BMW cars have always been distinguished by the fact that their production provided for the widest range of power units installed in them. Engines could be gasoline or diesel, have a different displacement and power, all this made it possible to make a choice of a particular machine. At the same time, there were significantly more variations of cars with gasoline engines than with diesel units, however, many compression ignition engines require special attention due to their successful design and high reliability. A separate example is the M57 engine.
M57 engine and its distinguishing features
The power unit was designed by BMW and its production began in 1998. The motor has several of its modifications, changes and improvements were made as performance was studied, and not all implemented engineering improvements had the same effect on the reliability of the unit.
The engine has an in-line and six-cylinder design. The material of the cylinder block was cast iron, only on the most recent versions the block was made of aluminum alloy to achieve low weight. The cylinder head is made of aluminium. The main innovation of this engine was the common rail diesel fuel injection system, with which it was possible to achieve high engine performance. The gas distribution system included the operation of two camshafts driven by a chain. The volume of the engine was 2.5 and 3 liters, depending on the modification. All power units had a piping system, in some versions two blowing turbines were installed.
Given that any in-line six-cylinder engine is the least susceptible to the appearance of vibrations of various kinds, the new M57 turned out to be a powerful, economical and balanced engine, and this is what led to an increased service life. The mileage of this unit before the overhaul usually exceeded 500,000 km, and sometimes reached 1,000,000 km!
A short list of features of the M57 motor:
- crankshaft with 12 balancers (balance weights);
- camshaft drive from one single-row type chain;
- not direct control of gas distribution valves, but through levers;
- pistons have a special bottom geometry that affects the quality of the fuel mixture;
- accumulator-type fuel injection system, under constant rail pressure;
- electronically adjustable air compressor blades;
- high level of balance.
An important characteristic of all M57 engines is their ability to provide high torque at low crankshaft speeds (exact data depends on the modification) and average maximum speeds, which has led to an increase in service life.
Technical characteristics of some modifications of the M57 motors
The first samples of the units had less power with a greater mass. As the modernization progressed, the power characteristics grew, and the weight of the engines was reduced due to the use of aluminum as the material for the cylinder block.
It is important to note that some samples of the M57 of certain modifications could have both a cast iron and an aluminum block.
BMW M57D25 engine:
- power, hp / rpm - 163/4000;
- working volume, cm3 - 2497;
- cylinder diameter and piston stroke, mm - 80/80.2;
- maximum torque, Nm / rpm - 350/2000–3000;
- weight, kg - 180.
This motor was installed on cars with an E39 (525d) body. The installation period took the interval from 2000 to 2003. Other modifications were installed on cars with a body of E60 and E61, (2004-2007).
BMW M57D30 engine:
- power, hp / rpm - 184/4000;
- working volume, cm3 - 2926;
- cylinder diameter and piston stroke, mm - 84/88;
- maximum torque, Nm / rpm - 410/2000–3000;
- weight, kg - 162.
The motor was installed on a car with an E46 body (1998-2000), the M57D30O0 modification was installed on the E38 (730d), E53 (X5) bodies. The latest version of the motor was in E39 (530d).
BMW M57TUD30 engine:
- power, hp / rpm - 218/4000;
- working volume, cm3 - 2993;
- maximum torque, Nm / rpm - 500/2000–2700;
- weight, kg - 150.
The first modification of this motor was installed on the bodies of the E60, E61, E65, E53. A weaker second modification was also installed on the E46, E6, E65, E83 (X3) bodies. The most powerful double-acting turbocharged version was installed only on the E60 and E61.
BMW M57TU2D30 engine:
- power, hp / rpm - 197;
- working volume, cm3 - 2993;
- cylinder diameter and piston stroke, mm - 84/90;
- torque, Nm / rpm - 400/1300;
- weight, kg - 170.
The motors had three modifications, differing in power and torque. Units with 193 hp were installed on the following bodies: E90, E91, E92, E93, E60. Engines with a power of 231 hp stood on such cars: E90, E91, E92, E93, E60, E61, E65, E66. The most powerful modifications were also used in cars with E60, E61, E70 and some X6 bodies.
All motors had a common design scheme and, regardless of specific modifications, had a significant resource. The differences were dynamic characteristics and efficiency factors. However, engines with increased power, equipped with two turbochargers, were the most complex and had slightly less overrun due to increased loads on the main parts.
Typical malfunctions of the power unit M57
The main problem of this engine, like other diesel engines, is low-quality diesel fuel with a high sulfur content. This, as a rule, leads to the failure of the injection nozzles. This is especially true in engines that were manufactured after 2003, since they installed new-style injectors, whimsical to fuel quality and non-repairable. At the same time, there are known problems with fuel filters, which become clogged with paraffin-like inclusions that appear in poor fuel at low temperatures.
