebearingshells.ThebearingshellcapsareequippedwithabearingshellwithoutIROX
coating.
TheIROXballbearingsareredduetotheirspecialcoating.
DetailedmagnificationoftheIrox-coatingoftheBx8engine
Index Explanation
1 Irox-coatedbearingshell
2 Oilfilm
3 Irox-coating
4 Bearingshell
5 Bindingresin
6 Hardparticle
7 Solidlubricant
TheIrox-coatingisappliedtoaconventionalbearingshell.Itconsistsofabindingresinmatrixmade
ofpolyamide-imidewithembeddedhardparticlesandsolidlubricants.Thepolyamide-imideensures,
incombinationwiththehardparticles,thatthebearingshellsurfaceissohardthatmateriallossis
nolongerpossible.Thesolidlubricantsreducesurfacefrictionandreplacetheoilfilmwhichbriefly
nolongerexistsbetweenthebearingshellandtheconnectingrodbearingjournalduringthestarting
phase.
42
B46Engine
2.EngineMechanical
Bearingshellclassificationofconnectingrodbearing
Theconnectingrodbearingshellsareavailableinonestandardsize.Itisthereforenotnecessaryto
followaproceduresimilartothatusedwiththemainbearingshellsofthecrankshaft.
2.2.3.Piston
PistonofBx8engine
Index Explanation
1 Pistoncrown
2 Valverelief
3 1stpistonring
4 2ndpistonring
5 3rdpistonring
6 Gudgeonpin
7 Pistonskirt
8 Ringbar
9 Fireland
43
B46Engine
2.EngineMechanical
Pistonrings
PistonringsofBx8engine
Index Explanation
1 Plaincompressionring
2 Steppedcompressionring
3 Oilscraperring
4 Piston
Toperformtheirfunctions,itisnecessaryforthepistonringstotouchthecylinderwallandtheedge
ofthepistongroove.Contactwiththecylinderwalliseffectedbytheradiallyactingspringforceofthe
ring.Theoilscraperringissupportedbyanadditionalring.
Thepistonringsrotateinthegrooveswhiletheengineisrunningandtherebyalterthepositionof
thegap.Thisstemsfromthelateralforcewhichactsonthepistonringsduringchangeofcontact.
Thisprocessremovesdepositsfromtheringgrooves.Italsopreventsthepistonringgapfromcutting
intothecylinderbarrel.
TheB46enginehastwocompressionringsandoneoilscraperring.
44
B46Engine
2.EngineMechanical
Theplainrectangularcompressionringsitsinthefirstpistonringgrooveandisusedasaplain
compressionring.
Thetaperfacedpistonringisalsoacompressionring.Asharpwiperedgedevelopsthroughthelug
forcontrollingtheoilsupply.Theundercutofthelugimpliesthattheoilscrapedfromtherunningedge
isdivertedandanoilblockagedoesnotformthere,whichwouldotherwisereducethescrapingeffect.
Theoilscraperringisasteelbandringwithspring.Thetwolandsandinparticularthechamfercreate
ahighsurfacecontactpressure,whichpromotestheoil-scrapingeffect.
TheplainrectangularcompressionringandthetaperfacedpistonringhaveaTopmark.When
installingthetwopistonringstheTopmarkmustbefacinginthedirectionofthepistoncrown.
2.2.4.Counterbalanceshafts
Duetotheoperatingprincipleofthepistonengine,undesiredoscillationsoccurattheenginehousing
whendriving,whichcanbetransmittedtothevehicleinterior.Tocounteractthisnegativeeffect,BMW
hasalreadybeeninstallingso-calledcounterbalanceshaftsinmorerecentenginegenerations.Uptill
now,theirrolewastocanceloutfreeinertiaforcesandthereforeincreaseridecomfort.Inadditionto
theinertiaforces,so-called'freemomentsofinertia'alsoexist,whichcanalsoadverselyeffectride
comfort.Dependingontheenginedesignandnumberofcylinders,varyingdegreesoffreeinertia
forcesandfreemomentsofinertiaoccur.
CounterbalanceshaftsystemoftheB46engine
Index Explanation
B CounterbalanceshaftsforthereductionoffreeinertiaforcesintheB46engine
Themassbalanceisusedtooffsetstructuralimbalances.Thetaskofthemassbalanceistoimprove
therunningandnoisecharacteristicsoftheengine,byneutralizingthefreeinertiaforcesandtorques.
Forthisreasonabriefdescriptionofthespecialfeaturesofforcesandtorquesisprovidedbelow.
45
B46Engine
2.EngineMechanical
Forces
Staticforce
Index Explanation
F1 Firstforcewithupwardsoperatingdirection
F2 Secondforcewithdownwardsoperatingdirection
S Static
1 Intensityofforce
2 Pointofaction
Forcesareinvisibleandcanonlybenoticedbytheireffects.Theyconsistofapointofactionandan
operatingdirection.Theirstatecanbedynamicorstatic.Theforcesareshownasanarrow(vector).
Thearrowheadprovidesinformationontheoperatingdirectionoftheforce.Attheotherendofthe
arrow(vector),oppositethearrowhead,isthepointofaction.Theintensityoftheforceisdetermined
bythearrowlength(vectorlength).Thephysicalunitofforceis[N]andthesymbolis[F].
Thepreviousgraphicshowstwoforcesactinginexactlyoppositedirectionswiththesameintensity.
Thesystemisbalanced(static)asbothforcescanceleachother.Whenobservedfromtheoutside,
areactioncannotbedetermined.
46
B46Engine
2.EngineMechanical
Torques
Statictorque
Index Explanation
F1 Contactforce[F]
F2 Largecounterforce[F]
F3 Smallcounterforce[F]
M1 Contacttorque[M]
M2 Counter-torque[M]
r1 Smallleverarm[r]
r2 Largeleverarm[r]
Torquesoccurifaforceistransmittedatitspointofactionviaaleverarm.Thephysicalunitoftorque
is[Nm]anditssymbolis[M].Theleverarmandtheforceactingatthepointofactionaredecisivefor
thesizeofthetorque.Thefollowingmathematicalcontextemerges:
M=Fr
Thepreviousgraphicshowstwotorqueswhichcanceleachotherout.Ifthecontactforceisincreased,
withoutincreasingthecounterforcetothesamedegree,thetwotorquesarenolongeratequilibrium.
Thependantwouldfalltothefloor.Tore-establishthestaticequilibriumofthesystem,eitherthe
counterforcehastobeincreasedortheleverarmextendedatwhichthecounterforceacts.
47
B46Engine
2.EngineMechanical
Oscillatingandrotatingforces
Theupwardsanddownwardsmovementofthepistons,aswellastheconnectingrods,iscalledan
oscillatingforceandtherotationalmovementofthecrankshaftiscalledarotatingforce.Thesetwo
differentforcesalsocausetheundesiredoscillationswhentheengineisrunning.
OscillatingforcesintheB38engine
Index Explanation
F1 Forcedirectedupwards
F2 Forcedirecteddownwards
1 Piston
2 Connectingrod
Oscillatingforcesoccurinthepistonenginewhenthedirectionchangesatbottomandtopdead
center.Duetotheinertiaofthepistonandtheconnectingrod,theforceisdirectedeitherupwardsor
downwards.Thefollowingthereforeapplies:thelowerthemassofthepistonandtheconnectingrod,
thelowerthecorrespondingoscillatingforceswillbe.
48
B46Engine
2.EngineMechanical
InordertoreducethefuelconsumptionaccordingtotheEfficientDynamicsstrategy,thepoweroutput
perliterisincreased.Throughtheuseofexhaustturbochargersmorepowerisobtainedfromthe
samedisplacement.Thismeansthepistonsandtheconnectingrodareexposedtohigherignition
pressuresandmusthaveamoresoliddesign.Themassesofthecomponentssubsequentlyincrease,
andthustheoscillatingforces.
RotatingforcesintheB38engine
Index Explanation
A Pistonstroke(offsetofconnectingrodbearingjournal)
Fx Rotatingforces
1 Connectingrodbearingjournal
2+3 Counterweights
Toproducearotatingmovementofthecrankshaftfromthestrokeofthepiston,theconnectingrod
bearingjournalsthatsupportthelargeconnectingrodeyearenotlocatedontheaxisofrotationof
thecrankshaft.Animbalancewhenturningthecrankshaftoccursbytheoffsetoftheconnectingrod
bearingjournals.Thearisingimbalanceiscounteractedbytheuseofcounterweights.
49
B46Engine
2.EngineMechanical
CounterweightsofcrankshaftofB38engine
Index Explanation
F1 Forceofthecrankshaftweightdirectedtotheleft
F2 Forceofthecrankshaftweightdirectedtotheright
Therotatinginertiaforcescanbecompletelyneutralizedwithhelpofthecounterweightsatthe
crankshaft.Someoftheweightatthecrankshaftisalsousedtoreducetheoscillatinginertiaforces
(changeofdirectionofthepistonandconnectingrod).Iftheentireoscillatinginertiaforcesare
reducedbycounterweightsatthecrankshaft,theforcesortorques(dependingonthedesignand
numberofcylinders)inthetopandbottomdeadcenterofthepistonsareneutralized.However,this
wouldalsomeanthatinthepistonintermediateposition(pistonbetweentopdeadcenterandbottom
deadcenter)theinertiaforcesofthecounterweightsworkinalateraldirection.Theresultwouldbe
vibrationswhicharetransmittedviathecrankshaftbearingtothecrankcaseandfinallytotheentire
vehicle.
Thisconflictcanberesolvedthroughtheuseofcounterbalanceshafts,aswellascleverweight
classificationofthecounterweightsatthecrankshaft.
50
B46Engine
2.EngineMechanical
Oscillatingtorques
Oscillatingtorques
Index Explanation
B 4-cylinderengine
Thisexampleshowswhythedesignplaysaroleinwhichforcesortorquesoccurduringengine
operation.
Incontrast,theforceswhichoccuratthecrankshaftofthe4-cylinderenginewhentheengineis
runningcanceleachotherout.Freemomentsofinertiathereforedonotoccur.
Order
Theinertiaforcesaredividedinto"orders".Themorefrequentlyaninertiaforceoccursduringeach
crankshaftrevolution(360),thegreateritsorderofmagnitudewillbe.
Thefreeinertialforcesandtorquescategorizedasfollows:
Inertiaforces,1storder
Inertiaforces,2ndorder
Inertiatorques,1storder
Inertiatorques,2ndorder.
Thefollowingtableprovidesanoverviewofthearisingforcesandtorquesdependingonthedesign
andnumberofcylinders
Inertiaforces, Inertiaforces, Inertiatorques, Inertiatorques,

1storder 2ndorder 1storder 2ndorder
4-cylinderin-line X
engine
6-cylinderin-line
engine
51
B46Engine
2.EngineMechanical
Thetableprovidesinformationonwhichforcesandtorquesoccurandtheirorderofmagnitude.Free
inertialforcesandmomentsofinertiaofthefirstorderarethemostnoticeable.Freeinertiaforcesand
momentsofinertiaofthesecondorderareperceivedismuchlesstroublesome.Thegreatertheorder
ofmagnitudeistherefore,themoreitcanbedisregardedforthepurposesofmassbalancing.
Thetableshowsthatthebestenginedesignintermsofsmoothrunningisthe6-cylinderin-line
engine.Allforcescanceleachotherout.Therefore,withthisenginedesignnoadditionalmeasuresfor
neutralizingtherotatingoroscillatingmasseshavetobeimplemented.
2.2.5.CounterbalanceshaftofB46engine
Freeinertiaforcesofthe2ndorderoccurinthe4-cylinderin-lineengine.Thefollowinggraphicshows
howtheforcesofthe1stordercanceleachother.
Freeinertiaforces,1storder,B46engine
Index Explanation
F1 Oscillatingandrotatinginertiaforcewithoperatingdirection0crankangle
1 Inertiaforcesinequilibrium(static)
52
B46Engine
2.EngineMechanical
Ifyoutakealookatthecrankshaftfromthefront,thenallforcesofthe1stordercanceleachother.
