Table of Contents N73B60 Engine - Workbook Subject Page N73B60 Engine Objectives of the Module.2 Purpose of the System.3 Technical Data.4 Disassembly - Components Intake Manifold.6 Cylinder Head Cover..8 Ancillary Components and Drive Belts.9 Cylinder Heads.10 Valvetronic.11 Fuel Injectors.14 Lubrication Components.15 Crankshaft and Bearings.17 Pistons and Connecting Rods.17 Crankcase.19 Lubrication System.19 Cooling System.21 N73B60 Engine Model: E66 - 760Li Production: MY 2003 This intent of this workbook is to assist you with key components for disassembly/reassem¬ bly in addition to the detailed information found in the Repair Instructions, Technical Data and Tightening Torques from the latest TIS information. This section will be instructor led for a brief review of the N73 engine. You are encouraged to use this workbook with the latest TIS information to make notes during disassembly/ reassembly of the engine. This will be valuable to you as supplementary information or a memory refresher when performing repairs in the future. Note: For more in depth and detailed information about the N73 engine, refer to the ST047 2003 Systems Diagnosis training manual. For additional and updated information, always refer to: www. bm wcenternet .com - TIS information/updates - Service Information Bulletins - DCS messages Objectives: After completion of this module you will be able to: • Disassemble the N73 engine. • Perform critical measurements and observations to determine engine condition. • Correctly reassemble (including valve gear timing) the N73 engine. 2 N73B60 Engine - Diagnosis N73B60 Engine Purpose of the System The N73 engine is a complete new BMW development from the NG Series (New Generation) as a B60 (6 liter). The N73B60 will be used in the E66 as a 760Li (USA). The BMW 760Li will set new standards in terms of performance and driving dynamics in the 12-cylinder market segment as well as significantly reduce fuel consumption. For the first time at BMW, Valvetronic technology (combination of Bi-VANOS and variable intake valve lift) is supplemented by direct injection (Dl). In addition, the N73 cylinder heads use 4 valve technology. The combination of these cutting edge technologies provides low fuel consumption and maximum power output and torque, making the N73 the best engine in its class. 3 N73B60 Engine - Diagnosis Technical Data Technical Data Comparison N73B60 M73B54 V-angle configuration 12 cyl. V / 60° 12 cyl. V/60° Displacement (cm 3) 5972 5379 Bore / Stroke (mm) 89/80 79/85 Cylinder spacing (mm) 98 91 Crankshaft main bearing diam. (mm) 70 75 Conrod big end diam. (mm) 54 48 Power output (kW/HP) 320 / 438 240 / 326 at engine speed (rpm) 6000 5000 Torque (Nm) 600 490 at engine speed (rpm) 3950 3900 Idle speed (rpm) 550 600 Maximum engine speed (rpm) 6500 6500 Compression ratio 11.3 : 1 10 : 1 Valves per cylinder 4 2 Intake valve diam. (mm) 35 42 Exhaust valve diam. (mm) 29 36 Intake valve lift (mm) 0.3 - 9.85 10.3 Exhaust valve lift (mm) 9.7 10.3 Engine weight (kg) 280 - Fuel requirement Premium unleaded Premium unleaded Knock control Yes Yes Injection pressure (bar) 50 - 120 3.5 Digital Motor Electronics (ECM) 2x MED 9.2.1 & Valvetronic ECU with 2x HDEV ECU 2x ME 5.2 & EML Ills Emission compliance level LEV LEV Firing order 1-7-5-11-3-9-6-12-2-8-4-10 1-7-5-11-3-9-6-12-2-8-4-10 Fuel consumption savings compared with M73 12 % Maxmimum regulated vehicle speed (km/h / mph) 250/155 250/155 4 N73B60 Engine - Diagnosis Power and Torque Output - N73B60 / M73B54 Nth hW psmp N73B60 M73B54 5 N73B60 Engine - Diagnosis Intake Manifold The intake system is a complete component constructed of magnesium in a shell type design and has separate manifold chambers for each cylinder bank. 1. Intake manifold pressure sensors 2. Captured gaskets 3. Pressure control valves for crankcase ventilation 4. Throttle valves The individual parts of the intake system are bonded and bolted to each other, providing considerable weight reduction (separating the shell halves is not permitted). The entire intake system is protected against corrosion by a dip coating procedure. The fastening bolts of the add on parts are also coated and must be replaced in the event of damage, to prevent corrosion and pitting. All of the gaskets (2) are secured by retainers (captured) to provide ease of installation. The intake system is isolated from the engine by rubber elements on the fastening bolts. An intake manifold pressure sensor (1) is used for each cylinder bank. Recording the man¬ ifold differential pressure is necessary for the correct throttle position (synchronization) so that a manifold differential pressure of 50 mbar can be balanced on each bank. Both sides of the induction system are fitted with a pressure control valve (3) for crankcase ventilation which is distributed to both banks. Note: When replacing the spark plugs, it is necessary to remove the entire intake system to avoid damaging the spark plugs during installation. The spark plugs must be replaced every 100,000 miles in US vehicles. 