Units and parts that can fail for structural reasons:
- gas recirculation valve;
- engine hydraulic mounts;
- collector flaps (weakening);
- oil filter housing cover;
- problems of cleaning crankcase gases going to the turbine.
The vast majority of problems are caused by the use of low-quality fuel. The precision common rail injection system requires the use of high-class fuel, the purchase of unknown diesel fuel leads to premature failure of injectors and high-pressure fuel pumps, the repair or replacement of which is expensive.
The M57 engine is a classic example of an attempt to create a powerful and at the same time economical unit that has the best physical performance in engines of this class.
The engines of the BMW M57 series are a large-sized, volumetric engine that replaced the M51 series of engines. These are reinforced diesel engines of increased power. High technical characteristics and a high environmental standard made it possible to make the power unit reliable and powerful.
Characteristics and features of motors
Diesel engines BMW M57 received an old cast-iron cylinder block with an increased cylinder size. A crankshaft with a piston stroke of 88 mm was placed inside the block, the length of the connecting rods was 135 mm, and the height of the pistons was 47 mm.
BMW with M57 engine
New cylinder head with two camshafts. It uses a common rail injection system and is turbocharged with an intercooler. Blowing in the M57 turbine Garrett GT2556V with variable geometry.
To all of the above, we add a two-row timing chain. With timely maintenance, the replacement of this element may not be required at all.
Consider the main technical characteristics of the M57 motors:
Name | Characteristics |
Manufacturer | |
Motor brand | |
engine's type | |
3.0 liters (2926 or 2993 cc) |
|
Power | |
Torque | 390/1750-3200 |
Cylinder diameter | |
Number of cylinders | |
Number of valves | |
Compression ratio | |
Economy | |
Fuel consumption | 7.1 liters for every 100 km in mixed mode |
Garrett GT2556V |
|
Engine oil | |
500+ thousand km |
|
Applicability | BMW 325d/330d/335d E46/E90 |
BMW M57 engine
- M57D30O0 (1998 - 2003) - M57D30 base engine with Garrett GT2556V turbocharger. Power 184 hp at 4000 rpm, torque 390 Nm at 1750-3200 rpm. The motor was intended for the BMW 330d E46 and 530d E39. For the BMW X5 3.0d E53 and 730d E38, a 184 hp version was produced. at 4000 rpm and with a torque of 410 Nm at 2000-3000 rpm.
- M57D30O0 (2000 - 2004) - a slightly more powerful version for the BMW E39 530d. Its return reaches 193 hp. at 4000 rpm, torque 410 Nm at 1750-3000 rpm.
For the BMW 730d E38, a modification was produced with a power of 193 hp. at 4000 rpm, the torque of which is 430 Nm at 2000-3000 rpm. - M57D30O1 / M57TU (2003 - 2006) - replacement for the M57D30O0 motor. The main differences of the M57TU series lie in the displacement of 3 liters and in the Garrett GT2260V turbine. The power of this engine is 204 hp. at 4000 rpm, torque 410 Nm at 1500-3250 rpm. You can meet him on the BMW 330d E46 and X3 E83.
- M57D30O1 / M57TU (2002 - 2006) - a more powerful version of the above motor. Power 218 hp at 4000 rpm, torque 500 Nm at 2200 rpm. They put it on the BMW E60 530d, 730d E65, X5 E53 and X3 E83.
- M57D30T1 / M57TU TOP (2004 - 2007) - top version of the M57TU. The main differences between the motor in two BorgWarner BV39 + K26 turbines. As a result, the power reached 272 hp. at 4400 rpm, and a torque of 560 Nm at 2000-2250 rpm.
- M57D30U2 / M57TU2 (2006 - 2010) - version for the BMW 525d E60 and 325d E90, released to replace the M57D25. The main difference is in the aluminum cylinder block, modified fuel and in accordance with Euro-4 standards. The internal combustion engine has a power of 197 hp. at 4000 rpm and a torque of 400 Nm at 1300-3250 rpm.
- M57D30O2 / M57TU2 (2005 - 2008) - a model with a return of 231 hp. at 4000 rpm and with a torque of 500 Nm at 1750-3000 rpm. The motor is on the E90 330d and E60 530d. For the 730d E65, torque has been increased to 520 Nm at 2000-2750 rpm.
- M57D30O2 / M57TU2 (2007 - 2010) - variation for E60 530d with 235 hp at 4000 rpm and with a torque of 500 Nm at 1750-3000 rpm. For models E71 X6 and E70 X5, the torque is increased to 520 Nm at 2000-2750 rpm.