However,inertiaforcesofthe2ndorderoccur,whichcanbeexplainedasfollows:
Freeinertiaforces,2ndorder,B46engine
Index Explanation
A Positionline,piston1
B Positionline,piston2
C Stroke,piston1
D Stroke,piston2
1 Piston1
2 Piston2
3 Crankshaftangle0
4 Crankshaftangle45aftertopdeadcenter
53
B46Engine
2.EngineMechanical
Ascanbeseeninthepreviousgraphic,bothpistonsareattoporbottomdeadcenteratthesame
time.Ifthecrankshaftisrotated45counter-clockwiseandthetwopistonpositionsarecompared,it
becomesclearthatthepathscoveredbybothpistonsdiffer.Piston1,whichstartedfromthetopdead
centerposition,coversagreaterdistancethanpiston2fromthebottomdeadcenterposition.Asboth
pistonscoveradifferentdistanceinthesameperiod,theymusthavetravelledatdifferentspeeds.This
speeddifferenceaffectstheaccelerationanddecelerationoftheoscillatingmasses,thusleadingto
undesiredoscillations.Asthisprocessoccurstwicepercrankshaftrevolution,thesearereferredtoas
freeinertiaforcesofthe2ndorder.
Overviewofcounterbalanceshafts,B46engine
Index Explanation
A Counterbalanceshaft
B Crankshaft
1 Straighttoothgearing
2 Needlebearing
3 Intermediategear
4 Outputdrivegear,crankshaft
5 Outputpinion,timingchain
6 Outputpinion,chain,oilpump
54
B46Engine
2.EngineMechanical
TheB46enginehastwocounterbalanceshaftswhichrotateattwicethespeedofthecrankshaft.
Thegearsofthecounterbalanceshaftshave48teeth.Thegearofthecrankshafthas96teeth.
Acorrectsettingofthetwocounterbalanceshaftsisaprerequisiteforreductionoftheoscillations.
Usingaspecialtoolthecounterbalanceshaftscanbesecuredintheirspecifiedinstallationposition
inService.
Agearbetweenthecrankshaftandthecounterbalanceshafteffectsthechangeofrotationaldirection
oftherightcounterbalanceshaft.Inthenewcondition,thetoothflanksoftheidlergearhaveaspecial
coating.Thiscoatinghelpsadjustthetoothbacklashbetweenthecounterbalanceshaftandthe
crankshaftduringinstallationinService.Anincorrectlyadjustedtoothbacklashcanleadtorunning
noisesofthegearswhentheengineisrunning.
Anewlycoatedidlergearmustbeinstalledforsettingthecounterbalanceshafts.
Therepairinstructionsmustbefollowed.
2.2.6.Torsionalvibrationdamper
AtorsionalvibrationdamperisusedonthebeltdriveofB46engine.Thetorsionalvibrationdamper
assumesthefollowingtasks:
Reductionofthetorsionaloscillationsofthecrankshaft.
Reductionoftherotationaldeformityofthesupportingcomponents.
55
B46Engine
2.EngineMechanical
Variantofatorsionalvibrationdamper,B46engine
Index Explanation
1 Beltpulley
2 Plainbearing
3 Beltpulleyrubberisolationelement
4 Uncoupledbeltpulleyhub
5 Pressurehub
6 Vibrationdamperhub
7 Vibrationdamperrubberpart
8 Flywheel
56
B46Engine
2.EngineMechanical
Vibrationdamper
Thevibrationdampercomprisesahub,arubberelement,whichactsasaspring,andaflywheel,which
servesasweight.Therotaryoscillationsofthecrankshaftarereducedbythecombinedactionof
thespringandmasselement.Thisreducestheloadofthecrankshaftandthenoisesemittedbythe
engine.
Uncoupledbeltpulley
Theuncoupledbeltpulleyisimportantforsmoothlow-weardriveofsupportingcomponents.The
beltpulleyisuncoupledfromthehubbytherubberisolationelement.Therubberisolationelement
permitsgreaterrotation,andreducestheremainingrotationalimbalanceandtherebytheloadonthe
drivebelt.Thebeltpulleyissupportedbytheplainbearing.
Toavoiddamagetothetorsionalvibrationdamper,theenginemustnotbeoperated
withoutdrivebelts.
2.2.7.Chaindrive
Features:
Chaindriveatthesideoftheengineemittingtheforces.
Two-partchaindrivefordriveofcamshafts,synergypartsforthedieselengines.
Simplesleeve-typechains.
Electricmotorofthecombinedoil-vacuumpumpviaaseparatechain.
Plastictensioningrailsandguiderails.
Hydraulicchaintensionerwithspringpreload.
57
B46Engine
2.EngineMechanical
Chaindrive,Bx8engines
Index Explanation
1 Uppertimingchain
2 VANOSwithintakecamshaftsprocket
3 Upperguiderail
4 Toptensioningrail
5 Lowertimingchain
6 Camshaftsprocket,intermediateshaft
7 Bottomtensioningrail
8 Lowerguiderail
9 Crankshaft
10 Chainoil-vacuumpump
11 Oil-vacuumpumpcamshaftsprocket
12 Lowerchaintensioner
13 Upperchaintensioner
14 VANOSwithexhaustcamshaftsprocket
58
B46Engine
2.EngineMechanical
Thechaindriveisonthetransmissionside.Theinertiaofthetransmissionatthisengineend
significantlyreducestherotaryoscillationsandalsothereforetheloadsactingonthechaindrive.
TheB46engineisequippedwithatwo-partchaindrive.Withthisarrangement,thebottomtiming
chaindrivesthecamshaftsprocketoftheintermediateshaft.Thedrivetorqueissimplydivertedtothe
toptimingchainviatheintermediateshaft.
Sufficientlubricationofthebottomtimingchainisensuredbytheoilmistinthecrankcaseandthe
engineoilthatdripsoff.
Thecombinedoil-vacuumpumpisalsodrivenbythecrankshaftviaaseparatedrivechain.
Thescrewconnectionoftheoilandvacuumpumpcamshaftsprockethasaleft-handthread.
Lubricationoftopchaindrive
Lubricationoftopchaindrive,B46engine
59
B46Engine
2.EngineMechanical
Index Explanation
1 Upperguiderail
2 Toptensioningrail
3 Uppertimingchain
4 Topchaintensionerwithoilspraynozzle
5 Spraypattern
Thetimingchainisalwaystensionedontheunloadedside.Thisisperformedbyatensioningrailon
whichachaintensioneracts.Theuppertimingchainislubricatedbyanoilspraynozzleinthetop
chaintensioner.Thereisanopeninginthetensioningrailtoensurethatoilreachesthetoptiming
chain.
2.3.Valvegear
2.3.1.Variants
Twodifferenttechnologiesareusedintheareaofthevalvegear.
Valvegear,B38B46engine.
Index Explanation
A DoubleVANOS
B Valvetronic
ThefollowingtableprovidesanoverviewofthetechnologyusedintheB46engine:
Engine DoubleVANOS Valvetronic

B46A20M0 Yes Yes
60
B46Engine
2.EngineMechanical
2.3.2.VANOS
Thevalveoverlaptimeshaveasignificantimpactonthecharacteristicsoftheengine.Anenginewith
smallervalveoverlapthereforetendstohaveahighmaximumtorqueatlowenginespeedsbutthe
maximumpowerwhichcanbeachievedathighenginespeedsislow.Themaximumpowerachieved
withalargevalveoverlapontheotherhandishigher,butthisisattheexpenseofthetorqueatlow
enginespeeds.
TheVANOSprovidesasolution.Itmakesahightorquepossibleinthelowandmediumenginespeed
rangeandahighmaximumpowerinthehigherenginespeedranges.AfurtherbenefitoftheVANOS
istheoptionofinternalEGR.ThisreducestheemissionofharmfulnitrogenoxidesNOx,particularlyin
thepartialloadrange.Thefollowingisalsoachieved:
Fasterheatingupofcatalyticconverter.
Lowerpollutantemissionsduringcoldstart.
Reductioninconsumption.
DoubleVANOS,Bx8engine
Index Explanation
A Intakecamshaft
B Exhaustcamshaft
1 Incrementwheel,intakecamshaft
2 Incrementwheel,exhaustcamshaft
3 Triplecamforhighpressurepumpdrivesystem
61
B46Engine
2.EngineMechanical
Index Explanation
4 Exhaustcamshaftsprocket
5 VANOSunit,exhaustside
6 VANOSsolenoidvalveactuator,exhaust
7 VANOSsolenoidvalveactuator,intake
8 VANOSunit,intakeside
9 Intakecamshaftsprocket
ReasonforusingthedoubleVANOS
TheadvantagesofaValvetronicarelowerchargecyclelossesandthereforepotentialforreducingfuel
consumptionbyadoptinganappropriatedrivingstyle.However,incontrasttothrottlevalve-controlled
systems,Valvetroniccannotreducecharge-cyclelossesinthefullloadrange.
VANOSunit
WitholderVANOSsystems,suchasthatusedintheN55engine,theVANOSunitswerecontrolledby
separateVANOSsolenoidvalvesintegratedintooilductsinthecylinderhead.
Theoilductsinthecylinderheadarereducedandtheadjustmentspeedisincreasedbyusinga
VANOSsolenoidvalveunitandamechanicalVANOScentralvalve,whichislocatedinsidetheVANOS
unit.
62
B46Engine
2.EngineMechanical
ThefollowinggraphicshowstheoilductsintheVANOSunit:
VANOSunit,intakecamshaft,Bx8engine
Index Explanation
1 Rotor
2 Oilductfortimingadvance
3 Oilductfortimingretardation
4 Oilductfortimingadvance
5 Oilductfortimingretardation
Theintakecamshaftcanbeadvancedwiththeductsshadedlightyellow;theVANOSunitcanbe
retardedwiththeductsshadeddarkyellow.
63
B46Engine
2.EngineMechanical
Lockingpin,Bx8engine
Index Explanation
1 Lockingcover
2 Lockingpin
3 Lockingspring
4 Cartridge
5 Oilduct
6 Lockingcover
7 Oilduct
8 VANOScentralvalve
64
B46Engine
2.EngineMechanical
ThelockingpinensuresthattheVANOSunitadoptsaclear,lockedpositioninthedepressurized
state.Thelockingspringensurestheunitislockedbycontinuouslypushingthelockingpinintothe
lockedpositionwhentheactuatorisde-energized.TheVANOSunitisblockedinthiscondition.The
timingcanbeadjustedinthisway.Thisisimportantwhentheengineisstartedtoensureexacttiming.
Theoilpressurewhichispresentfortimingadvancesimultaneouslyunlocksthelockingpinviaoil
ductsintheVANOSunit.Ifthecamshaftistobeadvanced,thelockingpinisthenforcedbythe
appliedoilpressureagainstthelockingspringtowardsthecartridgeandthelockingcoverisreleased
forVANOSadjustment.
ThefollowinggraphicshowstheoilflowrateintheVANOScentralvalvewhichisusedtocontrolthe
camshaftadjustment:
VANOScentralvalve,intakecamshaft,Bx8engine
65
B46Engine
2.EngineMechanical
Index Explanation
1 Filter
2 Ball
3 Spring
4 Piston
5 Sleeve
6 Housing
7 Openinginplunger
8 Oilsupplyfrommainoilduct
9 BoretooilductinVANOS(timingadvance)
10 BoretooilductinVANOS(timingretardation)
TheVANOSunitissecuredtothecamshaftbytheVANOScentralvalve.TheoilflowintotheVANOS
unitissimultaneouslycontrolledbythisVANOScentralvalve.Thesystemisactuatedbyasolenoid
actuatorwithitsownpistonthatpushesonanddisplacesthepistonoftheVANOScentralvalve.
Theoilflowiscontrolledbymeansoftheplunger.
Thepreviousgraphicshowsthede-energizedVANOScentralvalve.Thelockingpinblocksthe
VANOSunit.
Timingdiagram
Variablevalveoverlap,Bx8engine
66
B46Engine
2.EngineMechanical
Index Explanation
1 Valvetravel
2 Spread,exhaustcamshaft
3 Spread,intakecamshaft
4 Degreecrankshaft
A VANOSsolenoidvalve,exhaust,de-energized
B VANOSsolenoidvalve,exhaust,dutycycle100%
C VANOSsolenoidvalve,inlet,de-energized
D VANOSsolenoidvalve,inlet,dutycycle100%
E Smallestvalveoverlapinidle
F Maximumvalveoverlapinpartialload
ThefollowingistobeexpectediftheVANOSunitdropsout:
Emergencyoperation.
FaultcodeentryintheDigitalMotorElectronics(DME).
2.3.3.Valvetronic
TheValvetronichasbeenfurtherdevelopedforuseinthenewB46engine.Thefourth-generation
Valvetronicisusedintheengine.AdistinguishingfeatureistheValvetronicservomotorwhichisvisible
fromtheoutside.
