2008 BMW X5 48i

2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

2007-08 GENERAL INFORMATION

Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

2007 NG6 ENGINE

Model: All with NG6-cylinder from 2007

Production: from 9/2006

NG6 ENGINE

Previously in 2005, BMW introduced the beginning of a new generation of six cylinder engines with the N52.
Now, for the 2007 model year, BMW has 3 new variations of the NG6 engine family.

cardiagn.com
The first of the new engines is the N54, which will debut in the new 3-series coupe in September 2006. The
N54 engine is turbocharged and uses the second generation of direct injection (DI 2). This engine will power
the new 335i coupe in the fall of 2006.

Fig. 1: Identifying Engines - N54

Courtesy of BMW OF NORTH AMERICA, INC.

The N52 will eventually be replaced by the new N52KP.

2557 of The
3160N52 KP engine is an improved and cost optimized
version of the N52. The N52 KP will be available in the 328i and xi coupe from September and will replace the
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

N52 in various models.

cardiagn.com
Fig. 2: Identifying Engine - N52
Courtesy of BMW OF NORTH AMERICA, INC.

Finally, the N51 which is a SULEV II compatible engine, will be phased into selected production models from
9/06. The N51 features many of the same features of the previous SULEV engine (M56) including a "Zero
EVAP" system.

New Engine Designations

Along with the new engines for 2007, there is a new system for engine designations. The first few digits such as
"N54B30" are familiar from the past, however the suffix has been changed.

The former "TU" designation has been dropped in favor of two additional digits.

The breakdown is as follows:

2558 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com

Fig. 3: Identifying Engine Identification Numbers (1 Of 2)

Courtesy of BMW OF NORTH AMERICA, INC.
2559 of 3160
Crankcase Identification
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

The engine identification numbers are stamped on the block near the high pressure pump.

cardiagn.com

Fig. 4: Identifying Engine Identification Numbers

2560(2ofOf 2)
3160
Courtesy of BMW OF NORTH AMERICA, INC.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

New NG6 Versions

The new N54 engine is designated the "N54B3000". The "O" in the engine designation indicates the "upper"
output range.

The last digit, which is a "0", indicates the first version in this range of engines (N54). If the N54 engine is
updated, then the last digit will change to a "1" rather than the former "TU" suffix.

The N52KP, which replaces the N52, will have three possible variants as shown below:

cardiagn.com
Fig. 5: Identifying NG6 Versions
Courtesy of BMW OF NORTH AMERICA, INC.

All of the N52KP engines have a last digit of "1", which indicates that "KP" engines are an updated version of
the N52. There are three variants, the upper output (O), the medium output (M) and the lower output (U). Each
engine has specific characteristics and power output. The "O" engine has 260 horsepower, while the "M"
version has about 230 horsepower. The "U" engine is a possible future variant with 215 horsepower.

The N51 engine uses the designation - "N51B30M0". This engine is SULEV II compliant with 230 horsepower.

New Vehicles for 2007

The new engine variants will be initially installed into some new and updated vehicles for 2007. The new E92
coupe will be available with the N54B30O0 (335i) and the N52B30M1 (328i).

2561 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 6: Identifying Vehicles For 2007
Courtesy of BMW OF NORTH AMERICA, INC.

The N52B3001 will be initially available in the E83 LCI (X3 3.0 si) from 9/2006 and the new E70 (X5 3.0 si)
from SOP.

Fig. 7: Identifying E70 (X5)

Courtesy of BMW OF NORTH AMERICA, INC.

ENGINE MECHANICAL OVERVIEW

Crankcase

As far as the physical appearance and dimensions, the crankcase on the N54 is the same as the N52. The main
change is in the materials, the N54 uses an all aluminum alloy crankcase. There is also cast iron cylinder liners
similar to the previous M54 engine.

The reason for using the all aluminum configuration is to be more compatible with the increased torque output
and cylinder pressure in the N54.
2562 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 8: Identifying Aluminum Alloy Crankcase
Courtesy of BMW OF NORTH AMERICA, INC.

The N54 engine continues to use the "two-piece" crankcase featuring the "bedplate" design.

The N52KP and N51 engines continue to use the composite magnesium/aluminum alloy engine from the
existing N52.

2563 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 9: Identifying "Two-Piece" Crankcase
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The N54 engine has a different bolt pattern on the transmission mounting
(bellhousing) area.

Therefore, a new special tool is needed to mount the engine to an engine stand.
The new tool has slots which will accommodate all NG6 engines

Fig. 10: Identifying Bolt Pattern On Transmission Mounting

Courtesy of BMW OF NORTH AMERICA, INC.

Bolts
2564 of 3160
Although, the N54 engine has an all aluminum crankcase, many of the bolts are still aluminum as on the N52.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

This is to reduce any potential confusion between steel and aluminum bolts. Some bolts, for example, are steel
such as the cylinder head cover bolts. This is possible, due to the plastic cylinder head cover.

cardiagn.com
Fig. 11: Identifying Bolt
Courtesy of BMW OF NORTH AMERICA, INC.

The N52KP and N51 engines use the same aluminum bolt configuration as the N52 engine, with little change.
The cylinder head cover bolts are like the N54 - steel, due to the plastic cylinder head cover.

The same rules apply to the handling of aluminum bolts as in the past.

Strict adherence to repair instructions is required to ensure proper connections.

Be sure to follow the proper torque/tightening angle sequence as outlined in the "tightening torques" section of
TIS.

Fig. 12: Identifying Aluminum Bolt

Courtesy of BMW OF NORTH AMERICA, INC.

Cylinder Head Cover

2565 of 3160
As stated before, the cylinder head cover used on all of the new NG6 engines is made from plastic. However,
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

the design differs between the engines due to engine equipment.

For example, the N54 engine does not use Valvetronic and therefore does not need the accommodation for the
VVT motor. Also, the crankcase ventilation system is different on the N54. Some of the crankcase venting
components are integrated into the cylinder head cover such as the cyclone separator.

The N52KP and N51 engines have the same cylinder head cover. The cover also includes some of the crankcase
venting system components.

cardiagn.com
Fig. 13: Identifying Cylinder Head Cover
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Some engines with plastic cylinder head covers may have aluminum bolts.

Cylinder Head

Each of the new NG6 engines has a unique cylinder head design. Due to some of the technical requirements, the
cylinder heads are not interchangeable between these engines. The cylinder head from the N52KP is carried
over from the N52 with little change.

The cylinder head from the N54 engine does not have Valvetronic. The design of the engine also requires
accommodation of the "direct" fuel injector in the combustion chamber. Most of the external dimensions are the
same as the N52 to accommodate accessories and ancillary components.

The N51 engine is a SULEV II compliant design which has a lower compression ratio. The combustion
chamber design has been modified to work in conjunction with the N51 piston to achieve the required emission
goals.
2566 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 14: Identifying Fuel Injector In Combustion Chamber
Courtesy of BMW OF NORTH AMERICA, INC.