- M57D30T2 / M57TU2 TOP (2006 - 2012) - the most powerful engine of the M57 series. It features two BorgWarner KP39 + K26 turbines. Motor power 286 hp at 4400 rpm, and a torque of 580 Nm at 1750-2250 rpm.
Name | Characteristics |
Manufacturer | BMW Plant Dingolfing |
Motor brand | |
engine's type | |
2.5 liters (2497 cc) |
|
Power | |
Cylinder diameter | |
Number of cylinders | |
Number of valves | |
Compression ratio | |
Economy | |
Fuel consumption | 6.7 liters for every 100 km in mixed mode |
Engine oil | |
400+ thousand km |
|
Applicability | BMW 525d/525d E39/E60 |
Overhaul of the BMW M57 engine
In addition to the main power unit, there are quite a few modifications that were used in the production process of BMW series cars:
- M57D25O0 (2000 - 2003) - the basic version of the M57 D25 with a Garrett GT2052V turbine. Engine power 163 hp at 4000 rpm, torque 350 Nm at 2000-2500 rpm. The engine was on the E39 525d, and the 150 hp version. went for Opel Omega B and was called Y25DT there.
- M57D25O1 (2004 - 2007) - an updated motor of the M57TU series. Power increased to 177 hp. at 4000 rpm, the torque is 400 Nm at 2000-2750 rpm. It uses a Garrett GT2056V turbocharger. This internal combustion engine is found in BMW E60 525d cars.
Service
Maintenance of M57 engines is no different from standard power units of this class. Maintenance of engines is carried out at intervals of 15,000 km. Recommended maintenance should be carried out every 10,000 km.
Checking the injectors of the BMW M57 engine
Typical malfunctions
In principle, all motors are similar in design and characteristics. So, let's consider what common problems can be found on the M57:
Replacing the Timing Chain BMW M57
- Detachment of the swirl flap. A typical malfunction for a series of M diesel engines.
- Noise and knocks. The crankshaft damper is worn out and needs to be replaced.
- Lost power. Often the problem lies in the exhaust manifold.
Conclusion
The M57 engine is a fairly reliable and high-quality diesel engine. All of them have a high rating and respect of motorists, experts. Maintenance of the power unit can be carried out independently. As for repairs, it is recommended to contact a service station.
BMW's best diesel engine, technical introduction to the M57 fuel system.
Brief description of the operating principle.
In the M 57 engine, for the first time in BMW diesel engines, an injection system with a high-pressure accumulator (Common Rail) was used. With this new principle of injection by a high-pressure fuel pump, a high pressure is created in the Common Rail fuel line common to all injectors, which is optimal for the current engine operating mode.
In the Common Rail system, injection and compression are decoupled. The injection pressure is generated independently of the engine speed and the amount of fuel injected and is stored in the "Common Rail" (high pressure fuel accumulator) for injection.
The start of injection and the amount of injected fuel are calculated in the DDE and implemented by the injector of each cylinder via a controlled solenoid valve.
System device
The power supply system is divided into 2 subsystems:
- low pressure system
- high pressure system.
The low pressure system consists of the following parts:
- fuel tank,
- fuel pump,
- leakage protection valves,
- additional fuel priming pump,
- fuel filter with inflow pressure sensor,
- pressure limiting valve (LP system);
- and on the side of the fuel return flow from:
- fuel heater (bimetallic valve),
- fuel cooler.,
- distribution pipe with throttle.
The high pressure system consists of the following parts:
- high pressure pump,
- high pressure fuel accumulator (Rail),
- pressure reducing valve,
- rail pressure sensor,
- nozzle.
System pressure is approx.
in the ND system
- on the supply side 1.5< р < 5 бар
- on the outlet side< 0,6 бар
- in HP system 200 bar< р < 1350 бар
And now a little more detail on each system:
General scheme m57
- 1 FUEL high pressure pump (CP1)
- 2 pressure reducing valve
- 3 high pressure accumulator (Rail)
- 4 rail pressure sensor
- 5 injector
- 6 differential pressure valve
- 7 bimetal valve
- 8 fuel pressure sensor
- 9 fuel filter
- 10 additional fuel priming pump
- 11 fuel cooler
- 12 throttle
- 13 tank with ECR
- 14 pedal sensor
- 15 crankshaft incremental encoder
- 16 coolant temperature sensor
- 17 camshaft sensor
- 18 boost pressure sensor
- 19 HFM
- 20 turbocharger (VMT)
- 21 2xEPDW for AGR
- 22 VNT management
- 23 vacuum distributor
Node Description
The fuel tank in the E39 (M 57) and E38 (M 57, M 67) models was adopted from the corresponding version with the M 51TU engine.
Two leakage protection valves prevent fuel from escaping in the event of an accident (eg overturning).