67
B46Engine
2.EngineMechanical
Valvetronic4thgeneration,Bx8engine
Index Explanation
1 Exhaustcamshaft
2 Rollercamfollower
3 Hydraulicvalveclearancecompensationelement
4 Valvespring
5 Exhaustvalve
6 Intakecamshaft
7 Wormgear
8 Eccentricshaft
9 Electricalconnection,Valvetronicservomotor
10 Intakevalve
TheValvetroniccomprisesafully-variablevalveliftcontrolandadoubleVANOS.Itoperatesaccording
totheprincipleofthrottle-freeloadcontrol.Withthissystem,athrottlevalveisonlyusedtostabilize
theengineoperationatcriticaloperatingpointsandtoensureaslightvacuumfortheengine
ventilation.Averysmallvacuumcanbeproducedintheintakepipebyslightlytiltingthethrottlevalve,
whichallowstreatedblow-bygasestobeintroducedintotheintakeportduringnaturally-aspirated
engineoperation.
68
B46Engine
2.EngineMechanical
ThefollowinggraphicprovidesanoverviewofthedesignoftheValvetronic:
Valvetronic,Bx8engine
Index Explanation
1 Incrementwheel,exhaustcamshaft
2 Exhaustcamshaft
3 Triplecamforhighpressurepumpdrivesystem
4 VANOSunitwithexhaustcamshaftsprocket
5 VANOScentralvalve,exhaustside
6 VANOScentralvalve,intakeside
7 VANOSunitwithintakecamshaftsprocket
8 Returnspringwithinsertplate
9 Intermediatelever
10 Gate
11 Intakecamshaft
12 Incrementwheel,intakecamshaft
69
B46Engine
2.EngineMechanical
Index Explanation
13 Drivepinion,eccentricshaft
14 Valvetronicservomotor
15 Hexagonsocket(Inbus)
16 Eccentricshaft
ThefollowingcomponentsoftheValvetronicwerereworkedforuseintheB46engine:
Assembledeccentricshaft
Adjustmentrangeincreasedfrom190(N20/N55)to253(B46)
Smallerwormgearratioof37:1
Thinnerlighterslidingblockswithonlyonescrewconnection
Returnspringinsertedandnotscrewed
Oilspraynozzleforlubricationofwormgearomitted
SmallermorepowerfulValvetronicservomotor.
ComparisonofValvetronicN20withB46engine
Index Explanation
A Valvetronic,N20engine
B Valvetronic,B46engine
1 Eccentricshaft
2 Gate
70
B46Engine
2.EngineMechanical
Index Explanation
3 Returnspring
4 Camshaft
5 Intermediatelever
6 Heightofinstallationspace
ByreworkingtheValvetronic,ithas,mostimportantly,beenpossibletosignificantlyreducethe
installationspace.Aconsiderableheightadvantagehasbeengainedbyswappingroundtheintake
camshaftandtheeccentricshaft.Thenewpositionoftheintermediateleverandgatesimplifiesthe
applicationofforceinthecylinderhead.Thegateisthereforeonlyattachedtothebearingsupport
withonescrewandispositionedviatwoprecisecontactsurfacesinthecylinderhead.Thereturn
springfortheintermediateleverbetweenthecylinderheadandbearingpositionisself-supporting
anddoesnotrequireitsownattachmentpoint.Theeccentricshaftis,asisalreadythecasewiththe
camshaft,an"assembled"design.
71
B46Engine
2.EngineMechanical
LubricatingoilsupplytotheValvetronicwormgear
LubricatingoilsupplytotheValvetronicwormgear,B46engine
Index Explanation
1 Cylinderhead
2 Drivepinionoftheeccentricshaft
3 WormgearofValvetronicservomotor
5 Outletborehole
6 Firstbearingpositionofeccentricshaft
7 Inletborehole
8 Oilchamber
72
B46Engine
2.EngineMechanical
Duetothefastadjustmentspeedsoftheeccentricshaftoflessthan300millisecondsfromminimum
tomaximumstrokeandthewideadjustmentrangefrom0.2millimeters(minimum)to9.9millimeters
(maximum)valveliftwithasmalltransmissionratio,sufficientlubricationbetweenthewormgearof
theValvetronicservomotoranddrivepinionoftheeccentricshaftmustbeensured.Thelubricatingoil
reachestheoilchamberviaaninletboreholeatthefirstbearingpositionoftheeccentricshaft.Here,
theoilvolumerisestotheloweredgeoftheoutletborehole.Theexcessoilflowsbacktotheoilcircuit
viatheoutletborehole.Thegearingofthewormgearisnowsupportedintheoilbathandistherefore
lubricatedatalltimes.
Informationondisassemblyandinstallationwork
Asnumerouschangeshavebeenmade,anewspecialtoolisusedtoremovethereturnsprings.
ThehexagonsocketontheValvetronicservomotorisformanualadjustmentofthewormgear.This
isnecessaryiftheValvetronicservomotorneedstoberemoved,forexample.Toavoiddamagetothe
wormgear,itmustbegreasedpriortostart-upusingaspeciallubricant(LongtimePDpartnumber:
83192160340).TheValvetronicintheDigitalMotorElectronics(DME)canbetaught-inusingthe
teach-inroutineinISTA.Duringthisprocess,thelimitpositionsofthesystemaredeterminedonce
againandstoredintheDigitalMotorElectronics(DME).Thepreciseprocedureforremovingthe
Valvetronicisdescribedinthecurrentrepairinstructions.
73
B46Engine
2.EngineMechanical
2.4.Beltdrive
Beltdrive,transverse-mountedB46engine
Index Explanation
A Withairconditioningcompressor
1 RibbedV-belt
2 Alternator
3 Coolantpump
4 Airconditioningcompressor
5 Torsionalvibrationdamper
6 Deflectingelement
7 Tensioningpulley
Thelengthofthedrivebeltchangesduetothermalexpansionandageing.Sothedrivebeltcan
transmittherequiredtorque,itmustbecontinuouslyincontactwiththebeltpulleyatadefined
pressure.Tothisendthebelttensionisexertedbyanautomatictensioningpulleywhichcompensates
forbeltelongationoverthefullservicelife.
Astandardbeltwith6ribsisused.
74
B46Engine
3.OilSupply
3.1.Oilcircuit
Hydrauliccircuitdiagram,B38engine
Index Explanation
A Oilpump
B Crankcase
C Cylinderhead
D Oilfiltermodule
75
B46Engine
3.OilSupply
Index Explanation
E VANOSunit,intakecamshaft
F VANOSunit,exhaustcamshaft
I 3-cylinderengine
II 4-cylinderengine
1 Oilsump
2 Intakepipewithfilter
3 Oilandvacuumpump
4a Map-controlledcontrolchamber(normaloperation)
4b Second-levelcontrolchamber(emergencyoperation)
5 Oilsupplyofvacuumpump
6 Pressurelimitingvalve(built-intopump)
7 Oil-to-waterheatexchanger,bypassvalve
8 Engineoil-to-coolantheatexchanger
9 N/A
10 Filterbypassvalve
11 Oilfilter
12 N/A
13 Oilpressuresensor
14 Chaintensioner,bottom
15 Map-controlledvalve
16 Lubricatingoilsupplytocrankshaftbearingshellsofbearingseat
17 Oilspraynozzlesforpistoncooling
18 Throttle
19 Lubricationpointsonintakecamshaft
20 Hydraulicvalveclearancecompensation
21 Lubricatingpoints,eccentricshaft
22 Oilspraynozzles,intermediatelever
23 Chaintensioner,top
24 Throttle
25 Lubricationpoint,high-pressurepump
26 Lubricatingpoint,exhaustcamshaft
27 Hydraulicvalveclearancecompensation
28 Oilstrainer,solenoidvalve
76
B46Engine
3.OilSupply
Index Explanation
29 Non-returnvalve
30 Solenoidvalve
31 VANOSswivelrotor(intakecamshaft)
32 VANOSswivelrotor(exhaustcamshaft)
Withforce-fedcirculationlubricationtheoilisdrawnoutoftheoilsumpbytheoilpumpthrough
anintakepipeandforwardedintothecircuit.Theoilpassesthroughtheengineoilcoolerwithan
integratedfull-flowoilfilterandfromthereintothemainoilduct,whichrunsintheengineblockparallel
tothecrankshaft.Branchductsleadtothecrankshaftmainbearings.Thereareboreholesbetween
themainbearingsofthecrankshaftandtheconnectingrodbearingjournalwhichadmittheoiltothe
lubricatingpointsoftheconnectingrodbearing.
Someoftheoilisdivertedfromthemainoilductanddirectedtothecylinderheadtotherelevant
lubricatingpointsandadjustmentunits.Whentheengineoilflowsthroughtheconsumers,iteither
returnstotheoilsumpviathereturnductsoritdripsbackfreely.
3.2.Mapcontrol
Systemoverviewofmap-controlledoilsupplyofBx8engine
77
B46Engine
3.OilSupply
Index Explanation
A Oilpressuresensorsignal
B Activationofmap-controlledcontrolvalve
1 Mainoilducttotheoilpressuresensor
2 Oilpressuresensor
3 DigitalMotorElectronics(DME)
4 Oilpump
5 Oilducttomap-controlledcontrolchamberofoilpump
6 Mapcontrolvalve
TheB46engineisequippedwiththefamiliarmap-controlledoilpumpwhichisalreadyused.
TheactualoilpressureisrecordedviaanoilpressuresensorandforwardedtotheDigitalMotor
Electronics(DME).TheDigitalMotorElectronicsperformsatarget/actualcomparisonbasedonthe
storedcharacteristicmaps.Themap-controlledcontrolvalveisactivatedbymeansofapulse-width
modulatedsignaluntilthenominalpressurestoredinthecharacteristicmaphasbeenreached.During
thisprocess,thedeliveryrateoftheoilpumpvariesaccordingtotheoilpressureintheoilducttothe
map-controlledcontrolchamber.
3.3.Oilpump
Theoilpumpplaysacentralroleinmoderncombustionengines.Duetothehighpowerandenormous
torquewhichispresentevenatlowenginespeeds,itisnecessarytoensureareliableoilsupply.This
isnecessaryonaccountofthehighcomponenttemperaturesandheavilyloadedbearings.Toachieve
lowfuelconsumption,thedeliveryrateoftheoilpumpmustbeadaptedtotherequirements.
Theoilpumpisdrivenbythecrankshaftviaachain.
78
B46Engine
3.OilSupply
Designofoilpump,B46engine
Index Explanation
A Vacuumpump
B Oilpump
C Second-levelcontrolarea(emergencyoperation)
D Map-controlledcontrolarea(normaloperation)
1 Vacuumducttovacuumpump
2 Oilducttomap-controlledcontrolchamber
3 Oilducttosecond-levelcontrolchamber
79
B46Engine
3.OilSupply
Index Explanation
4 Oilpressurechannel,pumpoutput
5 Pressure-limitingvalve
6 Intakepipewithfilter
7 Dischargevalves,vacuumpump
8 Oilintakeport
9 Pumpshaft
10 Rotorwithpendulum
11 Suctionside
12 Adjustingring
13 Adjustingringspring(2x)
14 Pumpinput
15 Majorthrustface
16 Bearingtube(centerofrotation)
Avacuumpumpisintegratedintotheoilpumphousing.
Arotorwithpendulumrotatesasshowninthegraphiconthepumpshaft.Acrescent-shapedcavity
arisesthroughtheeccentricposition.Duringthisprocess,theoilisdrawnintotheexpandingchamber
(intakeside)andisdeliveredviathecontractingchamber(pressureside).
Whentheengineisinoperation,oilpressureisadmittedtothemap-controlledcontrolsurfaceand
thesecond-levelcontrolsurfaceoftheoilpump.Dependingontheoilpressure,theadjustingringis
pushedviathecenterofrotationatthebearingtubetovaryingdegreesofforceagainsttheadjusting
ringsprings.Thechangeineccentricpositionoftheadjustingringchangesthesizeofthechamber,
andthereforealsotheintakeandpressurepoweroftheoilpump.
Topreventoverloadingoftheoilpump,afilterisinstalledupstreamofthepumpinlet.Themaximum
oilpressureoftheoilcircuitatthepumpoutletisrestrictedbyapressurelimitingvalve.Theopening
pressureofthepressurelimitingvalveis11.4+/1.4bar.