Valvetrain

The valvetrain on the N52 introduced in 2006, used 5 mm valve stems on both the intake and exhaust. To
increase durability, the exhaust valve stems were increased to 6 mm from 6/06 production.

All of the new NG6 engine have adopted the 6 mm valve stem for the exhaust, the intake stem remains at 5 mm.
The valves are of the "solid" type design (not Sodium filled). The diameter of the valve head is engine specific.

Camshafts

The lightweight hydroformed camshaft will still be used on the NG6 engines. Be aware that some engines may
use the "cast" camshaft design. This is for supply and production reasons.

Cast and hydroformed camshafts are completely interchangeable. For example, a replacement camshaft may
differ from the original. This is no problem, they will fit and work properly without any modifications.

2567 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 15: Identifying Camshaft Diameter
Courtesy of BMW OF NORTH AMERICA, INC.

VANOS

The infinitely variable Bi-VANOS system is still in use on all NG6 engines. The VANOS system still retains
the use of the lightweight VANOS adjusting units introduced on the N52. The only change to the system is that
the N54 engine uses different spread ranges for compatibility with turbocharged engine operation.

2568 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 16: Identifying Compatibility With Turbocharged Engine Operation
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Do not mix up the intake and exhaust VANOS units. They appear similar, but
have different spread ranges. Improper installation can result in valvetrain
damage.

Valvetronic

The N51 and N52KP engines retain the already proven Valvetronic system from the N52. The only change for
2007 is an optimized VVT motor which has already been in production from 5/06.

The N54, on the other hand, does not use the Valvetronic system. Valvetronic is designed to reduce pumping
losses and improve engine efficiency. The turbocharging system on the N54 is also designed to reduce pumping
losses and increase engine efficiency.

Therefore, there is no need to have both systems on one engine. In summary, the efficiency of the N54 is gained
through exhaust turbocharging and direct injection2569
rather than Valvetronic.
of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 17: Identifying Injection Rather Valvetronic
Courtesy of BMW OF NORTH AMERICA, INC.

Gaskets and Seals

Head Gasket

The head gasket design on the N54 is unique to that engine.

It features a multi-layer steel design. There is no silicone rubber perimeter "shelf" as on the N52. This is not
needed due to the aluminum block on the N54.

The N52KP and N51 engines are still using the head gasket that is familiar from N52.

2570 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 18: Identifying Head Gasket
Courtesy of BMW OF NORTH AMERICA, INC.

Oil Pan Gasket

All of the new NG6 engine use the same oil pan gasket as introduced on the N52.

The oil pan gasket design is compatible with the N54, therefore it was not necessary to create an additional part.

Fig. 19: Identifying Oil Pan Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

Bedplate Sealing

The N54 continues to use the injected sealant method for the bedplate.

Crankshaft Drive Components

Crankshaft

The crankshaft on the N52KP and N51 remains a cast iron design. This crankshaft is carried over from the N52.
2571 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

The additional torque generated by the N54 requires the use of a forged steel crankshaft.

Piston and Connecting Rods

Due to the design requirements of each of the new NG6 engines, the piston design is unique to each version. For
instance, the N54 is turbocharged and direct injected and requires a piston which meets the design requirements
for compression and mixture formation.

The N51 engine need a piston which has lower compression and meets the SULEV II requirements for emission
compliancy.

The N52KP and N52 engines both use the same piston design.

The connecting rods on the new engines use a thicker beam design which has been in production on the N52

cardiagn.com
since 6/06. The N54 has a special connecting rod with M9 bolts instead of the M8 bolts on the other engines.

Torsional Vibration Damper

The vibration damper has been updated to improve the damping of first order vibrations. The damper is secured
with new bolts and has a revised tightening procedure. The procedure differs from the N52 and should therefore
not me mixed up. Damage to the belt drive can result from improper tightening procedures.

Intake Manifold

The plastic intake manifold from the N52 is carried over to the new NG6 engines. However, the 3-Stage DISA
version of the intake manifold is only used on the "O" version (high output).

The current N51 engine is designated as a medium output "M" version at 230 hp and does not require the 3-
stage DISA. The same applies to the "M" version of the N52KP engine as well.

There are small modifications to these intake manifolds due to the fact that the crankcase ventilation system has
been updated.

As far as the N54 engine is concerned, the intake manifold is designed specifically for the turbocharging
system. The N54 does not require DISA as turbocharging supplies the necessary torque increase when needed.

2572 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 20: Identifying 3-Stage DISA Intake Manifold
Courtesy of BMW OF NORTH AMERICA, INC.

Fig. 21: Identifying Intake Manifold N54

Courtesy of BMW OF NORTH AMERICA, INC.
2573 of 3160
Crankcase Ventilation
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

One of the major changes on the new NG6 engines is that the crankcase ventilation system has been upgraded
and improved. This applies to all of the new NG6 versions (N52KP, N51 and N54).

There are two distinct versions of crankcase ventilation. One type is unique to the N54 and the other applies to
N51 and N52KP.

The N52, which is still in production continues to use the "external" crankcase ventilation system with the
electrically heated crankcase ventilation valve/cyclone separator.

cardiagn.com
Fig. 22: Identifying Crankcase Ventilation System
Courtesy of BMW OF NORTH AMERICA, INC.

Crankcase Ventilation (N51 and N52KP)

The crankcase ventilation system on the N51 and N52KP has been modified as compared to the N52. The
system is integrated into the plastic cylinder head cover.

The crankcase gases are regulated by a crankcase ventilation valve similar to the design used on the N62. The
crankcase vent valve is currently part of the cylinder head cover and is not replaceable as a separate component.

Oil separation is carried out via a "labyrinth" system and

2574 of two
3160cyclone separators which are incorporated into the
cylinder head cover. By having the system components integrated into the cylinder head cover, the crankcase
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

gases are heated by the engine rather than an electric heater as on the N52. However, there is still one electric
heating element at the manifold inlet.

Once the liquid oil is separated from the crankcase vapors, the oil is allowed to drain back through check valves
back into the engine.

cardiagn.com
Fig. 23: Cylinder Head Cover Components Location
Courtesy of BMW OF NORTH AMERICA, INC.

Crankcase Ventilation (N54)

Since the N54 is a turbocharged engine, the crankcase ventilation system has to meet certain design
requirements. For example, when the engine is in turbocharged mode, the increased manifold pressure should
not have an adverse effect on the crankcase venting. This is why, there is no crankcase ventilation valve in the
system.

The system consists of four small cyclone separators which are integrated into the plastic cylinder head cover.
The flow of crankcase gases is metered through a series of restrictions which control the ultimate crankcase
pressure.

2575 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 24: Cyclone Separator Operation
Courtesy of BMW OF NORTH AMERICA, INC.

One of the main operating principles behind the crankcase venting system on the N54 is that there are two
strategies - one for the turbocharged mode and one for "non-turbocharged" operation such as decel. These
strategies are dependent upon the intake manifold pressure.

