BMW B58TU Reference Manual
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BMW B58TU Reference Manual

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R e f e r e n c e Ma n u a l
B 5 8 T U E N G I N E
T e c h n i c a l T r a i n i n g
T h e i n f o r ma t i o n c o n t a i n e d i n t h i s ma n u a l i s n o t t o b e r e s o l d , b a r t e r e d , c o p i e d o r t r a n s f e r r e d
w i t h o u t t h e e x p r e s s w r i t t e n c o n s e n t o f B MW o f N o r t h A me r i c a , L L C ( " B MW N A " ) .
C o p y r i g h t © 2 0 1 8 B MW o f N o r t h A me r i c a , L L C

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  • Page 1 R e f e r e n c e Ma n u a l B 5 8 T U E N G I N E T e c h n i c a l T r a i n i n g T h e i n f o r ma t i o n c o n t a i n e d i n t h i s ma n u a l i s n o t t o b e r e s o l d , b a r t e r e d , c o p i e d o r t r a n s f e r r e d w i t h o u t t h e e x p r e s s w r i t t e n c o n s e n t o f B MW o f N o r t h A me r i c a , L L C ( "...
  • Page 2 Technical￿training. Product￿information. B58TU￿Engine BMW￿Service...
  • Page 3 General￿information Symbols￿used The￿following￿symbol￿is￿used￿in￿this￿document￿to￿facilitate￿better￿comprehension￿or￿to￿draw￿attention to￿very￿important￿information: Contains￿important￿safety￿information￿and￿information￿that￿needs￿to￿be￿observed￿strictly￿in￿order￿to guarantee￿the￿smooth￿operation￿of￿the￿system. Information￿status:￿July￿2018 BMW￿Group￿vehicles￿meet￿the￿requirements￿of￿the￿highest￿safety￿and￿quality￿standards.￿Changes in￿requirements￿for￿environmental￿protection,￿customer￿benefits￿and￿design￿render￿necessary continuous￿development￿of￿systems￿and￿components.￿Consequently,￿there￿may￿be￿discrepancies between￿the￿contents￿of￿this￿document￿and￿the￿vehicles￿available￿in￿the￿training￿course. The￿information￿contained￿in￿the￿training￿course￿materials￿is￿solely￿intended￿for￿participants￿in￿this training￿course￿conducted￿by￿BMW￿Group￿Technical￿Training￿Centers,￿or￿BMW￿Group￿Contract Training￿Facilities. This￿training￿manual￿or￿any￿attached￿publication￿is￿not￿intended￿to￿be￿a￿complete￿and￿all￿inclusive source￿for￿repair￿and￿maintenance￿data.￿It￿is￿only￿part￿of￿a￿training￿information￿system￿designed￿to assure￿that￿uniform￿procedures￿and￿information￿are￿presented￿to￿all￿participants. For￿changes/additions￿to￿the￿technical￿data,￿repair￿procedures,￿please￿refer￿to￿the￿current￿information issued￿by￿BMW￿of￿North￿America,￿LLC,￿Technical￿Service￿Department. This￿information￿is￿available￿by￿accessing￿TIS￿at￿www.bmwcenternet.com. Additional￿sources￿of￿information Further￿information￿on￿the￿individual￿topics￿can￿be￿found￿in￿the￿following: • Owner's￿Handbook • Integrated￿Service￿Technical￿Application • Aftersales￿Information￿Research￿(AIR) The￿information￿contained￿in￿this￿manual￿is￿not￿to￿be￿resold,￿bartered,￿copied,￿or￿transferred without￿the￿express￿written￿consent￿of￿BMW￿of￿North￿America,￿LLC￿(“BMW￿NA”). ©2018￿BMW￿of￿North￿America,￿LLC The￿BMW￿name￿and￿logo￿are￿registered￿trademarks.￿All￿rights￿reserved.

  • Page 4: Table Of Contents

    B58TU￿Engine Contents Introduction ................................................1.1. Innovations ............................................1.2. Technical￿data ..........................................1.2.1. Performance￿diagrams ..............................1.2.2. Model￿overview ..................................Engine￿Mechanical ............................................. 2.1. Engine￿housing ......................................... 2.1.1. Cylinder￿head ....................................2.1.2. Crankcase ......................................2.2. Crankshaft￿drive ........................................2.2.1. Chain￿drive ...................................... 2.3. Valve￿gear ............................................2.3.1. VANOS ......................................Vacuum￿Supply ............................................
  • Page 5 B58TU￿Engine Contents 7.1. Digital￿Motor￿Electronics￿(DME) ..............................7.2. Component￿temperature￿sensor ...............................

  • Page 6: Introduction

    B58TU￿Engine 1.￿Introduction The￿product￿information￿"B58￿Engine"￿serves￿as￿the￿basis￿for￿this￿document.￿This￿document exclusively￿describes￿the￿changes￿to￿the￿B58￿engine￿and￿serves￿to￿support￿Technical￿Service. Due￿to￿the￿huge￿similarities,￿the￿two￿engines￿are￿described￿in￿the￿one￿document.

  • Page 7: Innovations

    B58TU￿Engine 1.￿Introduction 1.1.￿Innovations To￿meet￿the￿legal￿requirements￿for￿emissions,￿a￿number￿of￿technical￿improvements￿have￿been implemented.￿The￿technical￿updates￿for￿the￿B58TU￿engine￿include￿the￿following￿new￿features: New￿features￿on￿the￿B58TU￿engine...