80
B46Engine
3.OilSupply
3.3.1.Mapcontrolvalve
Themap-controlledcontrolvalveisaproportionalvalvewhichcancontroltheoilpressuresteplessly.
Map-controlledcontrolvalve,B46engine
Index Explanation
A Voltagecurve,maximumdeliveryrate
B Voltagecurve,minimumdeliveryrate
C Voltagecurve,50%deliveryrate
1 Oilductfromtheoilfilter
2 Oilducttooilpump
3 Sealingring
4 Solenoidcoil
5 Electricalconnection
6 Valvespool
7 Filter
81
B46Engine
3.OilSupply
Theoilpressuresensorisconnectedtothemainoilductanddeliverstheactualoilpressureatthe
DigitalMotorElectronics(DME).TheDigitalMotorElectronicscalculatestherequirednominaloil
pressurebasedontheenginespeedandfuelinjectionrate.Apulse-widthmodulatedsignalissentto
themap-controlledcontrolvalvebasedonthedeterminedsetpointdeviation.Dependingonthepulse-
widthmodulatedsignal,thewidthofthevalvespoolopeninginthemap-controlledcontrolvalvevaries.
Dependingontheavailableopeningcross-section,moreorlessengineoilcanflowfromtheoilductof
theoilfilterintotheoilductandtotheoilpump.Thisoilflowchangesthepositionoftheadjustingring
intheoilpump,andthereforethedeliveryrateofthepump.
3.3.2.Normaloperation
Theoilpumphastwoseparatecontrolloopsinordertoguaranteenormaloperation(map-controlled
controloperation)andemergencyoperation(second-levelcontroloperation).
Oilcircuitduringnormaloperation,B46engine
Thiscontrolloopoperateswithanexternalmap-controlledvalve.Themap-controlledcontrolvalve
controlstheoilpressureinthemap-controlledcontrolchamberviaasoftwareintheDigitalMotor
Electronics.Iftheoilpressureinthemap-controlledcontrolchamberincreases,theadjustingring
furthercompressestheadjustingringspringandthepumpeccentricityisreduced.Thisresultsina
lowervolumetricflow.
82
B46Engine
3.OilSupply
3.3.3.Emergencyoperation
Oilcircuitduringemergencyoperation,B46engine
Duringemergencyoperation,thesystemoperateswithoutthemapcontrolbytheDigitalMotor
Electronics.Themap-controlledcontrolvalveisde-energizedinthisoperatingconditionandis
thereforeclosed.Thepurposeoftheemergencyoperationistomaintaintheoilpressureintheoil
pumpataconsistentlyhighlevel.Theoilpressureisguideddirectlyfromthemainoilducttothe
second-levelcontrolchamber.Thisleadstoanadjustmentoftheadjustingringagainsttheadjusting
ringspringandthusareductionofthevolumetricflow.Asitcontainsnoactuators,interventioninthis
controlsystemisnotpossibleanditalsocannotbeswitchedoff.
83
B46Engine
3.OilSupply
Operatingprincipleofoilpumpcontrolsystem,B46engine
Index Explanation
A Normaloperation
B Emergencyoperation
3.4.Suctionpipe
Theoilpumpdrawsoilfromtheoilsumpthroughtheintakepipe.Thesuctionpipeispositioned
sothatthesuctionopeningisbelowtheoillevelunderalloperatingconditions.Theintakepipe
incorporatesanoilstrainer,whichpreventscoarsedirtparticlesfromgettingintotheoilpump.
IntakepipeinB46engine
Theintakepipeisaseparatecomponentwhichisscrewedontotheoilpump.
84
B46Engine
3.OilSupply
3.5.Pressure-limitingvalve
PressurelimitingvalveinoilcircuitinB46engine
Index Explanation
A Oilpressure<11.4+/1.4bar
B Oilpressure>11.4+/1.4bar
C Engineoilvolumetricflow
1 Pressurelimitingvalveclosed
2 Pressurelimitingvalveopen
Thepressurelimitingvalveisresponsibleforprotectingtheoilpumpandtheoilcircuitagainst
overloading.Thisvalveopensatanoilpressureof>10baranddirectstheexcessengineoilbackto
theoilsump.Thisvalveisusedifnecessarywhenstartingtheengineatcoldambienttemperatures
(values<0C),astheviscosityoftheengineoilisveryhighhere.
85
B46Engine
3.OilSupply
3.6.Oilfiltermodule
Oilfiltermodule
Index Explanation
2 Oilfilterhousing
3 Oilfiltercover
4 Hexagonheadforopeningtheoilfiltercover
5 Hexagonheadforopeningtheoildrainplug
Duetotheconstructionspace,theoilfilterhousingissuspendedinthetransversemounting.
Theinspectioniscarriedoutfromthebottomofthevehicle.UsinganoildrainplugtheService
employeecandraintheengineoilfromtheoilfiltermodulebeforeopeningtheoilfiltercover.
86
B46Engine
3.OilSupply
InService,thespecifiedtorquesfortheoildrainplugandtheoilfiltercovermustbeobserved.Thetwo
O-ringsmustbereplacedeachtimetheoilfiltercoverandtheoildrainplugareopened.BothO-rings
areincludedintheoilfilterservicekit.
Valvesoftheoilfiltermodule
Index Explanation
1 Filterbypassvalve
2 Heatexchangerbypassvalve
Anon-returnvalveisnotrequiredthankstothesuspendedmounting.Thefiltercannotrunemptyafter
theengineisstoppedduetoitsposition.
87
B46Engine
3.OilSupply
3.6.1.Filterbypassvalve
Whenafilterisblocked,thefilterbypassvalveensuresthatengineoilreachesthelubricationpointsof
theengine.Itopenswhenthedifferentialpressureupstreamanddownstreamoftheoilfilteris2.5bar
0.3bar.
3.6.2.Heatexchangerbypassvalve
Theheatexchangerbypassvalvehasthesamefunctionasthefilterbypassvalve.If,onaccountofa
blockedoil-to-waterheatexchanger,theoilpressurerises,theheatexchangerbypassvalveopensat
anoilpressureof2.5bar0.3barandthelubricatingoilcanflowuncooledtothelubricationpoints.
Toensuretheenginerunsperfectly,onlyengineoilsapprovedbyBMWcanbeused.
88
B46Engine
4.CoolingSystem
Inordertoprotectthethermallyloadedenginecomponents,theengineoilandthetransmissionoil
fromoverheating,theyarecooledusingcoolant.Amechanicalcoolantpumpcirculatesthecoolantin
thecoolingcircuit.Theheatquantitiesintroducedtothecoolantareemittedtotheambientairagain
usingaradiator.Anelectricfanassiststheradiatoroutput.
ThecoolantintheB46engineismainlycirculatedviaamechanicalcoolantpump.Severalenginesare
alsoequippedwithanelectricaloverrunpumpwhichmaintainsatrickleofcoolanttothebearingseat
coolingsystemoftheexhaustturbocharger.
Thefollowinggraphicsprovideanoverviewofthedifferentcoolingcircuits.
4.1.Coolingcircuit,B46engine
Coolingcircuit,B46engine
Index Explanation
1 Radiator
2 Electricfan
3 Mapthermostat
4 Coolantpump
5 Coolanttemperaturesensor
6 Coolant-cooledexhaustturbocharger
7 Enginehousing
89
B46Engine
4.CoolingSystem
Index Explanation
8 Heatexchanger
9 Electriccoolantpump(20W)
11 Tankventilationlinefromthecylinderhead
12 Expansiontank
13 Ventilationlineoftheradiator
4.1.1.Specialfeatures
Coolant-cooledexhaustturbocharger
Mechanicalcoolantpump
Electriccoolantpump
Characteristicmapthermostat
Duetothetwin-scrolltechnology,theB46enginesareequippedwithasteelmanifold.'Twin-scroll'
meansthattheexhaustflowsareroutedviatwoseparatechannelstotheexhaustturbocharger.The
heatproducedisabsorbedbythecoolantwhichissuppliedviaacoolantconnectionontheexhaust
turbocharger.Whenthemotorisnotrunning,post-coolingoftheexhaustturbochargerispossiblewith
theassistanceofanelectriccoolantpump(20W).Thispreventsabuild-upofheatintheareaofthe
exhaustturbocharger.
Formorein-depthexplanationsontheexhaustturbocharger,refertothechapterIntakeairandexhaust
emissionsystem.
90
B46Engine
4.CoolingSystem
4.2.Systemoverview,vehicle
Vehiclecoolingcircuit,B38engine
Index Explanation
A Coolantcooleddown
B Coolantwarmedup
C Coolantheatedup
I Cooledcoolanttocoolantpump
II Heatedcoolantfromenginetoradiator
III Cooledcoolanttothermostat
91
B46Engine
4.CoolingSystem
Index Explanation
IV Coolantflowviaexhaustturbocharger
1 Coolantpump
2 Radiator
3 Expansiontank
4 Heatexchanger
4.3.Coolingmodule
Coolingmodule
Index Explanation
1 Chargeaircooler
2 A/Ccondenser
3 Radiator
4 Electricfan
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B46Engine
4.CoolingSystem
4.4.Coolantpump
Coolantpumpwithcharacteristicmapthermostat
Index Explanation
A Cooledcoolant
B Warmedcoolant
C Heatedcoolant
1 Coolantductfromthecrankcase
2 supportingcomponentcarrier
3 Inletfromexpansiontankandheatexchanger
4 Feedfromradiator
5 Mapthermostat
6 Coolantducttothecrankcase
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B46Engine
4.CoolingSystem
Thecoolantpumpformsoneunitwiththecharacteristicmapthermostat.Thecoolantpumphousing
ismadefromthealuminiumalloyALSi9Cu3,theimpellerandthethermostatcoveraremadeofplastic.
TheDigitalMotorElectronicscontrolsthecoolingcircuitviaamap-controlledthermostat.
4.5.Expansiontank
Expansiontank
Index Explanation
1 Coolantline,coolantexpansiontankoutput
2 Tankventilationlinefromthecylinderhead
3 Ventilationlineoftheradiator
4 Sealingcap
5 Visiblefillinglevelindicator"Maximum"
6 Visiblefillinglevelindicator"Minimum"
Theexpansiontankisusedasareservoirforthecoolant.Theexpansiontankensuresthatthereis
alwaysasufficientquantityofcoolantavailableinthecoolingcircuit.
Inthesealingcapthereisapressurereliefvalvewhichrestrictsthepressureinthesystem.
Thesealingcapmustneverbeopenedwhentheengineishot.Thereasonforthisisnotjusttherisk
ofburning.Inhigherareasofthecoolingcircuit,suchasthecylinderhead,gasbubblesmayformasa
resultofthelossofpressure.Sufficientheatdissipationisnolongerguaranteedatthesepoints.
Thiswouldresultinoverheating.
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B46Engine
4.CoolingSystem
Thereisavisiblefillinglevelindicatorintheexpansiontank.Thefillinglevelcanbereadwhenthetank
isopen.Thefillinglevelshouldbebetweenmaximumandminimumforcorrectfilling.
4.6.Coolant
Thefamiliarcoolantwithasiliconebaseisused.Thecoolantisnotsubjecttoachangeinterval.
Thefillingisdesignedfortheentireservicelifeoftheengine.Forworkwhichrequiresanopeningof
thecoolingcircuitthecoolantmustbereplaced.Thepreciseprocedureforventilatingthecooling
circuitcanbefoundinthecurrentrepairinstructions.
ThecoolingsystemmustonlybefilledwithBMW-approvedcoolant.Ifthewrongcoolantisused,
damagetothecoolantpumps,coolanthoses,radiatorsandcylinderheadgasketmaysubtlycreepin.