2576 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Fig. 25: Cutaway View - Cylinder Head

Courtesy of BMW OF NORTH AMERICA, INC.

Crankcase Ventilation System Overview (N54)

cardiagn.com
Fig. 26: Identifying Crankcase Ventilation System Diagram - Decel Mode
Courtesy of BMW OF NORTH AMERICA, INC.

Crankcase Ventilation System Overview (N54)

2577 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 27: Identifying Crankcase Ventilation System Diagram - Turbocharged Model
Courtesy of BMW OF NORTH AMERICA, INC.

CRANKCASE VENTILATION COMPONENTS INDEX

Index Explanation Index Explanation
A Overpressure 7 Oil Sump
B Low pressure (vacuum) 8 Oil return channel
C Exhaust gas 9 Turbocharger
D Liquid oil 10 -
E Blow-by gases 11 -
1 Air cleaner 12 -
2 Intake manifold 13 Throttle valve
3 - 14 -
4 - 15 -
2578 of 3160
5 Venting channel 16 -
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

6 Crankshaft cavity - -

cardiagn.com
Fig. 28: Identifying Charge Air Suction Pipe
Courtesy of BMW OF NORTH AMERICA, INC.

Name the components above and their purpose:

Summary of Mechanical Changes

SUMMARY OF MECHANICAL CHANGES

Component/System N52 Engine N52KP N51 N54
Composite Composite Composite All aluminum
Crankcase
magnesium/aluminum magnesium/aluminum magnesium/aluminum alloy
Aluminum - Specific
Aluminum (same as to N51 due to Aluminum -
Cylinder Head Aluminum N52) combustion chamber specific to N54
modifications
Specific to N54
Silicone rubber - multi-layer
Cylinder Head
perimeter to prevent Same as N52 Same as N52 with no silicone
Gasket
contact corrosion rubber
perimeter
Plastic with
integrated
Plastic with integrated
Cylinder Head Plastic with integrated crankcase
Magnesium crankcase ventilation
Cover crankcase ventilation ventilation
(same as N52KP)
(specific to
N54)
2579 of 3160
No crankcase
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

vent valve -
uses calibrated
Crankcase vent valve Crankcase vent valve
orifice with
External crankcase and "labyrinth" and and "labyrinth" and
Crankcase cyclone
vent valve with cyclone oil separation cyclone oil separation
Ventilation separation
cyclone separator. integrated into integrated into
integrated into
cylinder head cover. cylinder head cover.
cylinder head
cover.
5 mm intake and 5 mm intake
5 mm intake and 6 5 mm intake and 6
exhaust valve stems and 6 mm
Valvetrain mm exhaust valve mm exhaust valve
(6 mm exhaust valve exhaust valve
stems stems
stem from 6/06) stems
Infinitely
Infinitely variable Bi- Infinitely variable Bi- Infinitely variable Bi-
VANOS variable Bi-
VANOS VANOS VANOS

cardiagn.com
VANOS
Valvetronic Valvetronic II Valvetronic II Valvetronic II No Valvetronic
Plastic with 3-stage Plastic with 3-stage Plastic (no
Intake Manifold DISA on high output DISA on high output Plastic
DISA)
version (OL) version (O)
High Precision
Fuel System Manifold injection Manifold injection Manifold injection
Injection (HPI)
2nd Generation 2nd Generation 2nd Generation
Electric coolant pump
Cooling System electric coolant pump electric coolant pump electric coolant
- 200 W
- 200 W - 200 W pump - 400 W
"Near Engine"
"Near Engine" "Near Engine"
catalysts with
"Near Engine" catalysts with catalysts with
Exhaust System underbody
catalysts underbody catalysts underbody catalysts catalysts
(ULEV II) (SULEV II)
(ULEV II)
Pistons/Compression
10.7 to 1 10.7 to 1 10 to 1 10.2 to 1
Ratio
Forged Steel
Forged Steel Forged Steel (stiffened) with
Forged Steel with 8
(stiffened) with 8 mm (stiffened) with 8 mm 9 mm bolts
Connecting mm bolts "cracked bolts "cracked bolts "cracked "cracked
Rods/Crankshaft design" (Cast
design" (Cast design" (Cast design" (Forged
Crankshaft)
crankshaft) crankshaft) steel
crankshaft)
HFM Analog Digital Digital Digital

MSD80 ENGINE MANAGEMENT OVERVIEW (E9X)

2580 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 29: Identifying Engine Management Communication Diagram - E9X (1 Of 2)
Courtesy of BMW OF NORTH AMERICA, INC.

2581 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Fig. 30: Identifying Engine Management Communication Diagram - E9X (2 Of 2)

Courtesy of BMW OF NORTH AMERICA, INC.

MSV80 ENGINE MANAGEMENT OVERVIEW (E70)

cardiagn.com
Fig. 31: Identifying Engine Management Communication Diagram - E70 (1 Of 2)
Courtesy of BMW OF NORTH AMERICA, INC.

2582 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 32: Identifying Engine Management Communication Diagram - E70 (2 Of 2)
Courtesy of BMW OF NORTH AMERICA, INC.

AIR MANAGEMENT

Air Management N52KP and N51

As far as the air management system on the N52KP and N51 engines is concerned, the previous intake manifold
system on the N52 is carried over. Depending upon application, the engines will use the 3-stage DISA or the
single stage (No DISA) intake manifold.

For more information on the DISA system refer to the previous training material in the training course "ST501 -
New Engine Technology".

2583 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 33: Identifying Intake Manifold System
Courtesy of BMW OF NORTH AMERICA, INC.

Throttle Valve

All variants of the new NG6 engines receive the new EGAS 08 throttle by Siemens/VDO. The new throttle uses
a plastic throttle valve and magneto-resistive feedback to the ECM.

The previous system used a potentiometer, whereas the new throttle uses a "contactless" system featuring
magneto-resistive technology which is familiar from the eccentric shaft sensor on Valvetronic systems.

2584 of 3160
Fig. 34: Identifying Throttle Valve
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Courtesy of BMW OF NORTH AMERICA, INC.

The magneto-resistive sensors are integrated into the housing cover. The sensors are also non-wearing.

For plausibility, the one sensor outputs the analog signal in the range from 0.3 to 4.6 V and the other sensor
inverts it again from 4.6 to 0.3 V.

Consequently, the contact force is 10 times greater than that of a conventional plug connector.

NOTE: It is possible to twist the connector before plugging it in. This can cause
damage to the harness and connector.

Air Intake Ducting

cardiagn.com
With regard to the N54 engine, the air intake ducting plays a significant role due to the requirements of a
turbocharged engine.

In principle, the energy of the escaping exhaust gases is utilized to "pre-compress" the inducted fresh air and
thus introduce a greater air mass into the engine. This is only possible if the air intake ducting is "leak-free" and
installed properly.

2585 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 35: Identifying Air Intake Ducting Components
Courtesy of BMW OF NORTH AMERICA, INC.