  • Page 8 B58TU￿Engine 1.￿Introduction Index Explanation Fuel￿preparation￿with￿350 bar￿injection￿pressure Cylinder￿head￿with￿integrated￿exhaust￿manifold Adapted￿exhaust￿turbocharger￿made￿from￿steel Split￿cooling Coolant￿pump￿with￿integrated￿pressure￿relief￿valve Heat￿management￿module￿with￿electric￿split￿cooling￿valve Single-part￿chain￿drive Weight￿savings￿in￿the￿crankshaft￿drive￿area,￿injection￿pressure￿boosting￿in￿the￿fuel￿preparation￿area, and￿function￿changes￿in￿the￿engine￿cooling￿area￿have￿made￿it￿possible￿to￿reduce￿the￿CO ￿emissions￿by 2.5%,￿while￿increasing￿engine￿performance￿by￿10 kW/50 Nm.￿(13￿hp/36￿lb-ft) 1.2.￿Technical￿data The￿following￿engine￿versions￿are￿described￿in￿this￿product￿information: B58B30M1 Output￿in￿[kW/(hp)] 250￿(335) at￿[rpm] 5500￿-￿6500 Torque￿in￿[Nm/(lb-ft)] 450￿(330) at￿[rpm] 1500￿-￿5200 Displacement￿in￿[cm³] 2998 Bore￿hole￿/￿Stroke￿in￿[mm] 82/94.6 Compression￿ratio 11.0￿:￿1 Combustion￿process Turbo-Valvetronic￿direct￿injection Maximum￿rotational￿speed 6500 Short-term￿overspeed￿(overboost)￿15￿s 7000 Idle￿speed Permissible￿fuel￿range...
  • Page 9 B58TU￿Engine 1.￿Introduction 1.2.1.￿Performance￿diagrams Comparison￿of￿performance￿curves￿between￿B58B30M1￿and￿B58B30M0￿engine 1.2.2.￿Model￿overview The￿following￿table￿provides￿an￿overview￿of￿the￿models￿in￿which￿the￿new￿B58TU￿engine￿is￿used￿from 07/2018: Model Engine BMW￿X5￿xDrive40i￿(G05),￿from￿07/2018 B58B30M1 BMW￿X7￿xDrive40i￿(G07),￿from￿12/2018 B58B30M1...
  • Page 10 B58TU￿Engine 2.￿Engine￿Mechanical 2.1.￿Engine￿housing 2.1.1.￿Cylinder￿head The￿following￿figures￿show￿the￿two￿cylinder￿head￿variants￿with￿and￿without￿the￿cylinder head-integrated￿exhaust￿manifold. Cylinder￿head￿of￿B58TU￿engine Index Explanation Cylinder￿head￿with￿integrated￿exhaust￿manifold￿ZIAK¹ Cylinder￿head￿without￿integrated￿exhaust￿manifold￿nZIAK² ZIAK¹￿=￿cylinder￿head-integrated￿exhaust￿manifold nZIAK²￿=￿non￿cylinder￿head-integrated￿exhaust￿manifold With￿the￿gravity￿casting￿process￿the￿aluminum￿alloy￿is￿embedded￿into￿a￿prefabricated￿mould￿of steel￿and￿sand￿using￿gravity.￿The￿result￿is￿a￿cylinder￿head￿made￿from￿aluminum￿gravity￿die￿casting AlSi7MgCu0.5￿T5. The￿cylinder￿head￿of￿the￿B58TU￿engine￿in￿the￿medium￿power￿level￿is￿a￿new￿design.￿The￿exhaust manifold￿was￿integrated￿in￿the￿housing￿of￿the￿cylinder￿head.￿Depending￿on￿the￿engine￿output,￿the engine￿weight,￿the￿operating￿strategy￿of￿the￿engine￿and￿the￿cooling￿surfaces,￿the￿exhaust￿manifold is￿integrated￿in￿the￿cylinder￿head￿housing￿and￿the￿exhaust￿turbocharger￿is￿interlocked￿at￿the￿cylinder head. Owing￿to￿the￿higher￿mechanical￿and￿thermal￿loads,￿gasoline￿engines￿in￿the￿upper￿power￿levels￿and higher￿have￿a￿traditional￿cylinder￿head￿without￿the￿exhaust￿manifold￿integrated￿in￿the￿cylinder￿head. The￿following￿benefits￿could￿be￿achieved￿with￿the￿integration￿of￿the￿exhaust￿manifold￿in￿the￿cylinder head￿housing: • Benefits￿in￿fuel￿consumption￿and￿pollutant￿emissions￿due￿to￿faster￿warm-up￿of￿the￿engine. • Weight￿reduction￿with￿the￿use￿of￿aluminum￿instead￿of￿steel. • Cost￿reduction￿by￿eliminating￿the￿need￿for￿a￿separate￿exhaust￿manifold. • Simple￿disassembly￿and￿installation￿both￿of￿the￿cylinder￿head￿and￿the￿exhaust￿turbocharger. The￿following￿table￿provides￿an￿overview￿of￿the￿engine￿versions￿that￿use￿a￿cylinder￿head￿with￿an integrated￿exhaust￿manifold:...