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B46Engine
5.IntakeAirandExhaustSystem
SystemoverviewofintakeairandexhaustemissionsystemintheB38engine
Index Explanation
1 Chargeaircooler
2 Intakesilencer
3 Hotfilmairmassmeter
5 Actuatorofelectricallyadjustablewastegatevalve
6 Broadbandoxygensensorupstreamofcatalyticconverter(controlsensor)
7 Catalyticconverter
8 Voltage-jumpsensordownstreamofcatalyticconverter(monitoringsensor)
9 DigitalMotorElectronics(DME)(MEVD17.2.3)
10 Tankventvalve
11 Intakemanifoldpressuresensor
12 Throttlevalve
13 Charge-airtemperatureandcharge-airpressuresensor
96
B46Engine
5.1.Intakeairsystem
Airintakesystem,transversemounting
97
B46Engine
Index Explanation
A Freshair
B Purifiedair
C Heatedchargeair
D Cooledchargeair
1 Engineventilationheating(onlywithcold-climateversion)
2 Blow-bychannelintocleanairpipe(turbochargedoperation)
3 Cleanairpipewithresonator
4 Airfilterhousing
6 Throttlevalveunit
7 Chargeairtemperatureandchargingpressuresensor
8 Connectionforcarboncanisterregenerationline
9 Unfiltered-airsnorkel
10 Chargeairhose
12 Intakemanifold
13 Chargeaircooler
14 Chargeairhose
15 Purgeairline
16 Exhaustturbochargercompressor,inletside
Theairductofthedifferentiatedairintakesystemdiffersdependingontheinstallationposition.
Thisdocumentationonlydealswiththeairductinthetransverse-mountedBx8engine.
Theintakeunfilteredairreachestheintakesilencerwithaircleanerviatheunfilteredairlinewithintake
airgrille.Theunfilteredairisfilteredintheintakesilencerwithaircleanerandbecomescleanair.Then
thecleanairisdirectedtotheexhaustturbochargerviathehotfilmairmassmeterandthecleanair
pipewithresonator.Theblow-bygasesfromthecrankcasearealsointroduced,dependingontheload
condition,intothecleanairpipeupstreamoftheexhaustturbocharger,orintotheintakeportsdirectly.
Thecleanairiscompressedandheatedintheexhaustturbocharger.Thecompressed,warmcharge
airisfurtherdirectedtothechargeaircoolerinthechargeairhose.Fromthechargeaircoolerthenow
cooledchargeairisdirectedtothethrottlevalveviaanadditionalchargeairhoseandtheadapterpipe
withchargeairtemperatureandchargingpressuresensor.Thecooledchargeairistakentotheintake
airsystemviathethrottlevalve.
5.1.1.Intakesilencer
Theintakesilencerismountedontheengineandcontainstheaircleaner.Airwhichhasbeeninducted
uptotheairfilterisreferredtoasfreshair.Afterleavingtheairfilterthecleanedairisreferredtoas
cleanair.
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B46Engine
5.1.2.Chargeaircooling
Chargeaircooler
Becausetheairheatsupduringcompressionintheexhaustturbochargerandthusexpands,the
amountofoxygenwhichcanberoutedintothecombustionchamberisreducedagain.Thecharge
aircoolerhasacounteractiveeffectinthatitcoolsthecompressedair.Thedensityisthusincreased
andtheoxygencontentpervolumeisalsoincreased.Thechargeaircoolerislocatedinthecooling
modulebelowtheradiator.Itisanair-airheatexchanger.Thecompressedairflowsthroughthecharge
aircoolerinseveralplates,aroundwhichfortheirpartthecoolingairflows.
5.2.Exhaustemissionsystem
5.2.1.Exhaustturbocharger
ExhaustturbochargerintheB46engine
ExhaustturbochargerintheB46engine
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B46Engine
Index Explanation
A Turbineside
B Compressorside
1 Exhaustduct
3 Twin-scroll
4 Electricwastegatevalve
TheexhaustturbochargeroftheB46engineisatwin-scrollexhaustturbocharger.Tofacilitateafast
anddirectresponse,theexhaustflowsfromcylinders1and4,and2and3aremergedandroutedto
thecompressorviatwoseparatechannels.Thisprincipleisreferredtoaspulseturbocharging.
Theexhaustmanifoldandexhaustturbochargerhousinghavebeendesignedasonecommoncast
partandcannotbereplacedindividually.
Thechargingpressureisadjustedviaanelectricalactuator.
5.2.2.Blow-offvalve
Ablow-offvalveisnotusedincurrentmodels.Pressurepeaks,causedbysuddenloadshedding
duetotheinertiaoftheturbineoftheexhaustturbocharger,canbeavoidedbycarefultuningofthe
DigitalMotorElectronicssoftware.Withforesightedchargingpressurecontrol,pressurepeakscanbe
predictedandreducedbyquickadjustmentoftheelectrically-adjustablewastegatevalve.Assisted
byadelayedloadcontroloftheValvetronic(intheminimumliftdirection)orthethrottlevalve(inthe
closeddirection),theremainingchargeairwhichisproducedcanberoutedtotheexhaustemission
systemviatheengine.Thisformofcontrolthuspreventstheexhaustturbochargershaftfrombeing
exposedtoexcessivetorsionalstressduetohighpressurepeaks.
5.2.3.Chargingpressurecontrol
ThechargingpressureinB46enginesiscontrolledviaanelectricallyadjustablewastegatevalve.
Electrifiedadjustment
Incontrasttoavacuum-controlledchargingpressurecontrol,thefollowingcomponentsarenot
required:
Vacuumunit
Vacuumlines
Electro-pneumaticpressureconverter
Vacuumreservoir
100
B46Engine
Overviewofelectricallyadjustablewastegatevalve,B38engine
Index Explanation
1 Exhaustmanifold
2 Wastegatevalve
3 Adjustinglinkage
4 Locknut
6 Exhaustturbocharger,compressorside
7 Exhaustturbocharger,turbineside
Advantagesofelectricalactivation
Fastercontrolspeed
Moreprecisecontrol
Simplerdiagnosis
Fewercomponents
Largeropeningangleofwastegatevalve
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B46Engine
Operatingprinciple
Actuatorofelectricallyadjustablewastegatevalve
Index Explanation
1 Strokelinkage
2 Adjustmentlinkage
3 Actuator
Adirectcurrentmotorandasensorarelocatedintheactuatoroftheelectricallyadjustablewastegate
valve,resultinginatotaloffiveelectricalconnections.Thewastegatevalveisopenedorclosedbya
liftingmovementofthelinkage.
TheactuatoroftheelectricallyadjustablewastegatevalvecanbereplacedseparatelyinService.
Eachtimetheadjustinglinkageisactivated,thesystemmustbere-adjustedwiththeassistanceof
theBMWdiagnosissystemISTA.Thismeasureisnotrequiredwhenreplacingtheentireexhaust
turbochargerasthelinkageissuppliedpreset.
Iftheactuatorisreplacedindividually,ateach-inroutinemustbeperformedusingtheBMWdiagnosis
systemISTA.
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B46Engine
Sensorsignaltoelectricallyadjustablewastegatevalve
Index Explanation
A Wastegatevalveclosed
B Wastegatevalveopened
Thesensorisusedtodeterminethepositionofthewastegatevalve.Thewastegatevalvecanmove
toanyrequiredpositionbetweenmaximumopenandmaximumclosed.Whenthesensorsignalor
actuatordropsout,thewastegatevalveadoptstheopenpositiontoallowchargingpressuretobuild
up.Thisensuresthejourneycontinueswithreducedengineperformance.
AsthepositionsensorisalinearHallsensor,aresistancemeasurementfortestingthesensorisnot
permitted.
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B46Engine
5.2.4.Exhaustsystem
OverviewofexhaustemissionsystemoftheBx8engineintheF48
Index Explanation
1 Exhaustmanifold
4 Decouplingelement
5 Centersilencer
6 Rearsilencer
TheB46enginesatisfiestheexhaustgasemissionregulationsoftheULEVIIexhaustemission
standardswhenintroducedonthemarket.
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B46Engine
Exhaustgastreatment,B38engine
Index Explanation
1 Exhaustpipe
2 Decouplingelement
3 Monitoringsensor(voltage-jumpsensor)
4 3-waycatalyticconverter
5 Controlsensor(broadbandoxygensensor)
6 Clamp
7 Turbinehousing
8 Wastegatevalve
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B46Engine
Measuresforreductionofexhaustgasemissions
Preciseandfastchargingpressurecontrol.
Catalyticconverterheatingduringcoldstart.
Positioningofcatalyticconverternearengine.
NewLSFXfourvoltage-jumpsensorbyBosch.
Catalyticconverterheating
Whenstartingthecombustionenginefromcold,thewastegatevalveisopenedaswideaspossible
andtheignitionpointisadjustedtoretard.Theretardedignitionpointdelaysthecombustionprocess
whichinturnsupportstheheatinputforheatingofthecatalyticconverter.Astheturbinehousingis
short,ithasbeenpossibletopositionthecatalyticconverterveryclosetothewastegatevalve.Asthe
exhaustgasflowsintothecatalyticconverterattheperfectangleandbecauseofitspositionclose
totheengine,thecatalyticconverterreachesitsoperatingtemperatureveryquickly.Ifthewastegate
valveisopenedwhencold,pulsationoftheexhaustgasmaycausevibrationsinthewastegatevalve,
whichareperceivedasnoise.Thisisnotduetoadefectivecomponent,andisnormalrunningnoise.
Thisnoisebecomeslessaudibleasthetemperatureofthecomponentincreases.
Controlsensor
Withastoichiometricair/fuelratio(=1),theproportionofoxygenintheexhaustgasisidealfor
conversionofthepollutantsinthe3-waycatalyticconverter.Bymeasuringtheoxygencontentinthe
exhaustgas,theoxygensensoroftheDigitalMotorElectronicsdeliversimportantinformationfor
mixturepreparation.
AbroadbandoxygensensorwiththedesignationLSUADVhasbeenspeciallydevelopedforengines
withexhaustturbochargersandisusedasthecontrolsensor.Oneofthemajorcharacteristicsof
broadbandoxygensensorsistheirextensivemeasuringrange.ThemeasuringrangeoftheLSUADV
isfromalambdaof=0.65to=air.
ThebroadbandoxygensensorLSUADVisacombinationofameasuringcellandpumpcell.Thereis
asmalldiffusiongapbetweenthesetwocellswhichservesasameasuringchamberandisconnected
totheexhaustgasduct.Themeasuringcelloperatesaccordingtotheprincipleofavoltage-jump
sensorandmeasurestheresidualoxygencontentintheexhaustgas.Ifthefuel-airmixtureistoolean
(>1),thecontrolelectronicsappliesvoltagetothepumpcellsothatoxygenionsarepumpedout
ofthediffusiongap.Ifthemixtureistoorich(<1),oxygenionsarepumpedintothediffusiongap
byactivatingthepumpcellaccordingly.Thepumpflowrequiredtocontrolthepumpcellisdirectly
proportionaltotheoxygenconcentrationandthereforeservesasthecontrolvariablefortheairratio.
Thecontrolstrategyhasbeendevisedsothattheoxygenconcentrationintheareaofthediffusion
gapcorrespondstoanairratioof=1.Asthiscontrolmethodisextremelyfastandincredibly
accurate,thevoltagevalueofthemeasuringcellalwaysremainsataconstantlevel(450mV).
Thefollowinggraphicshowsthetwovoltagecurvesofthemeasuringcellandthepumpcellwhenthe
engineisinoperation:
106
B46Engine
Voltagesignal,LSUADVbroadbandoxygensensor
Index Explanation
A Signalvoltage,measuringprobe
B Controlvoltage,pumpsensor
C Positivecontrolvoltage
D Negativecontrolvoltage
E Pressonaccelerator
t Time
V V
Inthepositiverangeofthecontrolvoltage(U>0V),thereisexcessoxygenintheareaofthediffusion
gap(>1).Theengineisrunningslightlytoolean.Thepumpcellpumpsoxygenoutofthediffusion
gapinordertomaintainthelevelof450mVinthemeasuringcellconstant.
Inthenegativerangeofthecontrolvoltage(U<0V),thereisinsufficientoxygenintheareaofthe
diffusiongap(<1).Theengineisrunningslightlytoorich.Thepumpcellpumpsoxygenintothe
diffusiongapinorderalsotomaintainthelevelof450mVinthemeasuringcellconstant.
Anintegratedheatingelementensuresthatthebroadbandoxygensensorquicklyreachesits
operatingtemperature.
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B46Engine
Connections,broadbandoxygensensor
Positiveterminalofpumpcell
Negativeterminalofpumpcellandmeasuringcell
Heatingminus
Heatingplus
Positiveterminalofmeasuringcell
Monitoringsensor
Anewvoltage-jumpsensorwiththedesignationLSFXfourisusedasthemonitoringsensor.Thenew
oxygensensorhasthefollowingbenefits:
Sturdierdesign
Smallinstallationspace
Highermeasuringaccuracy
Fastercontrolreadiness
Theoxygensensorissuitableforenginestart-stopoperation.Inthiscase,thesensormustbeheated
throughouttheentirestopphase.Thevoltagerequiredduringtheheatingphaseis7.5voltsandthe
heatingcurrentisaround1ampere.