6 N73B60 Engine - Diagnosis Intake Manifold - Removal Top Diagram • Remove plug connections on the throttle assemblies (1). • Detach engine vent hoses from pressure con¬ trol valves (2). • Detach oustide braces for intake manifold (3 UR). Lower Diagram • Remove plug connections on the intake mani¬ fold pressure sensors (1 L/R). • Remove bolts (2) along sections (3). • Lift intake manifold up to remove. Questions How many attaching bolts are there? What is the tightening torque? Nm How are the intake manifold gaskets held in place? Can the gaskets be reused? Notes: 7 N73B60 Engine - Diagnosis Cylinder Head Cover (right) - Removal Caution: Do not bend any high pressure lines! Top Diagram • Detach high pressure lines (1) at mounting points (2). On high pressure pump: • Detach feed line (3). • Detach high pressure line (4). • Detach leakage line (5). • Detach high pressure lines from fuel rail (6). Lower Diagram • Remove Valvetronic motor. • Remove mounting bolts (1) and high pressure pump (2). • Remove bolts (3) and pull out spacer (4). • Remove Non-Return Valves and cylinder head cover perimeter bolts. Questions What is the tightening torque for the coupling nuts on fuel lines 3-6? Nm What should you do to the sparkplug domes (sleeves) before reinstalling them? After removing the high pressure pump (2), what other component must be removed from the pump mount¬ ing base? Why should caution be taken to not bend any of the high pressure fuel lines? 8 N73B60 Engine - Diagnosis Ancillary Components and Drive Belts - Removal Remove the following compo¬ nents: 1. Water pump pulley 2. 6 rib main drive belt 3. Main drive belt tensioner 4. Alternator 5. Deflection pulley 6. Power steering and dynamic drive pump 7. A/C compressor drive belt tensioner 8. Crankshaft pulley 9. A/C compressor 10. 4 rib A/C compressor drive belt To remove the drive belts: The tensioning pulley is pushed back using a Torx tool in the recess provided (1) and fixed in this position by inserting a locking pin as shown i ( 2 ). The cooling module of the N73 includes an external engine oil cooler. The engine oil cooler is located in front of the engine coolant radiator above the A/C condenser. 42 - 02-16 The engine oil flows from the oil pump through a channel in the crankcase to a connection on the alternator support. The alternator support has an oil thermostat (arrow to the right). A wax element in the oil thermostat opens the supply flow to the engine oil cooler from an oil temperature of 100 °C to 130 °C. A partial amount of engine oil will permanently bypass the oil thermostat, even when it is fully open and flows uncooled through the engine. The engine oil cooler helps to keep the engine oil temperature below 150 °C. 9 N73B60 Engine - Diagnosis Cylinder Heads The two N73 cylinder heads are a new development from BMW and have been adapted to the new direct injection system. The cylinder heads are equipped with Valvetronic valve gear and Bi-VANOS. The inlet camshaft and the Valvetronic eccentric shaft are jointly guid¬ ed by a bridge support. The ports for the high pressure fuel injectors are located on the intake side. The engine is equipped with a high pressure fuel pump for each cylinder head. Each cylinder head has a bucket-tappet drive on the exhaust camshaft for the high pressure fuel pump. The secondary air ducts for subsequent exhaust gas treatment are integrated in the cylin¬ der heads. The cylinder heads are cooled by the “cross-flow” principle. The cylinder heads are made from aluminum and are manufactured using gravity die-casting. Cylinder Head Gaskets DCS00654 The cylinder head gasket is a triple layer steel gasket with rubber coating. This gasket ver¬ sion is already established in previous engines (N62). The cylinder head bolts for the N73 engine are Ml 0x160 necked-down “stretch” bolts. Note: These bolts should always be replaced when repairs are performed. The lower part of the timing chain housing is bolted to the cylinder head using two M8x45 bolts (arrows above). 10 N73B60 Engine - Diagnosis Cylinder Head - Preparation for Removal • Rotate the engine and set up cylinder number 1 valve gear “timing” for cylinder head removal, remove the VANOS solenoids, front cover and Bi- VAN OS units as per the Repair Instructions. Valvetronic The Valvetronic system simultaneously varies the valve opening time and the intake valve opening lift between 0.3 mm and 9.85 mm, according to engine speed and load. This means that the air volume is controlled according to engine requirements. The valve gear is essentially the same as the N62 engine and has been adapted to the geometry of the N73 (with two more cylinders). 