  • Page 11: Crankcase

    B58TU￿Engine 2.￿Engine￿Mechanical B58TU￿Engine Engine 3.0 l 3.0 l version Power￿level Medium￿power￿level Upper￿power￿level Cylinder￿head Cylinder￿head-integrated Non￿cylinder￿head-integrated exhaust￿manifold￿ZIAK exhaust￿manifold￿nZIAK 2.1.2.￿Crankcase Honing￿process Honing￿process￿"old/new" Index Explanation Previous￿manufacturing￿process￿of￿internal￿cylindrical￿honing New￿manufacturing￿process￿of￿form￿honing...
  • Page 12 B58TU￿Engine 2.￿Engine￿Mechanical The￿cylindrical￿bore￿hole￿of￿a￿combustion￿engine￿becomes￿deformed￿during￿the￿operating￿condition by￿thermal￿loads.￿Form￿honing￿allows￿this￿deformation￿to￿be￿achieved￿in￿production,￿so￿that￿there￿is￿an almost￿cylindrical￿shape￿in￿the￿operating￿condition.￿This￿has￿a￿positive￿effect￿on￿the￿emissions￿quality, oil￿and￿fuel￿consumption,￿as￿well￿as￿output￿and￿wear. 2.2.￿Crankshaft￿drive 2.2.1.￿Chain￿drive Features: • Chain￿drive￿at￿the￿side￿of￿the￿engine￿emitting￿the￿forces • Single-part￿chain￿drive￿for￿driving￿the￿camshafts • Single￿sleeve-type￿chain￿8 mm • Electric￿motor￿of￿the￿combined￿oil-vacuum￿pump￿via￿a￿separate￿chain • Plastic￿tensioning￿and￿guide￿rail • Hydraulic￿chain￿tensioner￿with￿spring￿preload￿and￿sealing￿sleeve.
  • Page 13 B58TU￿Engine 2.￿Engine￿Mechanical Comparison￿of￿the￿chain￿drive￿of￿B58￿engine￿and￿B58TU￿engine Index Explanation Two-part￿chain￿drive Single-part￿chain￿drive Slide￿rail Top￿timing￿chain Chain￿tensioner Tensioning￿rail Bottom￿timing￿chain Camshaft￿sprocket,￿oil￿vacuum￿pump Drive￿chain,￿oil￿vacuum￿pump Guide￿rail Timing￿chain...
  • Page 14 B58TU￿Engine 2.￿Engine￿Mechanical The￿main￿difference￿between￿the￿chain￿drive￿compared￿with￿the￿B58￿engine￿is￿the￿move￿from￿a￿two- part￿timing￿chain￿drive￿to￿a￿single-part￿timing￿chain￿drive.￿Deflection￿via￿the￿intermediate￿shaft￿on￿the top￿timing￿chain￿and￿the￿second￿timing￿chain￿is￿no￿longer￿needed.￿The￿chains￿used￿here￿are￿8 mm sleeve-type￿chains.￿Because￿the￿intermediate￿gearing￿is￿no￿longer￿needed,￿the￿number￿of￿teeth￿on￿the crankshaft￿(23 teeth)￿and￿the￿VANOS￿adjuster￿(46 teeth￿each)￿has￿also￿changed. Chain￿track Comparison￿between￿chain￿track￿of￿B58￿engine￿and￿B58TU￿engine Index Explanation Chain￿track,￿two-part￿timing￿chain￿drive￿B58￿engine Chain￿track,￿single-part￿timing￿chain￿drive￿B58TU￿engine 6-cylinder￿engine Upper￿timing￿chain Timing￿chain Lower￿timing￿chain Drive￿chain,￿oil￿vacuum￿pump The￿way￿the￿combined￿oil￿vacuum￿pump￿is￿driven￿via￿a￿separate￿drive￿chain￿from￿the￿crankshaft￿has not￿changed￿compared￿with￿the￿Bx8￿engines.￿Only￿the￿change￿of￿the￿chain￿tracks￿has￿changed: The￿drive￿chain￿of￿the￿oil￿vacuum￿pump￿is￿now￿in￿front￿of￿the￿timing￿chain. Dropping￿the￿second￿timing￿chain￿offers￿the￿following￿benefits: • Improved￿acoustics • Lower￿space￿requirement • Reduced￿weight...
  • Page 15 B58TU￿Engine 2.￿Engine￿Mechanical Chain￿tensioner Chain￿tensioner,￿Bx8TU￿engine Index Explanation Tensioning￿rail Sealing￿sleeve Chain￿tensioner￿with￿screw￿thread Due￿to￿the￿cylinder￿head￿manufacturing￿process,￿the￿chain￿tensioner￿now￿has￿a￿sealing￿sleeve￿with a￿height￿of￿12.5 mm￿instead￿of￿a￿sealing￿ring.￿The￿spring￿force￿of￿the￿chain￿tensioner￿lies￿between 40 Nm￿(extended)￿and￿90 Nm￿(retracted). 2.3.￿Valve￿gear 2.3.1.￿VANOS...
  • Page 16 B58TU￿Engine 2.￿Engine￿Mechanical Index Explanation VANOS￿B58￿engine VANOS￿B58TU￿engine Following￿the￿changeover￿from￿a￿two-part￿chain￿drive￿to￿a￿single-part￿chain￿drive,￿the￿camshaft sprockets￿on￿the￿VANOS￿now￿need￿46￿teeth￿instead￿of￿the￿previous￿36￿teeth.￿To￿compensate￿for￿the additional￿weight￿of￿the￿larger￿camshaft￿sprockets,￿the￿adjuster￿was￿designed￿to￿be￿shorter￿and￿more compact.