- 1 fuel tank
- 2 Fuel pump
The electric fuel pump (EKR) is located inside the fuel tank, in its right half.
(sliding roller pump) - E39 / E38
- 1 - suction side
- 2 - movable plate
- 3 - roller
- 4 - base
- 5 - discharge side
An electric fuel pump delivers fuel from the tank pot to the engine and drives the jet pumps in the left and right halves of the tank. The jet pumps, in turn, supply fuel to a pot in the right half of the fuel tank.
The pump is controlled by the controller through the ECR relay.
Additional fuel - priming pump
- The task of the additional fuel priming pump is to provide the high pressure fuel pump with a sufficient amount of fuel:
- in any mode of engine operation,
- with the required pressure
- during the entire service life.
An additional fuel priming pump in the M57 E39 / E38 engine - "inline" - an electric fuel pump (EKR), because it is located on the fuel supply line.
It is located under the bottom of the vehicle and is designed as a screw pump (high performance).
Consequences in case of failure
- OOE indicator warning light
- power loss at speeds > 2000 rpm. (i.e. moving uphill with a rotational speed< 2000 об / мин. возможно, при >2000 rpm engine will stall).
fuel filter - installation location in E38 M57
The fuel filter cleans the fuel before it enters the high pressure pump and thus prevents premature wear of sensitive parts. Insufficient cleaning can cause damage to pump parts, pressure valves and nozzles.
It does not have an electric fuel heater and water separator. The filter is similar to that used in the M51T0 engine.
The electrical contact is connected to the supply pressure sensor.
Fuel filter
To prevent clogging of the filter with paraffin flakes at low temperatures, there is a bimetallic valve in the fuel return line. Through it, the heated return fuel is mixed with the cold fuel from the tank.
The inflow pressure sensor is located in the fuel filter housing behind the filter element. It is a special BMW part.
fuel filter with inflow pressure sensor - installation location in E38 M57
Its task is to measure the inflow pressure to the high pressure fuel pump (TNFP) in the fuel line.
In this way, the DDE has the possibility, at reduced intake pressure, to reduce the amount of injected fuel so much that a reduction in engine speed and rail pressure occurs. This reduces the required amount of fuel supplied to the high pressure pump. This achieves the possibility of increasing the inflow pressure in front of the injection pump to the required level.
At supply pressure< 1,5 бар возможно повреждение ТНВД вследствие недостаточного наполнения.
With a pressure difference between the intake and discharge fuel lines on the injection pump<0,5 бар, двигатель резко глохнет (защита насоса).
The pressure relief valve is located between the fuel filter and the high pressure fuel pump. It is located in the connecting wire connecting the inlet fuel line before the injection pump and the fuel return line after the injection pump.
The function of the pressure relief valve is identical to that of the safety valve. It limits the inflow pressure to the high pressure pump to 2.0 - 3.0 bar. Excess pressure is eliminated by redirecting excess fuel to the fuel return line.
It protects the high pressure pump and the auxiliary fuel pump from overload.
Consequences in the event of a malfunction
- increased pressure shortens the life of the additional fuel priming pump,
- increased flow noise in the area of high pressure fuel pump and additional fuel priming pump,
- possible extrusion of the oil seal of the high-pressure fuel pump.
High pressure pump
The high pressure fuel pump (TNVD) is in front
on the left side of the engine (comparable to the distribution injection pump).
A task
The high pressure pump is the interface between the low and high pressure systems. Its task is to supply a sufficient amount of fuel at the required pressure in all engine operating modes throughout the entire life of the vehicle. This also includes providing a supply of reserve fuel necessary for a quick start of the engine and a rapid increase in rail pressure.
Device
- - drive shaft
- - eccentric
- - plunger pair with plunger
- - compression chamber
- - inlet valve
- - element shut-off valve (BMW does not have) 7 - exhaust valve
- 3 - seal
- - high pressure fitting to the rail
- - pressure reducing valve
- - ball valve 12 - fuel return
- -fuel release
- - safety valve with throttle
- - low pressure channel to the plunger pair
high pressure fuel pump - longitudinal section (CP1)
high pressure fuel pump - cross section
Operating principle
Fuel is supplied through a filter to the injection pump inlet (13) and the safety valve behind it. Then it is injected through the throttle hole into the low pressure channel (15). This channel is connected to the lubrication and cooling systems of the high pressure pump. Therefore, the injection pump is not connected to any lubrication system.
The drive shaft (1) is driven by a chain drive at a speed slightly higher than half the engine speed (max. 3300 min. "1). Via the eccentric (2), in accordance with its shape, three plunger (3).