1. Valvetronic motor * 2. Intermediate shaft * 3. Bridge support * 4. Eccentric shaft 5. Torque compensation spring * 6. Intake camshaft 7. Exhaust camshaft with “triple” cam lobe for high pressure pump * * Modifications have been made to these components making them different from the N62. Note: To remove the cylinder head, it is necessary to remove the vari¬ able valve gear and eccentric shaft in order to gain access to the cylin¬ der head bolts. 11 N73B60 Engine - Diagnosis The Valvetronic motor is rubber mounted at the rear (1 lower left) to isolate it from the cylin¬ der head cover. The Valvetronic motor is secured to the bridge support by the intermedi¬ ate flange and has a hexagon drive (2 lower left), which engages into the intermediate shaft (7 lower right). The intermediate shaft is mounted in the bridge support and is engaged by its spindle in the eccentric shaft teeth. This design provides ease of removal if the motor/gear fails. 1 2 KT-9574 Diagram shown to the right: KT-9571 1. Eccentric shaft 2. Intake camshaft 3. Mounting for high pressure fuel pump 4. Exhaust camshaft 5. Bridge support with receptacle for intermediate 6. Bridge support 7. Intermediate shaft shaft and Valvetronic motor To remove the intermediate shaft, use the spanner tool #90 88 6 11 7 270 to unthread the locking collar (lower left). If you remove the outer snap ring (as shown lower right), the tensioning drive washer can be removed along with the tensioning ring behind it. 12 N73B60 Engine - Diagnosis Note: When reinstalling the tension ring and tensioning drive washer, the ring eyelet must engage with the pin: • On the drive washer (1) and • In the intermediate shaft (2) Test fit (insert) the Valvetronic motor hex shaft. If it does not insert easily, remove the drive washer and flip the tension ring over to reassemble. • Remove torque compensation spring and Valvetronic bridge support assembly as per the Repair Instructions (N62 section can be used). • Remove bank 1 - 6 cylinder head. Questions (N62 section can be used) Can the N73 cylinder heads be machined? If so, what is the limit? If so, how does this affect cylinder head gasket replacement? What is the correct torque procedure for the cylinder head bolts? How are the BI-VANOS units distinguished? What special tools (numbers) are required for N73 valve gear timing? 13 N73B60 Engine - Diagnosis How are the camshafts identified? What markings indicate correct camshaft bear¬ ing cap installation? intake: exhaust: What is the correct postion for the hook sealing rings (6 & 7) when reassembling? 1&2. Rear Oil Duct with Four Holes 3&4. Front Oil Duct with Four Holes 5. Front Oil Duct Outlets 6&7. Hook Sealing Rings. VANOS Oil Ports 42-02-40 Fuel Injector Removal The fuel injector installed position and mounting pressure are maintained by a twin hold down fixture (one hold down fixture for every two fuel injectors). The twin hold down fixtures are bolted to the cylinder head with spring washers, the correct mounting pressure is ensured by the contact pressure of the spring washers. The high pressure fuel injectors are positioned on the intake side at a 30° angle to the cylinder head and reach directly into the combustion chamber between the two intake valves. • Remove the fuel rail and disconnect plug con¬ nections (1). • Remove bolts (3), nozzle holder (4), spring washers (2) and store exactly as removed for re-installation. • Install special tool #13 1 430 and 13 5 250 on injector nozzles and drive out by slide ham¬ mering. 14 N73B60 Engine - Diagnosis Engine Block Oil Sump The oil sump consists of two parts. The upper section of the oil sump is made from cast aluminum and is sealed to the crankcase with a rubber-coated sheet steel gasket. This section of the oil sump has a cross shaped cut out oil filter element recess. The upper sec¬ tion of the oil sump is inter connected to the oil pump and is sealed with a sealing ring. The double panel (noise insulation) lower section of the oil sump is flanged to the upper section of the oil sump. 1. Upper Section of The Oil Sump 2. Oil Pump 3. Oil Level / Condition Sensor 4. Lower Section of The Oil Sump 5. Oil Filter Housing 6. Oil Drain Plug 6 5 4 42-03-65 Oil Sump Components • Remove oil sump assembly and oil pump. Oil Filter The canister type oil filter (3) is located under the engine by the oil sump. The support for the oil filter is integrated in the rear oil pump cover. The oil filter housing (2 with o-ring) is threaded into the rear of the oil pump cover through an opening in the oil sump. A drain plug is integrated in the oil filter housing for draining the filter assembly before the hous¬ ing is removed (1 with o-ring). The filter element support dome contains an over pressure relief valve. If the filter element is blocked, this valve allows a bypass of unfiltered engine oil around the element to supply lubrica¬ tion to the engine. 