  • Page 17 B58TU￿Engine 3.￿Vacuum￿Supply 3.1.￿Vacuum￿pump Oil￿vacuum￿pump,￿B58/B58TU￿engine Index Explanation B58￿engine,￿tandem￿oil￿pump￿with￿integrated￿vacuum￿pump B58TU￿engine,￿oil￿pump Vacuum￿pump Oil￿pump Vehicles￿with￿a￿gasoline￿engine￿and￿"traditional￿brake￿system"￿need￿a￿vacuum￿pump￿to￿boost￿the pedal￿force.￿In￿vehicles￿with￿a￿gasoline￿engine￿and￿DSCi￿brake￿system￿no￿vacuum￿boost￿is￿required￿as in￿the￿DSCi￿brake￿system￿the￿pedal￿force￿is￿boosted￿hydraulically.￿The￿graphics￿show￿the￿oil￿pumps￿of the￿B58￿engine￿and￿the￿B58TU￿engine￿with￿combined￿vacuum￿pump￿and￿without￿vacuum￿pump.
  • Page 18 B58TU￿Engine 4.￿Cooling￿System 4.1.￿Split￿cooling A￿new￿development￿for￿the￿B58TU￿engine￿is￿the￿split￿cooling.￿A￿cooling￿concept￿which￿is￿used￿the N63￿TU2. The￿split￿cooling￿function￿uses￿the￿electric￿split￿cooling￿valve,￿eSCV,￿to￿enable￿on-demand￿decoupling of￿the￿crankcase￿from￿the￿coolant￿flow￿both￿in￿the￿warm-up￿phase￿and￿in￿partial￿load￿operation.￿In￿this situation,￿the￿coolant￿is￿exclusively￿routed￿through￿the￿cylinder￿head.￿The￿engine￿reaches￿its￿operating temperature￿more￿quickly￿in￿the￿warm-up￿phase,￿and￿can￿be￿operated￿with￿reduced￿emissions￿in partial￿load￿operation. Cooling￿circuit,￿B58TU￿engine...
  • Page 19 B58TU￿Engine 4.￿Cooling￿System Index Explanation High￿cooling￿requirement,￿split￿cooling￿cylinder￿head Low￿cooling￿requirement,￿split￿cooling￿crankcase Cylinder￿head Crankcase Heat￿management￿module Electric￿Split￿Cooling￿Valve￿(eSCV) Coolant￿pump...
  • Page 20 B58TU￿Engine 4.￿Cooling￿System Cooling￿system￿for￿B58TU￿engine...
  • Page 21 B58TU￿Engine 4.￿Cooling￿System Index Explanation Coolant￿radiator Coolant￿temperature￿sensor,￿radiator￿outlet Electric￿fan Electric￿split￿cooling￿valve Coolant￿pump Pressure￿relief￿valve Coolant￿temperature￿sensor,￿crankcase Crankcase Cylinder￿head Exhaust￿turbocharger Heating Component￿temperature￿sensor Expansion￿tank Engine￿oil/coolant￿heat￿exchanger Transmission￿oil/coolant￿heat￿exchanger Heat￿management￿module In￿split￿cooling,￿the￿cooling￿requirements￿for￿the￿crankcase￿and￿the￿cylinder￿head￿are￿managed￿by￿the electric￿split￿cooling￿valve.￿The￿fact￿that￿the￿engine￿reaches￿operating￿temperature￿more￿quickly￿again translates￿to￿substantial￿consumption￿and￿emission￿reductions. 4.1.1.￿Split￿cooling￿valve Heat￿management￿module￿with￿electric￿split￿cooling￿valve...
  • Page 22 B58TU￿Engine 4.￿Cooling￿System Index Explanation Electric￿split￿cooling￿valve To￿guarantee￿optimal￿heat￿distribution￿during￿the￿cylinder￿head￿and￿crankcase￿warm-up,￿the￿coolant supply￿for￿the￿cylinder￿head￿and￿crankcase￿is￿controlled￿individually.￿The￿coolant￿is￿controlled￿by￿the Digital￿Motor￿Electronics￿(DME).￿The￿coolant￿is￿distributed￿by￿the￿electric￿split￿cooling￿valve￿on￿the heat￿management￿module￿in￿the￿warm-up￿phase￿such￿that￿substantially￿more￿coolant￿is￿available￿to the￿cylinder￿head￿than￿to￿the￿crankcase.￿Depending￿on￿the￿engine's￿operating￿condition,￿the￿Digital Motor￿Electronics￿(DME)￿decide￿on￿the￿distribution￿of￿the￿coolant￿quantity￿to￿the￿cylinder￿head￿and￿the crankcase￿as￿required. Direct￿current￿motor￿(DC) B58TU￿engine Voltage￿range￿in￿volts￿(V) 6￿-￿16 Power￿consumption￿in￿ampere￿(A) 0.4￿-￿1 Control￿frequency￿of￿the￿DC￿motor￿(kHz) Gear￿reduction 1￿:￿440 Adjustment￿speed￿per￿second 65.5° 4.1.2.￿Switching￿logic￿of￿split￿cooling￿valve Switching￿logic￿of￿electric￿split￿cooling￿valve...