When the pressure in the low pressure channel exceeds the opening pressure of the inlet valve (5) (0.5 - 1.5 bar), the fuel pump pumps fuel into the compression chamber whose plunger moves down (suction stroke), when the plunger passes the dead point, the inlet valve closes. The fuel in the compression chamber (4) is closed. Now it is being compressed. The resulting pressure opens the release valve (7) as soon as the rail pressure is reached. The compressed fuel enters the high pressure system.
The pump plunger pumps fuel until it reaches top dead center (discharge stroke), after which the pressure drops so that the exhaust valve closes. The residual fuel is diluted. The plunger moves down.
When the pressure in the compression chamber drops below the pressure in the low pressure port, the inlet valve reopens. The process starts from the beginning.
The high pressure pump constantly creates system pressure for the high pressure accumulator (rail). Rail pressure is controlled by a pressure reducing valve.
Since the high-pressure pump is designed for a large delivery volume, an excess of compressed fuel occurs at idle or in the partial load range. Since the compressed fuel is rarefied when the excess is returned, the energy received during compression is converted into heat and heats the fuel.
This excess fuel is returned through the relief valve and fuel cooler to the fuel tank.
pressure reducing valve
The task of the pressure reducing valve is to regulate and maintain the pressure in the rail depending on the engine load.
With increased rail pressure, the pressure reducing valve opens, so that some of the fuel from the rail returns through the manifold wire to the fuel tank.
With reduced rail pressure, the pressure reducing valve closes and separates the low and high pressure systems.
Device
The pressure reducing valve in the M57 engine is located on the high pressure pump, and in the M67 engine on the distribution block (see Fig. High pressure accumulator - rail).
pressure reducing valve
The OOE controller acts on the armature by means of a coil, which in turn presses the ball into the valve seat and thus seals the high pressure system relative to the low pressure system. In the absence of influence from the anchor, the ball is held by a spring package. For lubrication and cooling, the anchor is completely washed with fuel from an adjacent node.
Operating principle
The pressure reducing valve has two control circuits:
electric circuit for regulating the variable pressure indicator in the rail,
mechanical circuit for damping high-frequency pressure fluctuations.
Since the time factor plays an important role in rail pressure control, the electrical circuit smooths out slow, and the mechanical circuit smoothes out fast oscillations and pressure changes in the rail.
Pressure reducing valve without actuating action
The pressure in the rail or at the outlet of the high pressure pump through the high pressure line acts on the pressure reducing valve. Since the de-energized solenoid has no effect, the fuel pressure exceeds the spring force so that the valve opens. The spring is designed in such a way that the pressure is set to a maximum of 100 bar.
Pilot operated pressure reducing valve
If a high pressure system needs to be pressurized, a magnet force acts in addition to the spring force. The pressure reducing valve is energized for such a long time, and it closes until the fuel pressure on one side, and the total force of the spring and magnet on the other, are balanced. The magnetic strength of an electromagnet is proportional to the control current. Control current changes are implemented by clocking (pulse width modulation). The clock frequency of 1kHz is high enough to avoid unnecessary armature movements and hence unwanted pressure fluctuations in the rail.
The high pressure fuel accumulator (Common Rail) is located next to the cylinder head cover, under the engine cover.
High pressure fuel accumulator
- - injectors
- - high pressure accumulator (rail)
- - pressure reducing valve
- - high pressure pump (CP1)
- - rubber element
- - rail pressure sensor
In the rail, it accumulates and provides high-pressure fuel for injection.
This common rail fuel accumulator for all cylinders maintains a virtually constant internal pressure even when discharging large quantities of fuel. In this way, an almost constant injection pressure is ensured when the injector is opened.
Pressure fluctuations caused by fuel pumping and injection are damped by the volume of the accumulator.
Device
The basis of the rail is a thick-walled pipe with sockets for connecting pipelines and sensors.
In the M57 engine, a rail pressure sensor is placed at the end of the rail.
The rail, depending on the type of installation in the engine, can be arranged in different ways. The smaller the volume of the rail, or, accordingly, its inner diameter with the same external dimensions, the higher loads become possible. The smaller rail volume also reduces the performance requirements of the high pressure pump when starting the engine and changing the rail pressure setpoint. On the other hand, the rail volume must be large enough to avoid a pressure drop at the time of injection. The inside diameter of the rail pipe is approximately 9mm.
The rail is continuously supplied with fuel by a high pressure pump. From this intermediate storage tank, fuel passes through the fuel line to the injectors. Rail pressure is controlled by a pressure reducing valve.
Operating principle
The internal volume of the rail is constantly filled with compressed fuel. The shock-absorbing effect of the fuel achieved due to the high pressure is used to maintain the accumulative effect.
When the fuel is released from the rail for injection, the pressure in the rail remains almost unchanged. In addition, pressure fluctuations are damped or smoothed out accordingly by the pulsating fuel supply by the high-pressure pump.
rail pressure sensor
The pressure sensor in the rail in the M57 engine is screwed into the end of the rail, and in the M67 engine, respectively, into the distributor block vertically from below.