15 N73B60 Engine - Diagnosis Oil Pump The oil pump is mounted at an angle to the crankshaft bearing cap and is driven by the crankshaft using a roller chain. The oil pump is a two-stage gear oil pump with two gear clusters. 1. Mounting points 2. Oil pump drive shaft 3. Oil pressure from pump to engine 4. Control valve (Pump Stage/Pressure Control) 5. Oil pressure control tube from the engine to the control valve. 6. Oil pickup strainer 7. Pressure relief valve (over 15 Bar) 8. Oil filter Pressure Control The oil pressure control valve in the oil pump has two functions: 1. Deactivates stage two oil pump circuit above 2 bar. Stage two is only active in the lower speed range. This is to ensure that there is always sufficient oil pressure for the VANOS units even at high oil temperatures and low speeds. The oil pump power consumption is reduced by deactivating stage two. 2. Monitoring the required oil pressure for the engine. The piston in the control valve is moved by a spring against the engine control pressure which is returning from the engine. This means that precise monitoring of the actual engine oil pressure is pos¬ sible. A separate pressure relief valve in the oil pump automatically opens at the maximum pres¬ sure of approximately 15 bar. This prevents damage in the oil pump especially at low oil temperatures. • Disassemble oil pump for visual inspection. Oil Pump 16 N73B60 Engine - Diagnosis Crankshaft The N73 uses a forged steel crankshaft (1 - front). Each crankshaft throw has two counterweights for balancing the moving masses (12 counter¬ weights in total). The crankshaft is supported by seven main bearings, the seventh is the thrust bearing. Crankshaft Crankshaft Thrust Bearing The thrust bearing halves are multiple pieces that are assem¬ bled as one part for the the number seven main bearing at the rear of the engine. Piston and Connecting Rod The iron coated cast aluminum alloy pistons are “domed” with valve reliefs in the crowns (1). The recess (2) directs the combustible mixture directly under the spark plug and pre¬ vents the combustion chamber from being divided into two parts. Piston rings: • First piston ring groove = square ring • Second piston ring groove = taperface ring • Third piston ring groove = two-part oil control ring Note: Due to the shaping of the piston crown and the wrist pin offset, the pistons are cylinder bank specific (crown index arrow always points to the front of the engine). The forged steel connecting rod and cap is separated by the familiar “cracked” process. The large end is angled at 30° allowing sufficient articulation in a very compact space. The pistons are cooled by oil jets spraying under the exhaust side of the piston crown. 17 N73B60 Engine - Diagnosis • Remove piston/connecting rod assembly from any cylinder of the bank (caution - use care around the oil spray jet). • Remove crankshaft thrust bearing cap for visual inspection. • Measure the piston diameter. • Measure the cylinder bore that the piston was removed from. Questions (N62 section can be used) What is the piston diameter? What are the cylinder bore measurements? Fill in the chart: What is the piston installation clearance on a “used” piston? What is the permissible total wear tolerance between piston and cylinder? What is the permitted out-of-round of a cylinder bore? What is the permitted conicity (taper) of a cylinder bore? How are the pistons identified for the cylinder bank? What is the correct way to install connecting rods (on the pistons) for cylinder bank 1-6? 18 N73B60 Engine - Diagnosis Crankcase The crankcase is a one-piece “open deck” design and is made entirely from AluSil. In mass production, the cylinder bores are finished by an etching procedure. This involves etching out a thin aluminium layer from the cylinder walls. By doing this, the high strength silicon crystals are exposed. The silicon crystals form a high strength running surface for the pis¬ tons. Open Deck: Exposed cylinder coolant jacket Lubrication System - Technical Data The recommended oil is BMW High Performance 5W-30 Synthetic Oil * P/N 07 51 0 017 866 Oil Capacity in Liters (quarts) Explanation 8.5 (9.0) Filling capacity with oil filter change Oil Pressure in Bar Explanation 1.0 Minimum oil pressure @ 20° C 4.0 - 8.0 Maximum oil pressure @ 20° C Oil Delivery Capacity Explanation 9-12 liters/minute At idle speed (550 rpm) @ 20° C 50 - 55 liters/minute At maximum engine speed (6500 rpm) @ 20° C 19 N73B60 Engine - Diagnosis Lubrication System Oil