  • Page 23 B58TU￿Engine 4.￿Cooling￿System Index Explanation End￿stop Delivery￿position End￿stop Valve￿opening￿in￿% Rotary￿valve￿position￿in￿degrees,￿angle￿of￿rotation Rotary￿valve The￿diagram￿shows￿the￿switching￿logic￿of￿the￿electric￿split￿cooling￿valve.￿Depending￿on￿the￿operating condition￿and￿coolant￿temperature￿of￿the￿engine,￿as￿well￿as￿the￿driver's￿desired￿load,￿the￿Digital￿Motor Electronics￿(DME)￿releases￿the￿coolant￿access￿from￿the￿crankcase￿to￿a￿greater￿or￿lesser￿extent￿via￿the rotary￿valve￿of￿the￿split￿cooling￿valve.￿The￿coolant￿now￿also￿flows￿through￿the￿crankcase￿and￿cools components. A￿bleeding￿procedure￿in￿line￿with￿the￿repair￿instructions￿is￿required￿following￿a￿part￿exchange￿in￿the cooling￿system￿or￿refilling￿of￿the￿cooling￿system.￿Filling￿without￿a￿vacuum￿filler￿device￿(watering can￿filling)￿is￿not￿approved￿￿There￿is￿a￿risk￿of￿engine￿damage￿in￿case￿of￿failure￿to￿comply￿￿The￿filling specification￿must￿be￿observed￿ Operation￿of￿the￿vehicle￿is￿not￿permitted￿without￿completing￿the￿entire￿filling￿and￿bleeding￿routine. There￿is￿a￿risk￿of￿functional￿limitations￿or￿overheating. 4.2.￿Heat￿management￿module The￿function￿of￿the￿heat￿management￿module￿is￿similar￿to￿that￿of￿the￿heat￿management￿module￿of￿the B58￿engine. B58TU￿engine￿heat￿management￿module...
  • Page 24 B58TU￿Engine 4.￿Cooling￿System Index Explanation Coolant￿output￿towards￿the￿coolant￿pump Electric￿split￿cooling￿valve Coolant￿outlet￿to￿coolant￿radiator Electrical￿actuator,￿heat￿management￿module Coolant￿entry,￿split￿cooling￿valve Coolant￿entry,￿heat￿management￿module Coolant￿outlet,￿heating A￿rotary￿valve￿inside￿the￿heat￿management￿module￿ensures￿needs-driven￿cooling￿of￿the￿various￿engine components.￿The￿opening￿cross-sections￿of￿the￿various￿coolant￿ducts￿can￿be￿opened￿or￿closed variably.￿A￿position￿sensor￿in￿the￿electrical￿actuator￿of￿the￿heat￿management￿module￿forwards￿the current￿position￿of￿the￿rotary￿valve￿to￿the￿Digital￿Motor￿Electronics￿(DME).￿The￿exact￿position￿of￿the rotary￿valve￿can￿thus￿be￿determined￿so￿that￿it￿opens￿or￿closes￿a￿precisely￿defined￿cross-section￿with respect￿to￿the￿various￿coolant￿ducts.￿Adjusting￿the￿cross-sections￿ideally￿adapts￿the￿flow￿rates￿of￿the coolant￿ducts￿connected￿to￿the￿heat￿management￿module￿to￿the￿engine￿operating￿points.￿To￿correctly position￿the￿rotary￿valve,￿the￿Digital￿Motor￿Electronics￿(DME)￿require￿information￿including￿the￿coolant temperature￿from￿the￿coolant￿temperature￿sensor,￿and￿the￿material￿temperature￿of￿the￿cylinder￿head from￿the￿component￿temperature￿sensor￿.￿Warm-up￿and￿cooling￿of￿the￿engine￿and￿the￿supply￿to ancillary￿components￿can￿be￿implemented￿as￿driven￿by￿requirements,￿thus￿optimizing￿consumption. The￿following￿tables￿provide￿an￿overview￿of￿the￿technical￿data￿of￿the￿heat￿management￿modules: Direct￿current￿motor￿(DC) B58￿engine B58TU￿engine Voltage￿range￿in￿volts￿(V) 6￿-￿16 9￿-￿16 Power￿consumption￿in￿ampere￿(A) 0.3￿-￿1.5 0.5￿-￿0.8 Gear￿reduction 1￿:￿492 5￿:￿769 Adjustment￿speed￿per￿second 40° 64° Position￿sensor B58￿engine B58TU￿engine...
  • Page 25 B58TU￿Engine 4.￿Cooling￿System 4.3.￿Operating￿strategy￿of￿the￿heat￿management￿module The￿following￿graphic￿shows￿the￿positions￿of￿the￿rotary￿valve￿as￿the￿coolant￿temperature￿increases. Circuit￿diagram￿of￿heat￿management￿module￿in￿B58TU￿engine Index Explanation 0 % Rotary￿valve￿closed 100% Rotary￿valve￿open Cold￿start Warm-up￿phase Operating￿temperature Transition￿from￿normal￿operation￿to￿maximum￿cooling￿requirement Maximum￿cooling￿requirement Rotational￿angle￿in￿angular￿degrees Heater￿circuit Main￿coolant￿circuit Minor￿coolant￿circuit The￿openings￿on￿the￿rotary￿valve￿vary￿the￿cross-sections￿of￿the￿different￿coolant￿ducts￿as￿a￿function of￿the￿rotational￿angle￿of￿the￿rotary￿valve.￿The￿following￿graphics￿schematically￿represent￿the￿various engine￿operation￿phases,￿from￿cold￿start￿to￿maximum￿cooling￿requirement.