1 - rail pressure sensor
common rail system - rail pressure sensor M57
The rail pressure sensor must measure the current rail pressure.
with sufficient accuracy
at suitably short intervals,
and transmit a signal in the form of a voltage corresponding to the pressure to the controller.
Device
- - electrical contacts 4 - joint with rail
- - measurement processing scheme 5 - fastening thread
- - diaphragm with sensing element
rail pressure sensor - section
The rail pressure sensor consists of the following parts:
- integrated sensing element,
- printed circuit board with measurement processing circuit,
- sensor housing with electrical plug contact.
Fuel through the junction with the rail enters the sensitive membrane. On this membrane is a sensitive element (semiconductor), which serves to convert the deformation caused by pressure into an electrical signal. From there, the generated signal enters the measurement processing circuit, which, through an electrical contact, transmits the finished measurement signal to the controller.
Operating principle
The rail pressure sensor works according to the following principle:
The electrical resistance of a membrane changes when its shape changes. This deformation caused by system pressure (approx. 1 mm at 500 bar) in turn causes a change in electrical resistance and, consequently, a change in voltage in the 5 volt powered resistance bridge.
This voltage is 0 to 70 mV (according to the applied pressure) and is amplified by the measurement processing circuit to a value of 0.5 to 4.5 Volts. Accurate pressure measurement is essential for the operation of the system. For this reason, the tolerances for the sensor when measuring pressure are very small. Measurement accuracy in the main mode of operation is approx. 30 bar, i.e. OK. + 2% of final value. When the rail pressure sensor fails, the controller controls the pressure reducing valve with an alarm function.
The injectors are located in the cylinder head, centrally above the combustion chambers.
Injector (nozzle).
- - outlet channels A - tangential channel (inlet)
- - injector 5 - glow plug pin
- - vortex channel (inlet)
The location of the injector relative to the combustion chamber - view M57
The injectors are attached to the cylinder head with clips, similar to how the injector bodies are attached to direct injection diesel engines. Thus, Common Rail injectors can be installed in existing diesel engines without significant changes in the design of the cylinder head.
Injector
This means that the injectors replace the injector pairs (injector body - atomizer) of conventional fuel injection systems.
The task of the injector is to accurately set the start of injection and the amount of fuel injected.
The nozzle needle has a simple guide to make it essential. avoid the risk of rubbing and tearing of the needle. At the same time, a new seating geometry with the designation ZHI (cylindrical base, calibrated part, inverse difference in seating angles) is applied, see the illustration below. In this way, due to the equalization of the pressure on the calibrated part, a symmetrical injection pattern is achieved. In addition, with such a seating geometry, there is no tendency to increase the amount of injected fuel due to wear.
injector with improved seating geometry (ZHI = cylindrical base, calibrated part, inverse difference seating angles)
Device
The injector can be divided into different functional blocks:
- pinless nozzle sprayer with needle,
- hydraulic drive with booster,
- magnetic valve,
- docking points and fuel lines.
Fuel through the high pressure inlet pipe (4) and channel (10) is directed to the atomizer, and through the inlet throttle (7) to the control chamber (8).
injector closed (rest state)
- - intake throttle
- - valve control chamber
- - control plunger
- - inlet to the atomizer
- - nozzle atomizer needle
injector open (suction)
- - fuel return
- - electrical contact
- - controlled unit (2/2 - magnetic valve)
- - inlet pipe, rail pressure
- - valve ball
- - exhaust throttle
injector - cut
The control chamber is connected to the fuel return (1) through the exhaust throttle (6), opened by a solenoid valve. In the closed state of the exhaust throttle, the hydraulic pressure on the control plunger (9) exceeds the pressure on the pressure stage of the atomizer needle (11). As a result, the atomizer needle is pressed into its seat and hermetically seals the high pressure channel relative to the cylinder. The fuel cannot enter the combustion chamber, although all this time it is already under the necessary pressure in the inlet compartment.
When a start signal is given to the controlled injector assembly (2/2 - solenoid valve), the exhaust throttle opens. As a result, the pressure in the control chamber, and with it the hydraulic pressure on the control plunger, fall.
As soon as the hydraulic pressure on the pressure stage of the atomizer needle exceeds the pressure on the control plunger, the needle opens the atomizer hole and the fuel enters the combustion chamber.
Such indirect control of the atomizer needle through a hydraulic amplification system is used for the reason that the force necessary to quickly open the atomizer hole with the needle cannot be developed directly by the solenoid valve. Necessary for this process, additional to the injected fuel, the so-called. the amplifying portion of fuel, through the outlet throttle of the control chamber, enters the return fuel line.