Circuit (view from engine front) A. Oil pressure from oil pump B. Oil supply to VANOS units C. Oil return 1. Oil supply to intake camshaft 2. Oil non-return valves 3. Oil circuit in oil thermostat 4. Oil return from oil cooler 5. Oil supply to oil cooler 6. Oil supply from oil pump 7. Oil supply , chain tensioner 8. Oil supply , VANOS solenoid valves 9. Oil supply to exhaust camshaft 10. Oil supply to high pressure injection pumps 11. Oil supply to HVA elements 12. Oil supply to Valvetronic eccentric shaft The engine oil is supplied by the oil pump to the lubrication points in the engine block and is pumped into the cylinder heads. The following components in the crankcase and cylin¬ der head are supplied with engine oil: Crankcase • Crankshaft bearings • Oil jets for piston cooling • Oil jet for the drive chain (bank 7-12) • Tensioning rail for drive chain (bank 1 -6) Cylinder head • Chain tensioner • Guide rail on cylinder head • Hydraulic valve adjustment elements (HVA) • VANOS supply • Camshaft bearings • Overhead oil tubes for the valve gear 20 N73B60 Engine - Diagnosis Cooling System Coolant Circuit -14.94 Liter (15.8 Quart) Capacity 20 19 9 8 7 5 2 1 3 6 4 Cooling System (Circuit Flow) kt-9704 1. Water pump 9. Coolant reservoir 14. Heater supply hose (hot) 2. Thermostat housing with MAP thermostat 10. Water cooled alternator 15. Water valves / electric pump 3. Coolant temperature sensor 11. Thermostat for transmission 16. Heater inlet hoses 4. Radiator oil heat exchanger 17. Holes (cylinder jacket venting) 5. Partition wall (low temperature area) 12. Oil/water heater exchanger 18. Cylinder head vent hose 6. Radiator (high temperature area) for automatic transmission 19. Cylinder head, bank 1-6 7. Return flow (cool) 13. Transmission oil line 20. Heater core(s) 8. Radiator vent line connections 21. Cylinder head, bank 7-12 21 N73B60 Engine - Diagnosis Coolant Circuit The coolant flow has been optimized allowing the engine to warm up as quickly as possi¬ ble after a cold start as well as even and sufficient engine cooling while the engine is run¬ ning. The cylinder heads are supplied with coolant in a cross-flow pattern. This ensures more even temperature distribution to all cylinders. The cooling system ventilation has been improved and is enhanced by using ventilation ports in the cylinder heads and in the radiator. The air in the cooling system accumulates in the reservoir/expansion tank. When a pressure of 2 bar is reached in the expansion tank, the air is bled out by the pressure relief valve in the reservoir cap. Note: The ventilation ports in the front of the cylinder heads provide quicker “self bleeding” during a routine coolant exchange. The complex cooling system and the small ventilation ports require that time should be allowed after the cooling system has been filled for the air to escape. Coolant flow in the Engine Block (similar to N62) The coolant flows from the water pump through the feed pipe in the engine's V and to the rear of the engine block. This area has a cast aluminum cover. From the rear of the engine, the coolant flows to the external cylinder walls and from there into the cylinder heads. The coolant then cross flows through the cylinder heads (exhaust to intake) into the engine block inner coolant jacket into the engine “V” and through the return connection to the ther¬ mostat housing. When the coolant is cold it flows from the thermostat (closed) directly into the water pump and back to the engine (recirculating for faster warm up). When the engine reaches operating temperature (85 °C-110 °C), the thermostat opens the entire cooling circuit to include the radiator. Notes: 22 N73B60 Engine - Diagnosis The coolant flows to the rear of the engine block, from there through the side channels to the cylinder walls and then into the cylinder heads (lower left picture). The cast aluminum cover at the rear of the engine block (with sealing bead) is shown on the lower right. 42-02-59 42-02-58 Water Pump/Thermostat Housing The water pump is combined with the thermostat lower section. 1. Map-controlled themostat (radiator cool return flow). 2. Electrical connection for Thermostat Heating element. 3. Thermostat Mixing Chamber 4. Temperature Sensor (hot coolant from engine) 5. Radiator in-flow (hot coolant from engine) 6. Heat exchanger (transmission oil return flow) 7. Leakage Chamber (evaporation space) 8. Alternator in-flow (cool supply) 9. Water Pump 10. Expansion Tank Connection Caution during installation of the water pump housing and is bolted to the timing case 42-02-60 Water Pump / Thermostat Housing The impeller is made from reinforced plastic. • Reassemble engine using your notes taken during disassembly in addition to the Repair Instructions. 23 N73B60 Engine - Diagnosis