It is important to note, when carrying out work on the air-intake ducting, it is important to ensure that the
components are installed in the correct position and that all pipes are connected with tight seals.
2586 of 3160
A leaking system may result in erroneous boost pressure. This would be detected by the engine management
system and will ultimately result in "limp-home" operation. There would also be a noticeable reduction in
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

engine power.

For some of the duct work, there are special tools to ensure proper connections.

Air Intake Ducting Function

cardiagn.com

2587 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com

2588 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Fig. 36: Identifying Air Intake Ducting Function Diagram

Courtesy of BMW OF NORTH AMERICA, INC.

The fresh air is drawn in via the air cleaner (10) and the charge-air suction lines (6 + 18) by the compressors of
turbochargers (23 + 24) and compressed.

Because the turbochargers can get very hot during operation, they are connected with the engine's coolant and
engine-oil circuits. The charge air is greatly heated when it is compressed in the turbocharger, making it
necessary for the air to be cooled again in an intercooler (16).

The compressed and cooled charge air is routed from the intercooler via the throttle valve (12) into the intake
manifold.

The system is equipped with several sensors and actuators in order to ensure that the load of fresh air is

cardiagn.com
optimally adapted to the engine's respective operating conditions. How these complex interrelationships are
controlled is discussed in the following sections.

Fig. 37: Identifying Air Intake Ducting

Courtesy of BMW OF NORTH AMERICA, INC.

Exhaust Gas Turbocharging

2589 of 3160
The turbocharger is driven by the engine's exhaust gases, i.e. exhaust gases under pressure are routed by the
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

turbocharger turbine and in this way delivers the motive force to the compressor, which rotates on the same
shaft.

It is here that the induction air is precompressed in such a way that a higher air mass is admitted into the
engine's combustion chamber. In this way, it is possible to inject and combust a greater quantity of fuel, which
increases the engine's power output and torque.

The turbine and the compressor can rotate at speeds of up to 200,000 RPM. The exhaust inlet temperature can
reach a maximum of 1050°C. Because of these high temperatures, the N54 engine's turbochargers are not only
connected with the engine-oil system but also integrated in the engine-coolant circuit.

It is possible in conjunction with the N54 engine's electric coolant pump even after the engine has been
switched off to dissipate the residual heat from the turbochargers and thus prevent the lube oil in the bearing
housing from overheating.

cardiagn.com

Fig. 38: Identifying Exhaust Gas Turbocharging

Courtesy of BMW OF NORTH AMERICA, INC.
2590 of 3160
Bi-turbocharging
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Utmost importance is attached to turbocharger response in the N54 engine. A delayed response to the driver's
command, i.e. the accelerator-pedal position, is not acceptable. The driver therefore must not experience any so-
called "turbo lag".

This requirement is met in the N54 engine with two small turbochargers, which are connected in parallel.
Cylinders 1, 2 and 3 (bank 1) drive the first turbocharger (5) while cylinders 4, 5 and 6 (bank 2) drive the
second (2).

The advantage of a small turbocharger lies in the fact that, as the turbocharger runs up to speed, the lower
moment of inertia of the turbine causes fewer masses to be accelerated, and thus the compressor attains a higher
boost pressure in a shorter amount of time.

cardiagn.com

2591 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 39: Identifying Turbocharging Components
Courtesy of BMW OF NORTH AMERICA, INC.

Boost-pressure Control

The boost pressure of the turbochargers is directly dependent on the flow of exhaust gas which reaches the
turbocharger turbines. Both the velocity and the mass of the exhaust-gas flow are directly dependent on engine
speed and engine load.

The engine-management system uses wastegate valves to 3160

2592 of control the boost pressure. These valves are operated
by vacuum-pressure actuators, which are controlled by the electro-pneumatic pressure transducers via the
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

engine-management system.

cardiagn.com
Fig. 40: Identifying Boost-Pressure Control
Courtesy of BMW OF NORTH AMERICA, INC.

The vacuum pressure is generated by the permanently driven vacuum pump and stored in a pressure
accumulator. The system is designed to ensure that these loads and consumers do not have a negative influence
on the brake-boost function.

The exhaust-gas flow can be completely or partially directed to the turbine wheel with the wastegate valves.
When the boost pressure has reached its desired level, the wastegate valve begins to open and direct part of the
exhaust-gas flow past the turbine wheel.

This prevents the turbine from further increasing the speed of the compressor. This control option allows the
system to respond to various operating situations.

In the idle phase, the wastegate valves of both turbochargers are closed. This enables the full exhaust-gas flow
available to be utilized to speed up the compressor2593 of 3160
already at these low engine speeds.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

When power is then demanded from the engine, the compressor can deliver the required boost pressure without
any noticeable time lag. In the full-load situation, the boost pressure is maintained at a consistently high level
when the maximum permissible torque is reached by a partial opening of the wastegate valves. In this way, the
compressors are only ever induced to rotate at a speed which is called for by the operating situation.

The process of the wastegate valves opening, removes the drive energy from the turbine such that no further
increase in boost pressure occurs, which in turn improves overall fuel consumption.

At full-load the N54 engine operates at an overpressure of up to Index Explanation Index Explanation 0.8 bar in
the intake manifold.

Blow-off Control

The blow-off valves in the N54 engine reduce unwanted peaks in boost pressure which can occur when the
throttle valve closes quickly. They therefore have an important function with regard to engine acoustics and

cardiagn.com
help to protect the turbocharger components.

A vacuum pressure is generated in the intake manifold when the throttle valve is closed at high engine speeds.
This leads to a build-up of high dynamic pressure after the compressor which cannot escape because the route to
the intake manifold is blocked.

Fig. 41: Identifying Turbocharger Components2594 of 3160

Courtesy of BMW OF NORTH AMERICA, INC.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

This leads to a "pumping up" of the turbocharger which means that:

z a clearly noticeable, disruptive pumping noise can be heard,

z and this pumping noise is accompanied by a component-damaging load being exerted on the
turbocharger, since high-frequency pressure waves exert axial load on the turbocharger bearings.

The blow-off valves are mechanically actuated spring-loaded diaphragm valves which are activated by the
intake-manifold pressure as follows:

In the event of a pressure differential before and after the throttle valve, the blow-off valves are opened by the
intake-manifold pressure and the boost pressure is diverted to the intake side of the compressor. The blow-off
valves open starting from a differential pressure of 0.3 bar. This process prevents the disruptive and component-
damaging pumping effect from occurring.

cardiagn.com
The system design dictates that the blow-off valves are also opened during operating close to idle (pressure
differential Pcharger/Psuction = 0.3 bar). However, this has no further effects on the turbocharging system.

The turbocharger is pressurized with the full exhaust-gas flow at these low speeds and already builds up a
certain level of induction-air precharging in the range close to idle.

If the throttle valve is opened at this point, the full boost pressure required is very quickly made available to the
engine.