Engineoperation Airratio Sensorvoltage

Richoperatingphase =0.98 0.9V
Leanoperatingphase =1.02 0.1V
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B46Engine
6.VacuumSupply
Themainpurposeofthevacuumsystemistogeneratethevacuumforthebrakeservo.
6.1.Systemoverview
Schematicrepresentationofvacuumsupply
Index Explanation
A B46engine
1 Brakeservo
2 Non-returnvalve
3 Vacuumpump
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B46Engine
6.VacuumSupply
6.2.Vacuumpump
Installationlocationofvacuumpump,Bx8engine
Index Explanation
A Vacuum,secondaryvolume
B Vacuum,mainvolume
1 Vacuumlineforauxiliaryconsumer
2 Crankcase
3 Oilpump
4 Non-returnvalve
5 Vacuumlineformainconsumer(brakeservo)
WiththeB46engine,thelowpressurepumpandoilpumpareinstalledtogetherinonehousing.
Thevacuumductleadstothevacuumpump,passingthroughthetransmissionendofthecrankcase.
Thereisaplasticconnectionattheoutputofthecrankcasetowhichthevariousconsumersare
connected.Thereisanon-returnvalveinsidetheplasticconnection.
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B46Engine
6.VacuumSupply
VacuumpumpintheB46engine
Index Explanation
1 Vacuumduct
2 Exhaustvalves
3 Steelrotor
4 Plasticvane
Thereisasteelrotorwithaplasticvaneontheinsideofthevacuumpump.Itisdriventogetherwith
theoilpumpbythecrankshaftviaachain.
Theevacuatingoutputofthevacuumpumpis500mbarvacuum(absolute)inlessthansixseconds.
Astherunningsurfacesofthevacuumpumparecoatedwithoil,thevolumeofairdrawnincannot
bereleasedintotheatmosphere.Theairvolumedeliveredbythevacuumpumpistransferredto
thecrankcaseviadischargevalves.Fromhere,itreachestheairintakesystemviathecrankcase
ventilation.
Leaksinthevacuumsystemleadtoareducedbrakepowerassistance.
111
B46Engine
7.FuelSystem
Thefuelsystemismadeupofthefuelsupplyandfuelpreparationsystems.Thefuelsupplyincludes
thefueltankwithallmountedpartsandthefuellinesuptotheenginecompartment.
Thefuelfilterlinesintheenginecompartmentandallthefuelsystempartsontheenginebelongto
thefuelpreparationsystem.
Thefuelsupplyisdescribedintherespectiveproductinformationbulletinsforthemodels.
Fuelsystem,Bx8engineintheF56
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B46Engine
7.FuelSystem
Index Explanation
A Fuelpreparation
B Fuelsupply
2 Fuelpumpcontrolmodule
3 Electricfuelpump
4 Fuelfillerneck
5 Emergencyrelease
6 Dustfilter
7 Fueltankleakdiagnosissystem
8 Fueltank
9 High-pressurepump
10 Quantitycontrolvalve
11 Rail(high-pressureaccumulator)
12 High-pressuresensor
13 Sensorline,railpressuresensor
14 Actuatingwire,quantitycontrolvalve
15 PWMdataline
16 Actuatingwire,electricfuelpump(three-phaselineU,V,W)
7.1.Fuelpumpcontrolmodule
IncontrasttotheEKPScontrolunitpreviouslyused,thenewgasengineshaveafuelpumpcontrol
module.Thefuelpumpcontrolmoduleisnotshowninthecontrolunitoverview.Thefuelpump
controlmoduleisresponsibleforprocessinginformationaboutthenecessaryfuelpressurefrom
theDigitalMotorElectronics(DME)andforactivatingtheelectricfuelpumpaccordingtothese
requirementsviaathree-phaseACvoltage.
7.2.Electricfuelpump
Theelectricfuelpumpisactivatedasrequired.TherequirementsarecalculatedbytheDigitalMotor
Electronics(DME).Therequestregardingtheextentofthefuellowpressureissenttothefuelpump
controlmodulewiththeassistanceofapulse-widthmodulatedsignal(PWMsignal).Thefuelpump
controlmoduleprocessesthepulse-widthmodulatedsignalandwithhelpofaninvertergeneratesa
three-phaseACvoltageU,V,Wtoactivatethethree-phasemotoroftheelectricfuelpumpaccording
torequirements.
IfthePWMdatalineisdisconnected,theelectricfuelpumpisactivatedwiththemaximumsystem
performance.IfaPWMdatalineisinterrupted,thisonlyleadstoafaultcodeentry.Thecustomeris
notinformedaboutthisstatus,bytheilluminationofawarningandindicatorlight,forexample.The
electricfuelpumpisdesignedforcontinuousfullloadoperationandisalsonotdamagedifthePWM
datalineisinterruptedforanlongerperiod.
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B46Engine
7.FuelSystem
Thereisnofuelpressuresensorinthelow-pressurerangeofthefuelsystem.Thefuellowpressureis
calculatedintheDigitalMotorElectronicsbasedonamathematicalmodel.Thepowerconsumptionof
theelectricfuelpumpalsoprovidesinformationonthefuellowpressure.Ifthepowerconsumptionis
high,thismeansthatahighfuel-lowpressureexistsandifthepowerconsumptionislow,thismeans
thatalowerfuel-lowpressureprevails.
Thefollowingtableprovidesinformationonthetechnicaldataoftheelectricfuelpump.
Technicaldata
Enginespeedrange 26006000rpm
Pressurearea 2.0-6.5bar
Supplyvoltage 12V
Deliveryrateat3200rpmand3.5bar >80liters/60minutes
Theelectricfuelpumpbecomesimpermissiblyhotwithexcessivedryrunning>1minute.
Thereisariskofacomponentfault
114
B46Engine
7.FuelSystem
7.3.Fuelpreparation
Thefuelpreparationhasbeenmodifiedtomeettherequirementsofemissionlegislation.Anewdirect
railwhichhasbeendevelopedtowhichtheinjectorsarenowscrewed.
Overviewoffuelpreparation
Index Explanation
1 Fueldeliveryline
2 Railpressuresensor
4 High-pressurepump
5 Directrail
6 Solenoidvalveinjector
ThedirectinjectionsystemissimilartotheN20andN55.Asingle-pistonreciprocatingpumpwith
integratedquantitycontrolvalveisused.
Thedirectrailrepresentsadeparturefromthefamiliarsystemsuseduptillnow.Withthissystem,
thehighpressurelineshavebeenomittedandtheinjectorsareattachedtotheraildirectly.
Directlyconnectingthesolenoidvalveinjectorstotherailhasthefollowingadvantages:
Lessvolumeneedstobeavailableforhigh-pressureinjection.
Fewerinterfacesandthereforelessproblematicwithrespecttoleaks.
Shortcycletimesduringproductionduetocompactdesign.
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B46Engine
7.FuelSystem
Strictcleanlinessmustbeobservedwhencarryingoutanyworkonthefuelsystem
7.3.1.Fuelhigh-pressurepump
Overviewoffuelhigh-pressurepump
Index Explanation
1 Fuelfeedlinetohighpressurepump
2 High-pressurepump
3 Rollertappet
4 Pumppiston
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B46Engine
7.FuelSystem
Index Explanation
5 Spring
7 Highpressurelinetorail
8 Rail
9 Exhaustcamshaft
11 Snapfastener,fuelfeedline
12 Cylinderhead
13 Actuatingcam,highpressurepump
14 Bearingbracket,highpressurepump
Thefamiliarsingle-pistonhighpressurepumpbyBoschisused.Thehighpressurepumpisdriven
byatriplecamwhichisattachedtotheexhaustcamshaft.Fuellowpressureissuppliedtothehigh
pressurepumpviathefuelfeedfromtheelectricfuelpump.
Duetothehighfuelpressures,thefuellinesmustneverbedetachedwhentheengineisinoperation.
Whenremovingthehighpressurepump,followthespecificationsinthecurrentrepairinstructions.
Excessivetiltingofthepumpcandamagethepumppiston
Boschhigh-pressurepump
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B46Engine
7.FuelSystem
Index Explanation
A Low-pressureconnection
B High-pressureconnection
1 Balancingchamber
2 High-pressurenon-returnvalve
3 Pressure-limitingvalve
4 Pumppiston
6 Electricalconnectionofquantitycontrolvalve
Thequantitycontrolvalveatthehighpressurepumpadjuststhefuelpressureintherail.The
maximumpressureintherailis200bar.Thehighpressurepumpcontainsapressurelimitingvalve
whichopensatapressureof245bar.Thequantitycontrolvalveisactivatedviaapulse-width-
modulated(PWM)signalandassumestheopenpositioninthede-energizedstate.Thismeansthe
pumppistonofthehighpressurepumpcannotcompressthefuel.
Itfollowsthatthehighpressurepumpcannotbuilduppressureinthehigh-pressurefuelsystemwhen
thequantitycontrolvalveisremoved.Inthissituation,themaximumfuellowpressure(6.5bar)would
bepresentintherailduringanenginestart.Thesystemwouldbeinemergencyoperation.Toensure
theengineremainscapableofrunninginthisstate,theopeningperiodofthesolenoidvalveinjectors
hasbeenextendedandtheidlespeedincreased.Althoughthevehicleremainsdrivable,themaximum
engineperformanceisnotavailable.
Thequantitycontrolvalveisnotresistanttocontinuouscurrent.Apermanentcurrentsupplywith12V
directcurrentvoltagewouldrenderthecomponentdefective.
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B46Engine
7.FuelSystem
7.3.2.Directrail
Mountingtheinjectors
Index Explanation
1 Mountingbolts
2 Plasticsleeve
3 Holdingclampwithbayonetfitting
4 Rail
5 Solenoidvalveinjector
6 Castinglug
Thesolenoidvalveinjectorsarefastenedtotheholdingclampwithabayonetfitting.Thereisaplastic
sleevebetweentheholdingclampanddirectrail.Thisisnotdesignedtocollectescapingfuel.Itsonly
purposeistocarryoutaheliumpressuretestduringpre-assemblyatthefactoryinordertocheckthe
tightness.Aftertheinitialassembly,thisplasticsleeveisofnorelevancetotheengineoperation.When
thesolenoidvalveinjectorsarereplaced,theplasticsleevesarenolongerrequiredanddonotneedto
bereinserted.
Whenmanufacturingtheholdingclamp,castinglugsareproducedwhenthecomponentisdetached
fromthetool.Duetothelowinstallationtolerances,wheninstallingthesolenoidvalveinjectorsitmust
beensuredthatthesecastinglugspointinthedirectionoftheexhaustmanifold.Iftheyarepointingin
thewrongdirection(towardstheintakepipe),thiscanleadtomechanicalcontactbetweentheholding
clampandcylinderheadcover.
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B46Engine
7.FuelSystem
Themountingboltsoftheholdingclampmustbereplacedeachtimetheyarereleased.
Theshankofthesolenoidvalveinjectorsissensitivetohightensileforcesandrotationalangles.
Whenremovingandinstallingthesolenoidvalveinjectors,theprocedureinthecurrentrepair
instructionsmustbefollowedIfthesolenoidvalveinjectorsaredamaged,fuelmaybedischarged.
120
B46Engine
7.FuelSystem
7.3.3.Solenoidvalveinjector
SolenoidvalveinjectorHDEV5.2
121
B46Engine
7.FuelSystem
Index Explanation
1 Fuellineconnection
3 Stem
4 Compressionspring
5 Solenoidcoil
6 Armature
7 Nozzleneedle
8 6-holenozzle
AsisalreadythecasewiththeN55andN20engines,thenewB46engineisequippedwiththeBosch
HDEV5.2solenoidvalveinjector.Thedesignationoftheinjectorsisacombinationofthefollowing:
HDEV=high-pressurefuelinjectionvalve
5=generationdesignation
1=maximumfuelinjectionpressureof150bar
2=maximumfuelinjectionpressureof200bar
Ifcurrentissuppliedtothesolenoidcoil,amagneticfieldisproducedwhichattractsthemagnet
armature.Themagnetarmaturerunsupwardsonthenozzleneedle.Thelineartravelofthemagnet
armatureinthedirectionofthesolenoidcoilcarriesthenozzleneedlealongwithitandthenozzle
boresarereleasedinthedirectionofthecombustionchamber.