  • Page 26 B58TU￿Engine 4.￿Cooling￿System 4.3.1.￿Cold-start￿phase Point￿A￿in￿the￿heat￿management￿module￿circuit￿diagram￿designates￿the￿cold￿start￿with￿an￿engine￿that has￿completely￿cooled￿down. Cold-start￿phase,￿Bx8TU￿engine In￿the￿cold-start￿phase,￿the￿coolant￿circulates￿exclusively￿via￿a￿bypass￿in￿the￿coolant￿pump.￿The￿rotary valve￿in￿the￿heat￿management￿module￿closes￿the￿coolant￿lines￿so￿that￿the￿excess￿pressure￿that￿builds up￿opens￿the￿pressure￿relief￿valve￿in￿the￿coolant￿pump￿(opening￿pressure￿2.1 bar)￿and￿the￿coolant￿is recirculated￿in￿the￿coolant￿pump. Because￿the￿coolant￿circuits￿through￿the￿exhaust￿turbocharger￿and￿the￿ventilation￿line￿of￿the￿cylinder head￿cannot￿be￿closed,￿a￿low￿volumetric￿flow￿is￿returned￿to￿the￿coolant￿pump￿here.
  • Page 27 B58TU￿Engine 4.￿Cooling￿System 4.3.2.￿Warm-up￿phase Area￿B￿in￿the￿circuit￿diagram￿for￿the￿heat￿management￿module￿shows￿the￿opening￿angle￿of￿the￿rotary valve￿in￿the￿warm-up￿phase. Warm-up￿phase,￿Bx8TU￿engine In￿the￿warm-up￿phase,￿the￿heat￿management￿module￿additionally￿opens￿the￿connection￿to￿the￿heating in￿addition￿to￿opening￿the￿bypass￿line.￿The￿coolant￿flows￿through￿the￿cylinder￿head,￿the￿exhaust turbocharger￿and￿the￿engine￿oil/coolant￿heat￿exchanger.￿The￿electric￿split￿cooling￿valve￿is￿closed;￿no coolant￿flows￿through￿the￿engine￿block￿(split￿cooling).
  • Page 28 B58TU￿Engine 4.￿Cooling￿System 4.3.3.￿Operating￿temperature The￿positions￿of￿the￿rotary￿valve￿at￿engine￿operating￿temperature￿are￿shown￿by￿area￿C￿of￿the￿circuit diagram. Operating￿temperature,￿Bx8TU￿engine The￿graphic￿shows￿control￿with￿the￿engine￿at￿operating￿temperature.￿The￿position￿of￿the￿rotary￿valve means￿that￿the￿cross-sections￿of￿the￿respective￿coolant￿lines￿are￿open￿to￿a￿greater￿or￿lesser￿extent depending￿on￿the￿coolant￿temperature.￿The￿coolant￿flows￿with￿a￿varying￿volumetric￿flow￿through￿the small￿coolant￿circuit,￿the￿large￿coolant￿circuit￿and￿the￿heater￿circuit.￿Depending￿on￿the￿load￿request, the￿crankcase's￿coolant￿connection￿is￿opened￿by￿the￿electric￿split￿cooling￿valve,￿thus￿cooling￿the crankcase.￿Large￿engine￿operation￿ranges￿are￿covered￿with￿the￿crankcase￿coolant￿circuit￿closed.
  • Page 29 B58TU￿Engine 4.￿Cooling￿System 4.3.4.￿Maximum￿cooling￿requirement The￿maximum￿cooling￿requirement￿is￿shown￿at￿point￿E￿of￿the￿heat￿management￿module￿circuit diagram. Maximum￿cooling￿requirement,￿Bx8TU￿engine To￿provide￿maximum￿cooling￿at￿high￿dynamic￿loads￿and/or￿high￿ambient￿temperatures,￿the￿radiator connection￿is￿fully￿opened￿(100%)￿and￿the￿small￿coolant￿circuit￿is￿completely￿closed.￿Additionally, the￿heater￿circuit￿is￿90%￿closed￿to￿achieve￿the￿maximum￿cooling￿thanks￿to￿the￿maximum￿coolant volumetric￿flow￿through￿the￿large￿coolant￿circuit.
  • Page 30 B58TU￿Engine 4.￿Cooling￿System 4.4.￿Coolant￿pump The￿layout￿and￿function￿of￿the￿coolant￿pump￿have￿been￿revised￿and￿adapted￿to￿match￿the￿cooling concept￿of￿the￿Bx8 TU engines. Coolant￿pump,￿Bx8TU￿engine Index Explanation Pressure￿relief￿valve￿closed￿(pressure < 2.1 bar) Pressure￿relief￿valve￿opened￿(pressure > 2.1 bar) A￿pressure￿relief￿valve￿is￿installed￿in￿the￿mechanical￿coolant￿pump￿housing.￿In￿combination￿with￿the heat￿management￿module,￿the￿pressure￿relief￿valve￿on￿the￿one￿hand￿ensures￿that￿the￿engine￿operating temperature￿is￿reached￿more￿quickly,￿while￿at￿the￿same￿time￿reducing￿leaks￿and￿component￿damage due￿to￿high￿pressure￿in￿the￿cooling￿system. If￿an￿excess￿pressure￿of￿more￿than￿2.1 bar￿builds￿up￿in￿the￿coolant￿circuits,￿the￿pressure￿relief￿valve opens￿and￿releases￿a￿bypass￿channel.￿The￿coolant￿is￿now￿exclusively￿circulated￿in￿the￿pump￿body. Once￿the￿pressure￿drops￿below￿2.1 bar￿or￿the￿engine￿speed￿rises￿above￿3000￿rpm,￿the￿pressure￿relief valve￿closes￿and￿the￿coolant￿is￿again￿routed￿through￿the￿engine's￿coolant￿ducts.