One of the major advantages of the vacuum pressure-actuated wastegate valves is that they can be partially
opened in the mid-range in order not to allow excessive induction-air precharging to the detriment of fuel
consumption. In the upper load range, they assume the required control position corresponding to the necessary
boost pressure.

Charge-air Cooling

Cooling the charge air in the N54 engine serves to increase power output as well as reduce fuel consumption.
The charge air heated in the turbocharger by its component temperature and by compression is cooled in the
intercooler by up to 80°C.

This increases the density of the charge air, which in turn improves the charge in the combustion chamber. This
results in a lower level of required boost pressure. The risk of knock is also reduced and the engine operates
with improved efficiency.

2595 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 42: Identifying Charge-Air Cooling Operations Diagram
Courtesy of BMW OF NORTH AMERICA, INC.

Load Control

Load control of the N54 engine is effected by means of the throttle valve and the waste gate valves.

The throttle valve is the primary component in this process. The wastegate valves are actuated to bring about a
fine tuning of the boost pressure. At full load the throttle valve is completely open and load control is
undertaken by the wastegate valves.

2596 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 43: Identifying Load Control Operations Diagram
Courtesy of BMW OF NORTH AMERICA, INC.

Controlled Variables

The following variables, among others, influence control of the N54 engine's boost pressure:

z Intake-air temperature
z Engine speed
z Throttle-valve position
z Ambient pressure
z Intake-manifold pressure
z Pressure before the throttle valve (reference variable)

The electropneumatic pressure transducers are activated by the engine control unit on the basis of these
variables. The result of this activation can be checked from the boost pressure achieved, which is measured
before the throttle valve.

There follows a comparison of the boost pressure achieved with the set point data from the program map, which
can if necessary give rise to an activation correction. The system therefore controls and monitors itself during
operation.
2597 of 3160
Limp-home Mode
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

In the event during operation of malfunctions, implausible values or failure of any of the sensors involved in
turbocharger control, activation of the wastegate valves is shut down and the valve flaps are thus fully opened.
Turbocharging ceases at this point.

The list below sets out those components or functional groups of the N54 engine in which a failure, a
malfunction or implausible values result in boost-pressure control being deactivated.

The driver is alerted to a fault of this type via an EML indication.

z High-pressure fuel system

z Inlet VANOS
z Exhaust VANOS
z Crankshaft sensor

cardiagn.com
z Camshaft sensor
z Boost-pressure sensor
z Knock sensors
z Intake-air temperature sensor

One principle of vehicle repair is particularly important in this respect:

It is important to focus on the causes rather than the effects.

With regard to diagnosis of the turbocharging system, always check the basics first. Look at such items as the
vacuum hoses, the solenoids and the vacuum reservoir.

Don't overlook the fundamentals. Check compression, fuel system pressure (low and high), secondary ignition
components etc.

The turbochargers are usually the last item to fail, but often one of the first items to be replaced.

Turbocharger Diagnosis

There are three "Golden Rules" to adhere to when diagnosing concerns on the N54 engine:

1. When diagnosing cases of smoke from the exhaust, it is important to avoid unnecessary replacement of
the turbochargers. Smoke can be caused by oil consumption such as the crankcase ventilation system.
Always evaluate the crankcase venting system completely before condemning any turbocharger
components. Also, any engine is also subject to the usual causes such as valve guide wear or piston ring
issues as on non-turbocharged engines.
2. Turbocharger damage is usually caused by -
z Insufficient lubrication and subsequent bearing and seal failure.

z Foreign bodies can damage the turbine and/or impeller.

z Oil contamination 2598 of 3160

z Restricted air filter
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

z Ensure that all duct work connections are tight and "leak-free". This situation can also result in
engine noise.
3. Do not make any alterations or modifications to the turbocharger. Do not make any adjustments to the
boost control linkage or any part of the turbocharger. Higher than normal boost pressure may have
adverse and detrimental effects on the engine. Any modification will cause the engine management to
enter in the "limp-home" program and will reduce performance and engine reliability.

cardiagn.com
Fig. 44: Identifying Modifications To Turbochargers
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: No Modifications to the turbochargers are permitted.

2599 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 45: Identifying Diagnosis Function Table
Courtesy of BMW OF NORTH AMERICA, INC.

Hot-Film Air Mass Meter

Some new NG6 engines use a digital HFM. The output of the sensor is converted to a digital signal. This
eliminates the need for signal conversion in the ECM. The signal corresponds proportionally to changes in air
mass. The N54 engine uses a virtual HFM. The signal is "calculated" in the ECM from various parameters such
as engine speed, intake air temperature, throttle position etc.

2600 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 46: Identifying Hot-Film Air Mass Meter Diagram (1 Of 2)
Courtesy of BMW OF NORTH AMERICA, INC.

2601 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 47: Identifying Hot-Film Air Mass Meter Diagram (2 Of 2)
Courtesy of BMW OF NORTH AMERICA, INC.

2602 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 48: Identifying BMW Measuring Oscilloscope Display Screen
Courtesy of BMW OF NORTH AMERICA, INC.

Fig. 49: Identifying Oscilloscope Settings Table

Courtesy of BMW OF NORTH AMERICA, INC.

FUEL SUPPLY AND MANAGEMENT

N52KP and N51 Fuel System

2603 of 3160
The N52KP and N51 engine continue to use the conventional "manifold injection" system carried over from the
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

N52. The fuel supply components are also carried over with regard to the EKP module, fuel pump etc.

cardiagn.com
Fig. 50: Identifying Fuel Supply System
Courtesy of BMW OF NORTH AMERICA, INC.

N54 Engine

The N54 engine uses the new High Precision Injection (HPI) system. The HPI system is a "direct" fuel injection
system which represents the second generation "DI" system from BMW. The first generation was on the N73
engine from 2003.

The N73 engine used a "wall guided" method of injection which used a recess in the piston to aid in mixture
formation. The HPI system on the N54 uses a "spray guided" process which allows the mixture to form and
ignite without the aid of any "walls" (i.e piston, cylinder wall etc.).

The spray guided system allows for more efficiency by cooling the cylinder charge without excessive cooling of
the associated engine components. The wall guided system cools the piston crown which reduces thermal
efficiency.

The HPI system also uses the new "piezo-electric" fuel injectors which are a vital components of the spray
guided process. These new injectors open in an outward direction, which forms a precise tapered spray pattern.

With the aid of high system pressure (200 bar), the HPI system is now capable of providing new levels of
efficiency which were not achievable with previous manifold injection systems.
2604 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Fig. 51: Identifying Manifold Injection Systems

Courtesy of BMW OF NORTH AMERICA, INC.

cardiagn.com

2605 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 52: Identifying HPI Function Systems
Courtesy of BMW OF NORTH AMERICA, INC.

HPI Function

The fuel is delivered from the fuel tank by the electric fuel pump via the feed line (5) at an "feed" pressure of 5
bar to the high pressure pump. The feed pressure is monitored by the low-pressure sensor (6). The fuel is
delivered by the electric fuel pump in line with demand.