In addition to the amplifying portion of fuel, fuel leaks at the atomizer needle and in the plunger guide (drain fuel).
Boost and drain fuel can be up to 50 mm3 per stroke. This fuel is returned to the fuel tank through the fuel return line, which is also connected to a bypass and pressure reducing valve and a high pressure pump.
Operating principle
The operation of the injector with the engine running and the high pressure priming pump can be divided into four operating states:
injector closed (with fuel pressure applied)
injector opens (injection starts),
the injector is fully open,
the injector closes (end of injection).
These operating states are determined by the distribution of forces acting on the structural elements of the injector. With the engine off and no pressure in the rail, the injector is closed by a needle spring.
The injector is closed (idle state).
2/2 - the magnetic valve is de-energized in the idle state of the injector and therefore is closed (see Fig. injector - section, a).
Since the exhaust throttle is closed, the armature ball is pressed against its seat on this throttle by the force of the valve spring. Rail pressure is applied to the control chamber of the valve. The same pressure is created in the spray chamber. By the force of the pressure of the rail on the plunger and the spring on the needle, opposing the pressure of the rail on the pressure stage of the needle, it is held in the closed position.
Injector opens (start of injection).
The injector is at rest. A retracting current (I = 20 amperes) is applied to the magnetic 2/2 - valve, which causes it to open quickly. The valve retract force now exceeds the valve spring force and the armature opens the exhaust throttle. After a maximum of 450 ms, the increased pull-in current (I = 20 amps) is reduced to a lower holding current (I = 12 amps). This is made possible by reducing the air gap in the magnetic circuit.
With the exhaust throttle open, fuel from the control chamber can flow into an adjacent chamber, and then through the fuel return line to the tank. At the same time, the intake throttle prevents a complete balancing of the pressures, and the pressure in the control chamber drops. As a result, the pressure in the atomizer chamber, hitherto equal to the pressure in the rail, exceeds the pressure in the control chamber. A decrease in pressure in the control chamber reduces the force on the plunger and leads to the opening of the atomizer needle. The injection starts.
The opening speed of the atomizer needle is determined by the difference between the flow rate of the inlet and outlet throttles. After a stroke of about 200 dm, the plunger reaches its upper stop and there it lingers on the fuel buffer layer. This layer is due to the flow of fuel between the intake and exhaust throttles. At this point, the injector is fully open and fuel is injected into the combustion chamber at a pressure approximately equal to the pressure in the rail.
The injector closes (end of injection).
When the current supply to the 2/2 - solenoid valve stops, the armature moves down with the force of the valve spring and closes the exhaust throttle with a ball. To prevent excessive wear of the valve seat by the ball, the armature is made in two parts. At the same time, the valve spring pusher continues to squeeze the armature plate down, but it no longer presses on the anchor with the ball, but plunges into the reverse action spring. By closing the exhaust throttle through the intake throttle, pressure equal to the pressure in the rail begins to build up in the control chamber again. An increase in pressure increases the effect on the plunger. The total pressure force in the control chamber and the spray needle springs exceed the pressure force in the spray chamber and the needle closes the spray hole. The closing speed of the needle is determined by the intake throttle flow. The injection process ends when the atomizer needle reaches its bottom stop.
The bimetallic valve is now installed externally, i.e. it is no longer located directly on the filter. Hot fuel in the heating mode returns to the distribution pipe and from there enters the fuel filter.
The principle of operation of fuel heating
Heating of fuel is regulated by means of a thermoregulator (bimetallic valve).
The principle of operation is similar to M47. Differences with M47 (switch points)
When the return fuel temperature is > 73°C (± 3°C), 100% of it is returned to the tank through the fuel cooler.
Fuel heating / cooling (air heat exchanger)
At return fuel temperature< 63°С (± 3°С), от 60% до 80 % топлива поступают напрямик к фильтру, остальное через охладитель в бак.
The principle of operation of fuel cooling
When the bimetal valve opens the fuel return line, fuel flows through the cooler.
This cooler is supplied with cool outside air through its own air duct and thus extracts heat from the fuel.
distribution pipe - E38 M57
Depending on the engine model, 2 different types of distribution pipes are used:
The distribution pipe is located in the area of the bottom of the vehicle on the left side, behind the additional fuel priming pump.
Distribution valve side with choke
- 5 - multiple distribution pipe with throttle (M57),
- H - shaped branch pipe with a throttle (M67).
The purpose of the 5-fold distributor pipe is to provide fuel from the fuel return line at reduced pressure in front of the electric fuel "inline" pump (EKP).
To do this, the fuel return line and the inlet side are connected directly. Thus, part of the returned fuel is mixed with the fuel supplied to the injection pump.