Therepairinstructionsthatarecurrentlyvalidmustbefollowedwhenremovingandinstallingthe
injectorsinService.Iftherotationalangleattheshankoftheinjectoristoolarge,thiscanleadto
damageandthereforeleaksinthefuelsystem.
Aspecialfueladditiveisrecommendedinmarketswithapoorfuelgradetopreventcokingofinjectors
indirectinjectionsystems.Theadditiveisaddedtothefuelinthefueltankfromwhereitarrivesatthe
injectors.
CokingattheinjectorsisreducedbyusingaBMW-approvedadditive(partno.83192183738).
ULEVIImeasuresatthesolenoidvalveinjector
DuetothemorestringentexhaustgasemissionregulationswhicharerequiredtomeettheULEVII
exhaustemissionstandards,technicalchangeshadtobemadetothesolenoidvalveinjectors.
Asisthecasewithdieselfuelpassengercarswhichhasbeendealtwithpreviously,inadditiontothe
limitvalueforparticulatemass(PM),thelimitvaluefortheparticleconcentration(PN)isalsostipulated
intheULEVIIexhaustemissionstandardsforgaspassengercars.
Thereasonforthisisthatinmoderngasengineswithdirectinjectionnohomogeneousfuel/airmixture
arisesincomparisontoengineswithintakepipefuelinjection.Therearethereforemoreparticlesin
theexhaustgas(particulatematter).
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B46Engine
7.FuelSystem
Differentdiametersoflaser-manufacturedboreholesareusedwiththenewhigh-pressurefuel
injectionvalves,forexample.Thefuelquantityofthetwosprayjetsintheexhaustdirectionisreduced
by20%,whichincreasestheothersprayjetsby10%respectively.
Thesolenoidvalveinjectorscanonlybeusedinapredefinedpositionintheinjectorshaftofthe
cylinderhead.Thisensurescorrectalignmentoftheinjectionpatterninthecombustionchamber.
ThefollowinggraphicillustratesthedifferencesbetweentheULEVandULEVIIversion:
ULEVIImeasures,solenoidvalveinjector
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B46Engine
7.FuelSystem
Index Explanation
A SolenoidvalveinjectorULEV
B SolenoidvalveinjectorULEVII
C Evennozzleboregeometry
D Unevennozzleboregeometry
X Openingperiod
Y Needletravel
1 Injectionquantitycompensationcode
2 Conventionaloperation
3 Automaticoperation
4 Spraypattern,intakevalveside
5 Spraypattern,exhaustvalveside
High-pressurefuelinjectionvalveswithsolenoidcoilsdonothavealinearbehaviorpatternacrossthe
entireservicelife,mainlyintheareaofminimalquantityfuelinjection.Thismeansovertheservice
lifethefuelinjectionratesvaryfromoneinjectortoanotherinjector.Althoughthehigh-pressurefuel
injectionvalvesareadaptedduringstart-upviatheinjectionquantitycompensationcodeintheDigital
MotorElectronics,inordertocompensateforpossiblemanufacturingtolerancesoftheindividual
high-pressurefuelinjectionvalvesintheDigitalMotorElectronics,andtoadaptallinjectorsinrelation
tooneanother,thisonlyhappensonceduringstart-up(injectionquantitycompensation).During
conventionaloperation,theparametersforactivationoftheinjectors,suchascurrentandactivation
duration,arethesameforallinjectorsthroughouttheentireoperatingtimeandcannotbeindividually
adapted.Anotheradaptationduringtheentireoperatingtimeisnolongerpossible.Thiswouldleadto
breachesofthestrictexhaustgasemissionslegislation,suchasULEVII,duringtheoperatingtime.
Anautomaticoperationallowsprecisedosingoffuel,particularlywhenusingextremelysmallinjection
quantities.Analysisofthevoltageandcurrentcurveininjectormodeallowsconclusionstobedrawn
aboutthemovementoftheneedle.Themostimportantinformationinrelationtothemovementofthe
needleistheneedletravelandopeningperiod.Thefuelinjectionratecanbedeterminedfromthese
twovariables.Ithasthereforebeenpossibletoomitprintingofainjectionquantitycompensationcode
ontheULEVIIsolenoidvalveinjectors.
ControlledValveOperating(CVO)
AsoftwareintheDigitalMotorElectronicspermanentlyensuresautomaticoperationofthesolenoid
valveinjectorsthroughouttheentireoperatingtime.
ThebasicprincipleofthisCVOfunctionisthatthepreciseopeningperiodofthehigh-pressurefuel
injectionvalvesisdetermined.TheDigitalMotorElectronicscandeterminethepreciseopeningperiod
basedonthefollowingparameters:
Powerconsumptionofthehigh-pressurefuelinjectionvalve
Voltageofthehigh-pressurefuelinjectionvalve
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7.FuelSystem
Currentandvoltagecurveofthesolenoidvalveinjector
Index Explanation
A Currentflow
B Voltagecurve
1 Startofactivation
2 Nozzleneedle,openingstart
3 Nozzleneedle,fullyopen
4 Endofactivation
5 Nozzleneedleclosing
Thesecurrentandvoltagevalueschangeintheeventofaneedlemovementinthehigh-pressurefuel
injectionvalve,forexample:
Armaturemistsup-whentheneedlevalveiswithdrawnfromthevalveseat.
Armaturemoves-needlevalvemovesindirectionofopenposition.
Armaturestationary-needlevalvecomestorestatthemaximumopenposition.
Reversemovement.
Armaturemoves-needlevalvemovesindirectionofclosedposition.
Armaturesuffersimpactandisbrakedhydraulically-needlevalveclosed.
Withthesevalues,calculatedfromcurrentandvoltagevaluesfromtheabovementionedneedle
movements,theDigitalMotorElectronicscandeterminetheactualopeningperiodofthehigh-
pressurefuelinjectionvalves.Ifthepreciseopeningperiodsareknown,theDigitalMotorElectronics
canalsodeterminetheexactfuelinjectionratebasedonthisinformation.
125
B46Engine
7.FuelSystem
Ifvariablefuelinjectionratesarenowtobeused,theDigitalMotorElectronicscanvarythefuel
injectionratethroughouttheopeningperiodbyactivatingtherespectivehigh-pressurefuelinjection
valveindividually.TheDigitalMotorElectronicsthushastheoptiontoadjustallhigh-pressurefuel
injectionvalvestothesamenominalfuelinjectionrate.
Thismeasureguaranteesthesamenominalfuelinjectionrateinallcylinders,especiallyintherange
whereextremelysmallamountsareinjected,aswellasatidlespeed,sothattheexhaustre-treatment
canalwaysworkefficiently.Thismeasureinsidetheenginereducesexhaustemissionsandtherefore
ensurescompliancewiththeexistingexhaustemissionstandards.
CylinderImbalanceMonitoring(CIM)
The"CylinderImbalanceMonitoring"functionisanadditionalsoftwarefunctionintheDigital
MotorElectronicswhichmonitorsthecorrectnessofthemixturepreparation.Theprimaryaimisto
determine,withtheassistanceofthisfunction,age-relatedoperatingtimeimpairmentsofthefueland
intakearea.Conclusionscanbedrawnabouttheairflowdifferencesanddifferentfuelinjectionrates,
forexample.Thesekindofdifferencesarenormallyattributabletoage-relatedleaksoftheintake-
componentsandpressurefluctuationsintherailorcokingoftheinjectors.
ThefollowinggraphicillustratestheoperatingprincipleoftheCylinderImbalanceMonitoringsoftware:
CylinderImbalanceMonitoringfunction
126
B46Engine
7.FuelSystem
Index Explanation
A Cylinderinnormaloperation
B Testcylinderwithhigherair/fuelratio
C Cylinderoutsidethetolerance
D Cylinderinsidethetolerance
E Richrange
F Leanrange
n Speedofcrankshaft
Airratio
1 Cylinderinrichrange
2 Testcylinderspeedconstant
3 Cylinderinidealrange
4 Testcylinderspeedslightlyslower
5 Cylinderinleanrange
6 Speedoftestcylindersignificantlyslower
ThefunctioniscyclicallyactuatedbytheDigitalMotorElectronics.Duringthisprocess,theair/fuel
ratioisincreasedforeachcylinderinsuccessionduringengineoperation.Atthesametimeastheair/
fuelratiointhetestcylinderisincreased,theremainingcylindersareenrichedinordertomaintain
theoveralllambdavalueoftheexhaustgaspassagewithintherange=1.Thisensuresperfect
functionalityofthe3-waycatalyticconverter.
Ifatestcylinderisoperatedwhentheair/fuelratioistoolow,aslightincreasewillnotbringabouta
changeinthecrankshaftspeed.
Whentheair/fuelratioinatestcylinderisincreasedintheidealrange,thisbringsaboutaslightchange
inspeedatthecrankshaft.
Ifatestcylinderisoperatedwhentheair/fuelratioistoohigh,thespeedatthecrankshaftdrops
rapidly.
Theenginespeedvariationsatthecrankshaftarenotevaluateddirectly,butratherthechangesin
smoothrunningduringengineoperation.Roughrunningofthecylindersinrelationtooneanotheris
balancedoutbyaso-called'cylinderbalancingcontrol'.Thetestcylinderintherichrangetherefore
bringsaboutaminorchangeinroughrunningandthetestcylinderintheleanrangebringsabouta
majorchangeinroughrunning.
MixtureerrorsdeterminedarestoredasafaultcodeentryintheDigitalMotorElectronics.Thefault
codeentryprovidesinformationaboutwhichcylinderisaffectedandtherichorleanvaluedetermined.
Thedriverisinformedabouttheerrorviaamalfunctionindicatorlamp.
127
B46Engine
7.FuelSystem
Servicenote
Whenreplacingtheinjector,thetaught-invaluesoftheCVOfunctionandCIMfunctionmustbe
reset.ThisisdonewiththeassistanceoftheBMWdiagnosissystemISTA.Adjustmentfunctionsare
availableintheservicefunctions.InordertoinformtheDigitalMotorElectronicsabouttheinjector
replacement,everyULEVIIsolenoidvalveinjectorwiththesamedummyvalue(215)istaughtin.
Oncetheteach-inprocedurehasbeensuccessfullycompleted,thestoredadaptationsareresetand
newadaptationsaretaughtinviatheCVOandCIMfunction.
Whenthesolenoidvalveinjectorsarereplaced,theymustbestartedupwiththeassistanceofthe
BMWdiagnosissystemISTA.
128
B46Engine
8.EngineElectricalSystem
8.1.DigitalMotorElectronics(DME)
DifferentvariantsoftheDigitalMotorElectronicsMEVD17.2.3areused,dependingonthecharge
cyclemethod.Thehardwareofthethrottlevalve-controlledenginecontrolunitsisthereforenotthe
sameasthehardwareoftheValvetronic-controlledenginecontrolunits.
Thecontrolunitnumberismadeupofthefollowing:
M=engineelectronics
E=electricalloadcontrol(withoutcable)
V=Valvetroniccontrol
D=directfuelinjection
17=controlunitgeneration
2=Bosch-internalprojectnumberforBMW
3=controlunitindex
TheDigitalMotorElectronicsisthecomputingandswitchingcenter.Sensorsontheengineand
thevehicledelivertheinputsignalsandactuatorsimplementthecommands.TheDigitalMotor
Electronicscalculatesthecorrespondingactivationsignalsfortheactuatorsfromtheinputsignals,
andalsothecomputingmodelsandcharacteristicmapsstored.
TheoperatingvoltagerangeoftheDigitalMotorElectronicsisbetween6and16volts.
AnambientpressuresensorandatemperaturesensorareintegratedintheDigitalMotorElectronics.
Theambientpressuresensorpermitsprecisedeterminationofthedensityoftheambientair.This
informationisrequiredforvariousdiagnosticfunctions.Inaddition,intheeventofafailureofthehot
filmairmassmeter,aprecisesubstitutevaluecanbecalculatedforthecylinderfillingwiththehelpof
additionalinputvariables.
Thetemperaturesensormeasuresthetemperatureinsidethecontrolunit.Ifthetemperaturethere
risestoosharply,multiplefuelinjectionisreducedforexample,inordertocooltheoutputstages
slightlyandtokeepthetemperatureinsidethecontrolunitinanon-criticalrange.
