2005 BMW 545i fuel

Downloaded from www.Manualslib.com manuals search engine 2
N62 Engine
N62 Engine
Purpose of The System
The N62B44 engine is a completely new development from the NG (New Generation) series
and is available as a B44 (4.4 liter).
The development objectives were:
• Reduction in fuel consumption
• Reduction in emissions
• Increased power
• Improved torque and torque curve
• Improved engine acoustics
The most important features of
the new N62 engine are:
• 8 cylinders in a 90º V configu-
ration
• 2 four-valve cylinder heads
• Light-alloy design
• Newly-developed variable
intake manifold
• Valvetronic system
In conjunction with the Variable Intake Manifold, the Valvetronic system adapts the intake
valve lift to ensure optimum cylinder filling. The throttle valve use is limited during engine
operation to maintain a constant intake manifold vacuum.
T Th
he
e
N
N6
62
2
i
is
s
t
th
he
e
b
be
es
st
t
e
en
ng
gi
in
ne
e
i
in
n
i
it
ts
s
c
cl
la
as
ss
s.
.
A
At
t
t
th
hi
is
s
t
ti
im
me
e
t
th
he
er
re
e
i
is
s
n
no
o
o
ot
th
he
er
r
e
en
ng
gi
in
ne
e
o
on
n
t
th
he
e
m
ma
ar
rk
ke
et
t
w wh
hi
ic
ch
h
u
us
se
es
s
c
co
om
mp
pa
ar
ra
ab
bl
le
e
t
te
ec
ch
hn
no
ol
lo
og
gy
y.
.
To achieve these objectives, enhancements
were made in the following areas:
• Engine mechanicals
• Treatment of exhaust emissions
• Valve timing
• Engine management control
• Intake air flow
43-02-01

Downloaded from www.Manualslib.com manuals search engine 3
N62 Engine
Technical Data

E En
ng
gi
in
ne
e
N N6
62
2B
B4
44
4


Design 8 Cylinder V

V Angle 90°

Displacement (cm3) 4,398

Bore/Stroke (mm) 92/82.7

Cylinder Gap (mm) 98

Main Crankshaft Bearing Diameter (mm) 70

Output (kW)
at speed (rpm) 325
6,100

Torque (Nm)
at Speed (RPM) 330
3,600

Cut-off speed (RPM) 6.500

Compression Ratio 10.0

Valves / Cylinders 4

Intake Valve Diameter (mm) 35

Exhaust Valve Diameter (mm) 29

Intake Valve Lift (mm) 0.3 – 9.85

Exhaust Valve Lift (mm) 9.7

Cams Open Period (º crankshaft) 282/254

Engine Weight (kg) 213

Fuel 91 Octane

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

Knock Sensor Yes

Variable Intake Manifold Yes

Digital Motor Electronics ME 9.2 with Valvetronic Control Unit

Complies with Exhaust Emission Regulations EU-3
EU-4
LEV
Engine Length (mm) 704

Fuel Consumption Saving Compared with the M62 14%

Downloaded from www.Manualslib.com manuals search engine Throttle Valve
The throttle valve on the N62 is not necessary for engine load control. This is carried out
by the intake valves variable lift adjustment.
The tasks of the throttle valve are:
S St
ta
ar
rt
ti
in
ng
g
t
th
he
e
e
en
ng
gi
in
ne
e
Airflow is controlled by the throttle valve during the starting procedure when the air temp-
erature is between 20 ºC and 60 ºC, .
If the engine is at operating temperature, it will be switched to non-throttle mode approx-
imately 60 seconds after start up. In cold conditions however, the engine is started with
the throttle valve fully opened because this has a positive effect on the starting characteris-
tics.
E En
ns
su
ur
ri
in
ng
g
a
a
c
co
on
ns
st
ta
an
nt
t
v
va
ac
cu
uu
um
m
o
of
f
5
50
0
m
mb
ba
ar
r
i
in
n
t
th
he
e
i
in
nt
ta
ak
ke
e
m
ma
an
ni
if
fo
ol
ld
d
This vacuum is needed to exhaust the blow-by gases from the crankcase and the fuel
vapors from the activated charcoal filter.
T Th
he
e
b
ba
ac
ck
ku
up
p
f
fu
un
nc
ct
ti
io
on
n
If the Valvetronic system should fail, the throttle valve implements conventional load con-
trol).
7
N62 Engine
42-02-25
Throttle Valve
• Throttle Valve Housing with Throttle Valve.
• Throttle Valve Actuator
• Two Throttle Valve Potentiometers

Downloaded from www.Manualslib.com manuals search engine Valvetronic
Over the entire speed and load range, the gasoline engine needs a combustible fuel-air
mixture within the ideal ratio (Lambda = 1). The mixture quantity must be altered to vary the
speed and output. This variation is effected by the throttle valve. The mixture, which falls
within the narrow range of Lambda = 1, is formed outside the combustion chamber using
the fuel injection system (external mixture formation).
The mixture control is influenced by the throttle valve and is not optimal in all the different
load ranges. This is particularly true in the idle to part-load ranges, since the throttle valve
is only opened slightly in these ranges. The consequences are less than optimal cylinder
filling, torque and increased fuel consumption.
Technical measures were previously introduced; such as the optimization of air/fuel mixing,
improved valve overlap, introduction of DISA and the steady improvement of mixture con-
trol all depend on the throttle valve. This is where the new completely unique Valvetronic
design comes in.
The Valvetronic system simultaneously varies the valve opening time and the valve opening
lift between 0.3 mm and 9.85 mm, according to engine speed and load. This means that
the air/fuel mixture volume is controlled according to engine requirements. This type of mix-
ture and volume control makes the typical throttle valve control unnecessary.
23
N62 Engine