  • Page 31 B58TU￿Engine 5.￿Intake￿Air￿and￿Exhaust￿System 5.1.￿Crankcase￿monitoring 5.1.1.￿On-board￿diagnosis Feed-in￿point￿of￿the￿blow-by￿gases￿to￿the￿clean￿air￿line￿upstream￿from￿the￿exhaust￿turbocharger Index Explanation Non-return￿valve Connection￿to￿exhaust￿turbocharger Captive￿screws Crankcase￿bleeding￿connection Tank￿ventilation￿connection Connection￿to￿clean￿air￿line Aluminum￿heating￿pipe Electrical￿connection￿of￿heating￿element Owing￿to￿the￿stricter￿legislation￿in￿the￿USA,￿the￿engines￿for￿the￿US￿market￿have￿an￿OBD￿concept "pressure￿sensor".￿With￿a￿differential￿pressure￿sensor￿in￿the￿tank￿ventilation￿system￿and￿the￿hot￿film air￿mass￿meter,￿leaks￿in￿the￿crankcase￿ventilation,￿tank￿ventilation,￿as￿well￿as￿the￿blow-by￿lines￿can￿be identified.￿Via￿a￿feed-in￿point￿at￿the￿exhaust￿turbocharger￿the￿blow-by￿gases￿are￿fed￿back￿into￿the￿clean air￿line￿of￿the￿air￿intake￿system.
  • Page 32 B58TU￿Engine 5.￿Intake￿Air￿and￿Exhaust￿System 5.2.￿Exhaust￿turbocharger 5.2.1.￿B58TU￿exhaust￿turbocharger Exhaust￿turbocharger￿in￿the￿B58TU￿engine Index Explanation Exhaust￿turbocharger￿made￿of￿steel,￿for￿cylinder￿head-integrated￿exhaust manifold￿ZIAK¹ Exhaust￿turbocharger￿made￿of￿steel,￿for￿non￿cylinder￿head-integrated￿exhaust manifold￿nZIAK² ZIAK¹￿=￿cylinder￿head-integrated￿exhaust￿manifold nZIAK²￿=￿non￿cylinder￿head-integrated￿exhaust￿manifold Due￿to￿the￿exhaust￿manifold￿integrated￿into￿the￿cylinder￿head,￿the￿exhaust￿manifold￿and￿exhaust turbocharger￿housing￿are￿no￿longer￿designed￿as￿a￿single￿component￿for￿the￿B58TU￿engine.￿This means￿that￿the￿exhaust￿turbocharger￿can￿be￿individually￿replaced.￿The￿charging￿pressure￿is￿still controlled￿by￿an￿electrical￿wastegate￿valve. The￿exhaust￿manifold￿and￿exhaust￿turbocharger￿housing￿on￿the￿B58TU￿engine￿can￿be￿implemented either￿as￿one￿part￿or￿separately.￿Depending￿on￿the￿engine￿version,￿the￿exhaust￿turbocharger￿can￿be replaced￿individually.￿The￿following￿table￿shows￿which￿variant￿is￿used￿by￿which￿engine. B58TU￿engine Engine￿version B58B30M1 B58B30O1 Cylinder￿head Cylinder￿head-integrated Non￿cylinder￿head- exhaust￿manifold integrated￿exhaust￿manifold Exhaust￿turbocharger Steel...
  • Page 33 B58TU￿Engine 6.￿Fuel￿System 6.1.￿Fuel￿preparation The￿fuel￿preparation￿has￿been￿modified￿to￿meet￿the￿requirements￿of￿emission￿legislation.￿The￿high pressure￿pump￿and￿the￿injectors￿have￿been￿revised￿and￿designed￿for￿a￿fuel￿injection￿pressure￿of 350 bar. Fuel￿preparation,￿B58TU￿engine Index Explanation Injector Holding￿clamp Rail￿pressure￿sensor Rail High-pressure￿line High￿pressure￿pump Quantity￿control￿valve Fuel￿feed￿line Strict￿cleanliness￿must￿be￿observed￿when￿carrying￿out￿any￿work￿on￿the￿fuel￿system￿...
  • Page 34 B58TU￿Engine 6.￿Fuel￿System 6.1.1.￿Direct￿rail Mounting￿the￿injectors Index Explanation Mounting￿bolts Plastic￿sleeve Holding￿clamp￿with￿bayonet￿fitting Rail Solenoid￿valve￿injector Cast￿lug The￿solenoid￿valve￿injectors￿are￿fastened￿to￿the￿holding￿clamp￿with￿a￿bayonet￿fitting.￿There￿is￿a￿plastic sleeve￿between￿the￿holding￿clamp￿and￿direct￿rail.￿This￿is￿not￿designed￿to￿collect￿escaping￿fuel.￿This is￿only￿used￿to￿support￿a￿helium￿leakage￿test￿during￿pre-assembly￿at￿the￿factory￿in￿order￿to￿check￿the tightness.￿After￿the￿initial￿assembly,￿this￿plastic￿sleeve￿is￿of￿no￿relevance￿to￿the￿engine￿operation.￿When the￿solenoid￿valve￿injectors￿are￿reinstalled￿or￿replaced,￿the￿plastic￿sleeves￿are￿no￿longer￿required￿and do￿not￿need￿to￿be￿reinserted. The￿mounting￿bolts￿of￿the￿holding￿clamp￿must￿be￿replaced￿each￿time￿they￿are￿released.