129
B46Engine
8.2.Systemwiringdiagram,B46engine
Systemwiringdiagram(ULEVIIversion),Bx8engine
130
B46Engine
Index Explanation
1 EngineelectronicsValvetronicdirectfuelinjectionMEVD17.2.3
2 Temperaturesensor
3 Ambientpressuresensor
4 Startermotor
5 Brakelightswitch
6 BodyDomainController(BDC)
7 Airconditioningcompressor
8 Refrigerantpressuresensor
9 Fuelpumpcontrolmodule
10 Electricfuelpump
11 N/A
12 Relay,terminal15N
13 Relay,Valvetronic
14 Relay,ignitionandfuelinjection
15 Diagnosticmodulefortankleaks(DMTL)
16 Relay,terminal30B
17 Relayforelectricfan
18 Electricfan
19 Mapthermostat
20 Electriccoolantpump(20W)
21 Tankventvalve
22 VANOSsolenoidvalve,intakecamshaft
23 VANOSsolenoidvalve,exhaustcamshaft
24 Map-controlledvalve,oilpump
2629 Injectors,4-cylinderengine
3033 Ignitioncoils,4-cylinderengine
34 Engineventilationheating(cold-climateversiononly)
35 Earthconnections
36 Actuatorforelectricallyadjustablewastegatevalve
37 Oxygensensoraftercatalyticconverter
(LSFXfourvoltage-jumpsensor)
38 Oxygensensorbeforecatalyticconverter
(LSUADVbroadbandoxygensensor)
39 Diagnosticsocket
40 Intake-manifoldpressuresensorafterthrottlevalve
131
B46Engine
Index Explanation
42 Chargeairtemperatureandchargingpressure
sensorupstreamofthrottlevalve
43 Knocksensor
44 Knocksensor
46 Gearsensor
47 Camshaftsensor,intakecamshaft
48 Camshaftsensor,exhaustcamshaft
49 Crankshaftsensor
50 Acceleratorpedalmodule
51 Electromotivethrottleactuator
53 Oilpressuresensor
55 Oillevelsensor
56 Alternator
57 DynamicStabilityControl(DSC)
8.3.Mapignition
TheB46engineisequippedwithaninductiveignitionsystemwithstaticignitiondistribution.
Eachcylinderhasaseparateignitioncoilwhichisinserteddirectlyintothecylinderheadcover.
Toachieveoptimumconsumptionandminimumpollutantemissionsandthehighestpossibletorque,
theignitionpointmustbeperfectlyadjusted.
Thefollowingfactorsinfluencetheignitionpoint:
Enginespeed
Enginetorque
Chargingpressure
Currentairratio
Coolanttemperature
Intakeairtemperature
Fuelgrade
Operatingcondition(enginestart)
132
B46Engine
ThesevariablesarerecordedbytheDigitalMotorElectronicsviasensors,processedwiththe
assistanceofdifferentcharacteristicmapsandoutputascontrolsignalstotheignitioncoils.
8.3.1.Diagnosticfunctions
Asfaultsintheareaoftheignitionsystemdirectlyaffectthequalityoftheexhaustgas,theignition
processesaremonitoredbytheDigitalMotorElectronics.Duringthisprocess,thecombustionperiod
fortheignitionofeachindividualcylinderisevaluatedasapriority.Thevoltagedifferenceofthe
primarycoilatterminal1andterminal15isdeterminedandevaluatedbycarryingoutameasurement
withintheDigitalMotorElectronics.Anincreasedvoltagedifferenceismeasurablewhileanignition
sparkispresent.Theperiodofthisvoltagedifferenceisreferredtoas'combustionperiod'.
Thecombustionperiodisnotevaluatedduringthefollowingoperatingconditions:
Duringthestartingoperation
Vehiclevoltage<12volts
Currentandvoltagecurveofignition
Index Explanation
A Voltagecurve
B Currentflow
1 Chargingtimeofprimarycoil
2 Combustionperiodofignitionspark
3 Startofchargingofprimarycoil
4 Startofignition
5 Endofignition
133
B46Engine
Combustionperiodtooshort
TheminimumthresholdsforthecombustionperiodaredeterminedbytheDigitalMotorElectronics
dependingontheenginespeedandload.Whentheseminimumthresholdsareundercutandmisfiring
alsooccurs,afaultcodeentry"Combustionperiodtooshort"isstoredintheDigitalMotorElectronics.
Combustionperiodoutsidethetolerance
Thecurrentcombustionperiodofallindividualcylindersisreadinandcombinedtoobtainamean
value.Asthespeedandloadisthesameinallcylinders,thecalculatedmeanvalueissimilartothe
individualvaluesreadin.Bycomparingtheindividualvalueswiththemeanvalueobtained,theDigital
MotorElectronics(DME)candrawconclusionsaboutthecombustionperiod.Ifanindividualvalue
exceedsorundercutstheminimumthresholdsstored,afaultcodeentry"Combustionperiodoutside
thetolerance"isstoredintheDigitalMotorElectronics.
NoteforService
Faultcodeentrieswiththenote"Combustionperiodtooshort"or"Combustionperiodoutside
thetolerance"arenotnecessarilyalwaysattributabletoadefectinoneorseveralignitioncoils.
CombustionperiodabnormalitiescanbeidentifiedviathediagnosisentryintheDigitalMotor
Electronics,theircausescanbefoundinmanydifferentenginesystems.
Thefollowingcancausedeteriorationofthecombustionperiod:
Contactresistancesattheenginewiringharnessoftheignitioncoil.
Poorplug-incontactattheconnectoroftheignitioncoil.
Coilresistanceofignitioncoilsoutsidethepermissiblerange.
Ignitionsparksinsidesiliconehoseoftheignitioncoil.
Heavilycarbonfouledsparkplug(s).
Thefollowinggraphicshowsaheavilysootedsparkplug.
Heavilycarbonfouledsparkplug
Thefaultcodeentry"Combustionperiodtooshort"isfrequentlycausedbyoneorseveralheavily
carbonfouledsparkplug(s).Thecarbonloadingleadstodeteriorationoftheignitionsparkand
thereforeaveryshortcombustionperiod.
134
B46Engine
Increasedsootloadingatthesparkplugsaccompaniedbyareductioninthecombustionperiodmay
becausedbythefollowing:
Faultinthemixturepreparation
-leaksattheairintakesystem
-faultattheinjector
-faultatthehighpressurepump
-depositsintheareaoftheintakevalves
Faultintheengineelectricalsystem
-faultintheareaofthecoolanttemperaturesensor
-faultintheareaoftheoxygensensor
-faultintheareaofthehotfilmairmassmeter
Largenumberofcoldstarts
-frequentcatalyticconverterheatingphases
-fewself-cleaningphasesofthesparkplugs
Withthefaultcodeentry"Combustionperiod",apotentialcomponentfaultattherelevantcoilcanbe
confirmedordisprovedbycross-swappingtheignitioncoil.
Ifmisfiringoccursfollowingcomponenterrors,differenttestmodulesintheworkshopanddiagnosis
systemISTAcanbeprocessed.Asthecausesoffaultsintheignitionsystemaremanyandvaried,the
varioustestanddiagnosisinstructionsinthetestmodulemustbefollowed.Ifafaultycomponentis
replacedwithouteliminatingtheactualcause,thiswillonlyremedytheproblemintheshortterm.
8.3.2.Ignitioncoils
Overviewofignitioncoils
Thefollowinggraphicprovidesanoverviewofthedifferentignitioncoilscurrentlyusedwiththe
variousBMWengines:
135
B46Engine
Overviewofignitioncoils
Index Explanation
A Compactignitioncoil(manufacturer:Eldor)
B Rodignitioncoil(manufacturer:Delphi)
1 Electricalplug-incontact
2 Siliconehose
3 Mountingbolt
4 Rearclosureplate
Thetablebelowprovidesanoverviewoftheenginesinwhichthevariousignitioncoilsareused:
Engine Compactignitioncoil Rodignitioncoil

B46 X
N20 X
N55 X
N63TU2 X
N74TU X
136
B46Engine
Compactignitioncoil
Ignitioncoil,Bx8engine
Index Explanation
1 ManufacturedforBMW
2 BMWpartnumber
3 Supplier
4 Suppliercode
5 Productiondate
6 Terminal15
7 Terminal4a
8 Siliconehose
9 Serialnumber
10 Terminal1
11 Mountingbolt
Theprimaryandsecondarycoilrequiredtoraisetheignitionvoltagecanbefoundintheareaofthe
electricalplug-incontact.Thetransferfactorachievedbybothcoilsisaround1:80.
137
B46Engine
Whenservicingtheignitioncoils,observethefollowing:
Aslightrotationalmovementwhenpullingoutandinsertingtheignitioncoilsmakes
disassemblyandinstallationeasier.
Theremustbenosignofcontaminationbyoilorotherfluidsintheareaofthe
electricalplug-incontact.
Thepinsoftheelectricalplug-incontactmustnotbebent.
Theremustbenosignofcrackingonthesiliconehose.
Thespringwhichtransmitstheignitionsparkmustbepositionedatthecenter
ofthesiliconehose.
Thesiliconehoseoftheignitioncoilsmustnotcomeintocontactwithfuelormineraloils.
Thespecifiedtorqueofthemountingboltmustbeobserved.
Priortodisassemblyoftheignitioncoil,removetheplug-incontactfromtheengine
wiringharness,astheignitioncoilscannotbeoperatedwithoutsparkplugs.
Theignitioncoilsarenotfuel-resistant.Allignitioncoilsshouldthereforeberemovedbeforeopening
thefuelsystem.Fuelresiduesmustberemovedbeforeinsertingtheignitioncoilsinthesparkplug
shaft.
8.3.3.Sparkplugs
Thepositionofthesparkplugelectrodeinthecombustionchamberisthereforeparticularlyimportant.
Toavoidcoatingthesparkplugelectrodewithfuel,itispositionedgeometricallybetweenthefuel-
injectionsprayoftheinjector.
Achangeintervalappliesforsparkplugsandtheymustberenewedinaccordancewiththe
manufacturer'sspecifications.Toavoiddamageandensureperfectfunctionofthesparkplugs,
theprescribedtighteningtorquesmustbeobserved.
8.4.Systemoverviewforengineelectricalsystem
Thesensorsandactuatorsarealreadyknownfromotherenginesandarethereforenotdescribedin
detailinthisdocumentation.Thefollowinggraphicsprovideanoverviewofthedifferentinstallation
positionsofthesensors.
138
B46Engine
8.4.1.Transmissionside
SystemoverviewforelectricalsystemintheB38engine,transmissionside
Index Explanation
2 Ignitioncoil
4 High-pressurepump
6 Broadbandoxygensensorbeforecatalyticconverter
7 VANOSexhaustcamshaft
8 Voltagejump,oxygensensoraftercatalyticconverter
9 Pinionstarter
10 Crankshaftsensor,crankshaft
139
B46Engine
Index Explanation
11 Electromotivethrottlecontroller
12 Combinedchargingpressureandtemperaturesensor
13 Throttlevalveunit
14 VANOSintakecamshaft
8.4.2.Sideview
SystemoverviewforelectricalsystemintheB38engine,topview
Index Explanation
3 Knocksensor
5 Hot-filmairmassmeter
6 Combinedchargingpressureandtemperaturesensor
7 Throttlevalveunit
140
B46Engine
Index Explanation
8 Oilpressuresensor
9 Map-controlledcontrolvalveofthevane-typecompressor
10 Combinedoilqualityandoil-levelsensor
11 Mapthermostat
12 Localinterconnectnetworkbusconnection
13 Valvetronicservomotorwithintegratedpositionsensors
8.4.3.Beltside
SystemoverviewforelectricalsystemintheB38engine,beltside
Index Explanation
1 Camshaftsensor,exhaustcamshaft
4 Valvetronicservomotorwithintegratedpositionsensors
5 Generatorwithintelligentgeneratorcontrol
141
B46Engine
Index Explanation
6 Solenoidswitch,pinionstarter
8 Broadbandoxygensensorbeforecatalyticconverter
9 Voltagejump,oxygensensoraftercatalyticconverter
142
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Rntgenstrae7
85716Unterschleiheim,Germany

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Position Meaning Index Explanation

Engine Numberofcylinders Firingorder Firinginterval

Characteristics Unit B46engine

Inertiaforces, Inertiaforces, Inertiatorques, Inertiatorques,

Engine DoubleVANOS Valvetronic

Engineoperation Airratio Sensorvoltage

Engine Compactignitioncoil Rodignitioncoil

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