Downloaded from www.Manualslib.com manuals search engine Physical considerations:
On engines with throttle valve control, the throttle valve is slightly open in the idling and part-
load ranges. This results in the formation of up to 500 mbar vacuum in the intake manifold,
which prevents the engine from aspirating freely and in turn prevents optimum cylinder fill-
ing. The Valvetronic system with an open throttle valve largely counteracts this disadvan-
tage. The air-mass flow to the intake valves is unrestricted. The full ambient pressure is
available directly at the intake valves for cylinder filling and scavenging.
The Valvetronic system primarily controls the fill by adapting the valve opening time and the
valve lift (short opening time/small valve lift = lower fill, and vice versa). During the valve
opening phase the engine aspirates more freely via the intake valves even with small valve
lifts vs. a throttle valve which is continuously blocked.
The slower cylinder filling from the intake valves with partial lift results in more turbulence in
the combustion chamber, thus faster and better mixture control and more efficient com-
bustion. At lower engine speeds this effect is intensified by opening the intake valves later,
after top dead center (ATDC) using VANOS. This increases vacuum in the combustion
chamber which accelerates filling and turbulence when the intake valves are opened.
I In
n
s
su
um
mm
ma
ar
ry
y,
,
the additional variability of the Valvetronic system results in optimization of
cylinder filling and scavenging throughout the engine's entire operating range. This has a
positive effect on output, torque and a decrease in fuel consumption and exhaust emis-
sions.
F Fe
ea
at
tu
ur
re
es
s:
:
• Valve lift adjustment
• VANOS for intake and outlet
• Variable intake manifold
• Mixture control and ignition control
• Other individual engine design measures
T Th
hi
is
s
r
re
es
su
ul
lt
ts
s
i
in
n:
:
• Improved engine idling
• Improved engine torque
• Improved engine torque curve
• Fewer pollutant emissions
T Th
he
es
se
e
b
be
en
ne
ef
fi
it
ts
s
r
re
es
su
ul
lt
t
i
in
n
a
a
c
cl
le
ea
ar
r
i
im
mp
pr
ro
ov
ve
em
me
en
nt
t
i
in
n
p
pe
er
rf
fo
or
rm
ma
an
nc
ce
e
a
an
nd
d
f
fu
ue
el
l
c
co
on
ns
su
um
mp
pt
ti
io
on
n
r
re
ed
du
uc
c-
-
t ti
io
on
n
(
(1
14
4%
%)
)
f
fo
or
r
t
th
he
e
d
dr
ri
iv
ve
er
r.
.
24
N62 Engine
T Th
he
e
m
ma
ai
in
n
b
be
en
ne
ef
fi
it
ts
s
o
of
f
t
th
he
es
se
e
f
fe
ea
at
tu
ur
re
es
s
a
ar
re
e:
:
• Improved cylinder filling with air/fuel mix-
ture
• Improved mixture control before the cylin-
der inlet
• Improved combustion procedure

Downloaded from www.Manualslib.com manuals search engine Principle of Operation
T Th
he
e
V
Va
al
lv
ve
et
tr
ro
on
ni
ic
c
s
sy
ys
st
te
em
m
i
is
s
a
a
c
co
om
mb
bi
in
na
at
ti
io
on
n
o
of
f
V
VA
AN
NO
OS
S
a
an
nd
d
v
va
al
lv
ve
e
l
li
if
ft
t
a
ad
dj
ju
us
st
tm
me
en
nt
t.
.
This combi-
nation of abilities allows the ECM to control when the intake valves are opened and closed,
and also the opening lift. The intake air flow is set by adjusting the valve lift while the throt-
tle valve is fully opened. This improves cylinder filling still further and reduces fuel con-
sumption.
Each cylinder head in the N62 engine has a Valvetronic assembly. This Valvetronic assem-
bly consists of a bridge support with eccentric shaft, intermediate levers with retaining
springs, drag lever and the intake camshaft.
In addition, the following components belong to
the Valvetronic system:
• A Valvetronic motor for each cylinder head
• A Valvetronic control module
• A Valvetronic sensor for each cylinder head
The intake valve lift can be adjusted to anywhere between 0.3 mm and 9.85 mm.
The cylinder heads are precision manufactured together to ensure precise flow rate and
uniform distribution. The valve gear components on the intake side are precisely matched
together to the tightest limits.
The bridge support, lower eccentric shaft and inlet camshaft bearings are matched togeth-
er in the cylinder head once it is assembled. If the bridge support or the lower bearings are
damaged, the entire assembly must be replaced.
N No
ot
te
es
s:
:

25
N62 Engines
42-02-30

Downloaded from www.Manualslib.com manuals search engine 42
N62 Engine
Map-controlled Thermostat
The map-controlled thermostat allows the engine to be cooled relevant to operating con-
ditions. This reduces fuel consumption by approximately 1-6%. The electrical connections,
the design and the map-controlled thermostat response have been enhanced. The map-
controlled thermostat function is the same as previous engines (M62).
Cooling Module
The cooling module contains the following main cooling system components:
• Cooling radiator
• Air conditioning condenser
• Transmission oil/water heat exchanger
• Hydraulic fluid radiator
• Engine oil radiator
• Main electric fan
• Fan shroud for viscous coupling fan
All the components (with the exception of the transmission oil radiator) can be removed for
repairs without disassembling any other coolant circuit. All connections have been fitted
with the quick-release coupling which are used in current models.
Maped-Controlled Thermostat
1. Radiator Return Flow To Thermostat
2. Connection for Thermostat Heating Element
3. Temperature Sensor
4. Radiator in-flow (hot coolant from engine)