If this sensor fails, the electric fuel pump continues to run at 100% delivery with terminal 15 ON.

The high pressure pump is driven "in-tandem" with the vacuum pump which is driven by the oil pump chain
2606 of 3160
drive assembly.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

The fuel is compressed in the permanently driven three-plunger high-pressure pump (8) and delivery through
the high-pressure line (9) to the rail (3). The fuel accumulated under pressure in the rail in this way is
distributed via the high-pressure lines (1) to the piezo injectors (2).

The required fuel delivery pressure is determined by the engine-management system as a function of engine
load and engine speed. The pressure level reached is recorded by the high-pressure sensor (4) and
communicated to the engine control unit.

Control is effected by the fuel-supply control valve (7) by way of a setpoint/actual-value adjustment of the rail
pressure. Configuration of the pressure is geared towards best possible consumption and smooth running of the
N54 engine. 200 bar is required only at high load and low engine speed.

High Pressure Pump Function and Design

The fuel is delivered via the supply passage (6) at the admission pressure generated by the electric fuel pump to

cardiagn.com
the high-pressure pump. From there, the fuel is directed via the fuel supply control valve (4) and the low-
pressure non-return valve (2) into the fuel chamber (14) of the plunger-and-barrel assembly. The fuel is placed
under pressure in this plunger-and-barrel assembly and delivered via the high pressure non-return valve (9) to
the high pressure port (7).

2607 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 53: Identifying High Pressure Pump Function & Design
Courtesy of BMW OF NORTH AMERICA, INC.

The high-pressure pump is connected with the vacuum pump via the drive flange (11) and is thus also driven by
the chain drive, i.e. as soon as the engine is running, the three plungers (12) are permanently set into up-and-
down motion via the pendulum disc (10).

Fuel therefore continues to be pressurized for as long as new fuel is supplied to the high-pressure pump via the
fuel-supply control valve (4). The fuel-supply control valve is activated by means of the engine management
connection (3) and thereby admits the quantity of fuel required.

Pressure control is effected via the fuel-supply control valve by opening and closing of the fuel supply channel.
The maximum pressure in the high-pressure area is limited to 245 bar.

If excessive pressure is encountered, the high-pressure circuit is relieved by a pressure-limiting valve via the
ports (8 and 5) leading to the low-pressure area.
2608 of 3160
This is possible without any problems because of the non-compressibility of the fuel, i.e. the fuel does not
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

change in volume in response to a change in pressure. The pressure peak created is compensated for by the
liquid volume in the low-pressure area.

Volume changes caused by temperature changes are compensated for by the thermal compensator (1), which is
connected with the pump oil filling.

Pressure Generation in High-pressure Pump

The plunger (2) driven by the pendulum disc presses oil (red) into the metal diaphragm (1) on its upward travel.
The resulting change in volume of the metal diaphragm thereby reduces the available space in the fuel chamber.
The fuel thereby placed under pressure (blue) is forced into the rail.

The fuel-supply control valve controls the fuel pressure in the rail. It is activated by the engine management
system via a pulse-width modulated (PWM) signal.

cardiagn.com
Depending on the activation signal, a restrictor cross-section of varying size is opened and the fuel-mass flow
required for the respective load point is set. There is also the possibility of reducing the pressure in the rail.

Fig. 54: Pressure Generation In High-Pressure Pump

Courtesy of BMW OF NORTH AMERICA, INC.

2609 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 55: Identifying High-Pressure Pump Location (HDP)
Courtesy of BMW OF NORTH AMERICA, INC.

Limp-Home Mode

If a fault is diagnosed in the system, such as e.g. failure of the high-pressure sensor, the fuel-supply control
valve is de-energized; the fuel then flows via a so-called bypass into the rail.

In the event of HPI limp-home mode, turbocharging is deactivated by an opening of the wastegate valves.

Causes of HPI limp-home mode can be:

z Implausible high-pressure sensor values

z Failure of the fuel-supply control valve
z Leakage in the high-pressure system
z Failure of the high-pressure pump
z Failure of the high-pressure sensor

2610 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 56: Identifying Limp-Home Mode Diagram
Courtesy of BMW OF NORTH AMERICA, INC.

Fuel System Safety

Working on this fuel system is only permitted after the engine has cooled down. The coolant temperature must
not exceed 40°C. This must be observed without fail because otherwise there is a danger of fuel sprayback on
account of the residual pressure in the high-pressure system.

When working on the high-pressure fuel system, take particular care to ensure conditions of absolute cleanliness
and follow the work sequences described in the repair instructions. Even the tiniest contaminant's and damage
to the screw connections on the high-pressure lines can cause leaks.

Fig. 57: Identifying Fuel System Safety Label

Courtesy of BMW OF NORTH AMERICA, INC.

2611 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 58: Identifying High-Pressure Fuel Lines
Courtesy of BMW OF NORTH AMERICA, INC.

Piezo Fuel Injectors

It is the outward-opening piezo-injector that renders possible spray-directed direct injection and thus the overall
innovations of the N54 engine. Due to the fact that only this component ensures that the injected fuel spray cone
remains stable, even under the prevailing influences of pressure and temperature in the combustion chamber.

This piezo-injector permits injection pressures of up to 200 bar and extremely quick opening of the nozzle
needle. In this way, it is possible to inject fuel into the combustion chamber under conditions released from the
power cycles limited by the valve opening times.

The piezo-injector is integrated together with the spark plug centrally between the inlet and exhaust valves in
the cylinder head. This installation position prevents the cylinder walls or the piston crown from being wetted
with injected fuel. A uniform formation of the homogeneous air/fuel mixture is obtained with the aid of the gas
movement in the combustion chamber and a stable fuel spray cone.

2612 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 59: Identifying Piezo Fuel Injectors
Courtesy of BMW OF NORTH AMERICA, INC.

The gas movement is influenced on the one hand by the geometry of the intake passages and on the other hand
by the shape of the piston crown.

The injected fuel is swirled in the combustion chamber with the boost air until a homogeneous mixture is
available throughout the compression space at the point of ignition.

NOTE: When working on the fuel system of the N54 engine, it is important to ensure
that the ignition coils are not fouled by fuel. The resistance of the silicone
material is significantly reduced by heavy fuel contact. This can cause
secondary ignition misfires.

z Before performing any repairs to the fuel system, remove the ignition coils
without fail and protect the spark-plug slot against the ingress of fuel with
a cloth.
z Before refitting the piezo-injector, remove the ignition coils and ensure
conditions of absolute cleanliness.
z Ignition coils heavily fouled by fuel must be replaced.