  • Page 35 B58TU￿Engine 6.￿Fuel￿System The￿housing￿on￿the￿solenoid￿valve￿injectors￿is￿sensitive￿to￿excessive￿tensile￿forces￿and￿excessive rotational￿angles.￿When￿removing￿and￿installing￿the￿solenoid￿valve￿injectors,￿the￿procedure￿in￿the current￿repair￿instructions￿must￿be￿followed￿￿If￿the￿solenoid￿valve￿injectors￿are￿damaged,￿fuel￿may￿be discharged. 6.1.2.￿Solenoid￿valve￿injector Measures￿at￿the￿solenoid￿valve￿injector The￿following￿graphic￿illustrates￿the￿differences￿between￿the￿EURO￿6b￿and￿EURO￿6c￿versions:...
  • Page 36 B58TU￿Engine 6.￿Fuel￿System EURO￿6￿measures,￿solenoid￿valve￿injector Index Explanation Solenoid￿valve￿injector￿HDEV5￿Bx8￿engine,￿EURO￿6b Solenoid￿valve￿injector￿HDEV5￿EVO￿Bx8￿engine,￿EURO￿6c Solenoid￿valve￿injector￿HDEV6￿Bx8TU￿engine,￿EURO￿6c Injector￿seat Injection￿pattern￿and￿volumetric￿distribution...
  • Page 37 B58TU￿Engine 6.￿Fuel￿System The￿Bx8TU￿engines￿use￿the￿HDEV6￿solenoid￿valve￿injector￿by￿Bosch.￿Due￿to￿the￿more￿stringent exhaust￿gas￿emission￿regulations￿required￿to￿meet￿the￿EURO￿6c￿exhaust￿emission￿standards, technical￿changes￿were￿again￿made￿to￿the￿solenoid￿valve￿injectors. Due￿to￿the￿fuel￿system￿pressure￿increase￿from￿200 bar￿to￿350 bar,￿the￿solenoid￿valve￿injectors￿HEDV6 were￿optimized￿using￿suitable￿materials￿and￿coatings.￿The￿injection￿pattern￿and￿volumetric￿distribution have￿not￿changed￿compared￿with￿the￿HDEV5￿EVO. The￿repair￿instructions￿that￿are￿currently￿valid￿must￿be￿carefully￿followed￿when￿removing￿and installing￿the￿injectors￿in￿Service.￿An￿excessive￿rotational￿angle￿at￿the￿injector￿shank,￿and￿excessive tensile￿and￿compressive￿forces￿during￿removal￿and￿installation￿can￿lead￿to￿damage￿and￿therefore￿leaks in￿the￿fuel￿system.
  • Page 38 B58TU￿Engine 7.￿Engine￿Electrical￿System 7.1.￿Digital￿Motor￿Electronics￿(DME) DME￿8￿control￿unit The￿8th￿generation￿engine￿electronics￿form￿a￿common￿control￿unit￿platform￿for￿gasoline￿and￿diesel engines￿that￿have￿been￿used￿since￿modular￿engines￿were￿introduced.￿Its￿appearance￿is￿characterized by￿a￿uniform￿housing￿and￿a￿uniform￿connector￿strip.￿The￿hardware￿inside￿has￿been￿adapted￿to the￿respective￿applications.￿The￿Bx8TU￿engines￿have￿the￿DME￿8￿engine￿electronics￿generation. Depending￿on￿the￿engine￿version,￿the￿Digital￿Motor￿Electronics￿(DME)￿will￿be￿given￿a￿specific designation. DME￿8.xTyz￿(x￿=￿number￿of￿cylinders,￿Ty￿=￿vehicle￿electrical￿system￿architecture,￿z￿=￿H￿(hybrid))￿can￿be decoded￿as￿follows: • DME￿8.4T1￿=￿B48 • DME￿8.4T0.H￿=￿B48￿PHEV • DME￿8.6T0￿=￿B58 • DME￿8.8T0￿=￿N63...

  • Page 39: Component￿Temperature￿Sensor

    B58TU￿Engine 7.￿Engine￿Electrical￿System 7.2.￿Component￿temperature￿sensor B58TU￿engine,￿component￿temperature￿sensor Index Explanation Component￿temperature￿sensor The￿B58TU￿engine￿uses￿a￿component￿temperature￿sensor￿in￿addition￿to￿the￿coolant￿temperature sensor￿to￿control￿the￿coolant￿more￿precisely￿with￿the￿heat￿management￿module.￿Except￿for￿the installation￿location,￿no￿changes￿have￿been￿made￿to￿the￿function￿of￿the￿component￿itself.￿It￿records the￿material￿temperature￿of￿the￿crankcase￿close￿to￿the￿cylinder￿head￿in￿the￿area￿of￿the￿6th￿cylinder￿and forwards￿this￿to￿the￿DME￿engine￿control￿unit.￿As￿a￿result,￿power,￿consumption￿and￿pollutant￿emissions can￿be￿influenced￿even￿more￿efficiently. A￿variable￿temperature￿resistance￿(negative￿temperature￿coefficient),￿which￿covers￿a￿temperature range￿from￿-￿40°￿C￿to￿150°￿C￿(-￿40°￿F￿to￿302°￿F),￿has￿been￿tried￿and￿tested.￿The￿temperature￿is transferred￿to￿the￿sensor￿using￿an￿elastic￿heat￿coupler￿attached￿to￿the￿outside￿of￿the￿sensor.

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