Injector Design and Function

The piezo-injector essentially consists of three sub-assemblies. The expansion of the energized piezo-element
lifts the nozzle needle outwards from its valve seat. To be able to counter the different operating temperatures
with comparable valve lifts, the injector has a thermal compensating element.
2613 of 3160
The nozzle needle is pressed outwards from its tapered valve seat. This opens up an annular orifice. The
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

pressurized fuel flows through this annular orifice and forms a hollow cone, the spray angle of which is not
dependent on the backpressure in the combustion chamber.

cardiagn.com
Fig. 60: Identifying Injector Design & Function
Courtesy of BMW OF NORTH AMERICA, INC.

Fig. 61: Identifying Outward Opening Injector 2614

Nozzle Needle
of 3160
Courtesy of BMW OF NORTH AMERICA, INC.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

The spray cone (1) of a piezo-injector can diverge during operation (2). Due to the formation of soot inside the
engine, such divergence is perfectly normal and acceptable to a certain extent.

If, however, spray divergence reaches the stage where it begins to spray the spark plug wet, the spark plug may
incur damage.

cardiagn.com
Fig. 62: Identifying Spray Piezo-Injector Operation
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: Do not attempt to clean the injectors in any way.

This may result in damage which can effect the spray pattern. Any divergence
in the spray pattern can cause damage to the spark plug or the engine itself.

NOTE: Replace the Teflon sealing ring when fitting and removing the piezo-injector.
This also applies when an injector that has just been fitted has to be removed
again after an engine start. A piezo-injector provided with a new Teflon sealing
ring should be fitted as quickly as possible because the Teflon sealing ring
could swell up. Please observe the repair instructions and follow without fail.

When fitting, make sure that the piezo injector is correctly seated. The hold-
down element for securing the piezo-injectors must rest on both injector tabs,
otherwise the necessary force is not applied to the piezo-injector.

Injection Strategy

Injection of the fuel mass required for the operating situation can take place in up to three individual injections.
Which option is used in the relevant operating situation
2615 ofis3160
dependent on engine load and speed. Here, the actual
time resulting from the engine speed available for metering the fuel is an important framework quantity.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

A special situation during the operation of any engine is the range in which a high load occurs at low engine
speed, so-called "Low End Torque" operation. In this operating situation, the required fuel mass is metered to
the engine in three individual injections.

This results in a highly effective mixture formation which in the final analysis has the effect of both increasing
power output and saving fuel.

cardiagn.com
Fig. 63: Identifying Injection Strategy
Courtesy of BMW OF NORTH AMERICA, INC.

In order to bring the catalytic converters up to operating temperature as quickly as possible, the N54 engine has
a catalyst-heating mode for when the engine is started from cold. In this mode, combustion heat is intentionally
introduced into the exhaust train and not used first and foremost to develop power output.

The point of ignition is moved to 30° (crankshaft degrees) after TDC. The main quantity of the required fuel is
injected before TDC and mixed with the boost air. The piston is situated after TDC in its downward travel such
that the air/fuel mixture is already expanding again, which reduces the ignitability of the mixture.

In order to ignite the mixture reliably, a small residual quantity of fuel is injected 25° after TDC and this
guarantees an ignitable mixture at the spark plug. This small fuel quantity therefore provides for ignition of the
residual charge in the combustion chamber.

This operating mode is set by the engine-management 2616system

of 3160after a maximum period of 60 seconds from
engine starting but is terminated if the catalytic-converter response temperature is reached earlier.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Piezo Element

The movement of the nozzle needle in the injector is generated no longer by a solenoid coil but rather by a
piezo-element.

A piezo-element is an electromechanical converter, i.e. it consists of a ceramic material which converts

electrical energy directly into mechanical energy (force/travel). A familiar application is the piezo cigarette
lighter - when a piezo-crystal is pressed, voltage is generated until a spark flashes over and the gas ignites.

cardiagn.com
Fig. 64: Identifying Piezo Element
Courtesy of BMW OF NORTH AMERICA, INC.

In the case of the piezo-actuator, voltage is generated so that the crystal expands. In order to achieve greater
travel, it is possible to design a piezo-element in several layers.

The actuator module consists of layers of the piezo-ceramic material connected mechanically in series and
electrically in parallel. The deflection of a piezo-crystal is dependent on the applied voltage up to a maximum
deflection; the higher the voltage, the greater the travel.

Injector Adjustment

When the injectors are manufactured, a multitude of measurement data is recorded at specific points in the
factory. In this way, the tolerance ranges for injector-quantity adjustment are determined and specified in a six-
digit number combination.

Information on the lift performance of the injector is also added for injector voltage adjustment. Injector
adjustment is required because of the individual voltage demand of each piezo actuator. An allocation is made
to a voltage demand category, which is included in the number combination on the injector.
2617
These data items are transmitted to the ECM. During of 3160
engine operation, these values are used to compensate for
deviations in the metering and switching performance.
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

NOTE: When replacing an injector, it is absolutely essentially to carry out an injector

adjustment.

cardiagn.com
Fig. 65: Identifying Tolerance Range Numbers
Courtesy of BMW OF NORTH AMERICA, INC.

Injector Control and Adaptation

The fuel mass required for the operating situation is injected by the piezo-injector into the combustion chamber.
This mass can be influenced by three correcting variables:

z the rail pressure

z the injector opening time
z and the injector opening lift

The injector opening time and the injector opening lift are activated directly at the piezo injector. The opening
time is controlled via the ti signal and the opening lift via the energy quantity in the activation of the piezo-
injector.

Injector Adaptation

The fuel masses and injection cycles determined from the load/speed map are included in a pilot-control
program map. Here, while further framework parameters are taken into consideration, the energy quantities and
injector opening times required to activate the injectors are determined.

The N54 engine can be safely and reliably operated with these program-map values.

Optimization

For optimization of:

2618 of 3160
z Emission values
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

z Smooth running
z Fuel consumption
z Power output

The controlled variables of energy quantities and injector opening times are continuously monitored. This
occurs on a bank-selective basis by way of lambda closed-loop control.

The residual oxygen in the exhaust gas is measured in each case for cylinder bank 1 and cylinder bank 2. This
measurement result is compared with the values expected from the set correcting variables. The result of a
deviation is that the injector opening signal is adapted. This adaptation is stored in the control unit and is
therefore available for subsequent engine operation.

However, these stored values are lost when the system is flashed and must be relearned. A further adaptation of
the injector activation takes place depending on time and use. This cylinder-selective adaptation involves a

cardiagn.com
check of the residual-oxygen content with a conclusion as to the cylinder causing the situation. To this end, it is
necessary for part of the exhaust-gas flow not to be swirled in the turbocharger. For this reason, the flap of the
wastegate valve must be fully opened, i.e. swung out of the exhaust-gas flow.

This wastegate-flap position extends beyond its normal opening position in engine operation. Based on the
result of this cylinder-selective monitoring, the energy quantity is adapted if necessary to activate the injectors.

Furthermore, the cylinder-selective adaptation includes if necessary an adaptation of the injector opening signal
based on smooth running monitoring of the N54 engine. Overall adaptation of the injectors is limited to a 15%
additional quantity.

2619 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Fig. 66: Identifying BMW Measuring Oscilloscope Display Screen

Courtesy of BMW OF NORTH AMERICA, INC.

cardiagn.com
Fig. 67: Identifying Oscilloscope Settings Table
Courtesy of BMW OF NORTH AMERICA, INC.

Fig. 68: Identifying HPI Injection Testing Table

Courtesy of BMW OF NORTH AMERICA, INC.

IGNITION MANAGEMENT 2620 of 3160

 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Most of the ignition system components have remained the same for all NG6 engines for 2007. There are some
minor changes to the ignition coils that apply to all versions. The coils have been optimized for more durability.

Spark Plugs

The spark plugs for the N51 and N52KP remain the same as N52. However, the N54 uses a completely new
spark plug from Bosch. The spark plug design consists of a 12 mm thread which contrasts from the 14 mm
design on the N52 which prevents any possibility of improper installation.

The hex on the spark plug is also a 12 point design which requires a special tool. The tool (socket) has a
"thinwall" design to facilitate access in the confined area of the N54 cylinder head.

cardiagn.com
Fig. 69: Identifying Spark Plugs
Courtesy of BMW OF NORTH AMERICA, INC.

Spark Plug Diagnosis (N54)

Due to the proximity of the spark plug to the fuel injector nozzle, any divergence in the fuel spray may cause
possible spark plug damage. This makes spark plug diagnosis an important part of N54 service concerns.
Information gained by the spark plug diagnosis may indicate possible fuel injector faults. Spark plug
replacement interval has been reduced to 45,000 miles for the N54.

The Fig. 70 below can be used to assist in diagnosis:

2621 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 70: Identifying Spark Plug Wear Pattern
Courtesy of BMW OF NORTH AMERICA, INC.

EMISSIONS MANAGEMENT

The N54 and N52KP meet ULEV II requirements for 2007. There are not many changes to the emission
systems on these engines. The N54 engine has 2 underbody catalysts in addition to the "near engine" catalysts
already in use from the N52.

The N51 engine, however, is a SULEV II compliant engine which meets the 2007 requirements. In addition to
the 5 existing SULEV states of California, New York, Maine, Massachusetts, and Vermont - four states have
been added for 2007. These states include, Connecticut, Rhode Island, Oregon and Washington State.

The N51 emissions measures include:

z Secondary Air System with mini-HFM

z Radiator with "Prem-air" coating
z Lower compression ratio (10:1) via modified combustion chamber and pistons
z Underbody catalyst in addition to "near engine" catalyst
2622 of 3160
z Activated carbon air filter in air filter housing
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

z Steel fuel lines with threaded fittings and sealed fuel tank
z Crankcase ventilation system integrated into cylinder head cover
z Purge system piping made from optimized plastic

NOTE: The SULEV II information above is only preliminary and is accurate as of 8/06.
Additional information will be released as it becomes available.

PERFORMANCE CONTROLS

Cooling System

The cooling system of the N54 engine consists of a radiator circuit and an isolated oil cooling circuit. The fact
that there is an isolated oil-cooling circuit ensures that heat is not introduced via the engine oil into the engine's

cardiagn.com
coolant system.

2623 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com

2624 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Fig. 71: Identifying Cooling System Diagram

Courtesy of BMW OF NORTH AMERICA, INC.

There is a significantly greater quantity of heat on account of this engine's increased power of 75.5 kW/l in
comparison with other 3-liter spark-ignition engines.

This boundary condition is satisfied by the engine cooling system with its increased performance. This increase
in power was to be realized in spite of some factors less advantageous to cooling.

Factors to be mentioned here are:

z Approximately 15% less flow area is available on account of the intercooler located below the radiator.
z The already small amount of space provided by the engine compartment is further limited by the
accommodation of further components.

cardiagn.com
z Because the exhaust turbochargers are cooled by the coolant, an additional quantity of heat is introduced
into the system via these turbochargers.

Measures for increasing cooling-system performance:

z Coolant pump with increased power - 400 W/9000 l/h

z Separation of water and engine-oil cooling
z Radiator with increased power
z Electric fan with increased power 600W for all gearbox variants

The structure of the coolant circuit is the same as that of the N52 engine. The engine is flushed through with
coolant in accordance with the cross-flow concept. Cooling output can be influenced as a function of load by
activating the following components:

z Electric fan
z Electric coolant pump
z Map thermostat

It is also possible that an N54 engine equipped with an automatic gearbox to utilize the lower area of the
radiator to cool the gearbox by means of the gearbox oil cooler. This is achieved as in the N52 engine with
control sleeves, which are introduced into the radiator tank.

Engine-oil Cooling

The N54 engine is equipped with a high-performance engine oil cooler. The pendulum slide pump delivers the
oil from the oil sump to the oil filter. A thermostat flanged to the oil filter housing admits the oil to the engine-
oil cooler. The engine oil cooler is located in the right wheel arch in the E92. The thermostat can reduce the
resistance opposing the oil by opening the bypass line between the feed and return lines of the engine oil cooler.
This ensures that the engine warms up safely and quickly.
2625 of 3160
Radiator
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

Design measures have been used to increase the performance of the radiator itself. The performance of a
radiator is dependent on its radiation surface. However, the intercooler location had to be underneath the
radiator, and this meant that is was necessary to compensate for the smaller flow area available.

Compared with the N52 engine, the radiator used in the N54 engine has a block depth which has been increased
to 32 mm. In addition, the water pipes are situated closer together than in previously used radiators. The upshot
of this is an increase in the utilizable radiation surface.

Electric Coolant Pump

The coolant pump of the N54 engine is an electrically driven centrifugal pump with a power output of 400W
and a maximum flow rate of 9000 l/h. This represents a significant increase in power of the electric coolant
pump used in the N52 engine, which has a power output of 200 W and a maximum flow rate of 7000 l/h.

cardiagn.com
The power of the electric wet-rotor motor is electronically controlled by the electronic module (3) in the pump.
The electronic module is connected via the bit-serial data interface (BSD) to the MSD80 engine control unit.

The engine control unit uses the engine load, the operating mode and the data from the temperature sensors to
calculate the required cooling output.

Based on this data, the engine control unit issues the corresponding command to the electric coolant pump. The
electric coolant pump regulates its speed in accordance with this command.

The system coolant flows through the motor of the coolant pump, thus cooling both the motor as well as the
electronic module. The coolant lubricates the bearings of the electric coolant pump.

2626 of 3160
 2008 BMW X5 48i
2007-08 GENERAL INFORMATION Engine Service Information - 328i, 328xi, 335i, 335xi, X3, X5

cardiagn.com
Fig. 72: Identifying Engine-Oil Cooling Diagram
Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: The same rules apply to all electric coolant pumps. The pump must be filled
with coolant when removed for service to prevent any corrosion. Also, the
pump impeller must be turned by hand before installation to ensure the pump is
not seized.

2627 of 3160