- When creating the article, technical materials were usedTIS, DIS BMW.
Leave your comments! Good luck driving!
The history of the creation of the M57 engine line dates back to 1998. She replaced a series of diesel engine installations marked M51. M57 engines as a whole have high reliability and economic indicators, combined with good technical characteristics. Thanks to this, engines from this series have received a large number of international awards. The development of M57 engine installations was carried out on the basis of the previous generation, whose name is M51. The e39 model became the most common version on which the M57 power plants were installed.
Fuel system and cylinder block
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The fuel injection system in the M57 series engines is called Common Rail. These units also use a turbocharger and an intercooler. Each modification from this line has a turbocharger. The most powerful of them are additionally equipped with two turbine superchargers. Turbines for these engines are supplied by Garret. They are marked as follows: GT2556V. These turbine units have variable geometry.
The camshafts rotate due to the timing chain, the resource of which is very long. With careful operation of the car and careful attitude to the engine installation, the replacement of the chain can not be done at all, since it is made very high quality. The conical recess made on the surface of the pistons provides improved mixing of the working mixture. The connecting rod journals of the crankshaft are located at an angle of 120 degrees. Thanks to the ideally matched movement of the masses in the engine, vibration is practically absent during the operation of the unit.
The cylinder block is made of cast iron. Compared with the previous generation, the cylinder diameter was increased, its value was 84 mm. The crankshaft piston stroke is 88 mm, the length of the connecting rods and the height of the pistons are 135 and 47 mm, respectively. The working volume of engines in the M57 line is 2.5 and 3 liters. Modifications M57D30 and M57D25 are the earliest versions. The M57D30TU version was produced in the largest number among other M57 engines. The engine number is located near the starter.
Unlike the cylinder block, the head of this block is made of aluminum. The crankshaft has a design that has twelve counterweights. The camshafts are driven by a single row roller type chain. The gas distribution mechanism is equipped with 24 valves, therefore, there are 4 valves for each cylinder. Valves and springs are borrowed from the M47 diesel engine. In these engines, the valves are pressed not directly, but with the help of a lever. Valve dimensions: inlet and outlet 26 mm, valve stem diameter 6 mm. The last engine in this series was marked. M57TUD30
The second generation of M57 engines
In 2002, for the first time, a new version of the engine marked M57TUD30 was installed in cars, the cylinder displacement is exactly 3 liters. This was made possible by increasing the piston stroke on the crankshaft to 90 mm. They also installed a new model of the Garrett GT2260V turbine and a DDE5 engine control unit.
The most powerful modification was named M57TUD30TOP. Its difference is that it has 2 turbocharged compressor units of various sizes: BorgWarner KP39 and K26. With their help, a high boost pressure is achieved, which is 1.85 bar. In this internal combustion engine, the compression ratio reaches 16.5. This engine was later replaced by a modified version with the M57D30TOPTU.
All engines of the M57 series have electronic adjustment of the impeller geometry. Also, in the Common Rail direct fuel injection system, a pressure accumulator is installed. Thanks to the intercooler, it is possible to increase the amount of air supplied. The oil level in the engine is controlled by electronic sensors. To accurately supply the required amount of fuel to the combustion chambers of the engine, a piezo injector is used, located in the injection system. It also helps to provide improved economic and environmental performance. To fully comply with all environmental standards for diesel engines, the designers installed intake manifolds with swirl flaps on all units of the M57 line. When the engine is running at a low crankshaft speed, each damper closes one intake port, resulting in improved mixture formation and fuel combustion.
Also in these motors, an exhaust gas recirculation valve - USR is installed. Its function is to return part of the exhaust gases back to the working chambers of the engine cylinders, which allows for better combustion of the fuel-air mixture. Depending on the modification, the engine is equipped with two types of control units: Bosch DDE4 or DDE6.
In 2005, new engine modifications from the M57 line appeared, which received the M57D30TU marking. They have a lightweight aluminum cylinder block, an improved Common Rail system, new piezo injectors, improved camshafts, and an exhaust manifold made of cast iron. The diameter of the intake valves in new engines is 27.4 mm. Despite the installation of an upgraded Garrett GT2260VK turbocharger and DDE6 Electronic Control Unit, the engine complies with Euro-4 environmental standards.
The TOP version was replaced by a motor unit with the index M57D30TU2. In it, the designers used two turbines from BorgWarner: KP39 and K26. The total boost pressure was 1.98 bar. Also for the first time used electronic control unit Bosch seventh generation DDE7. This engine became the final unit of the M57 line and was produced until 2012. However, since 2008, it has been gradually replaced by a new generation of diesel engines with the N57 marking.
The main disadvantages and advantages of BMW engines from the M57 line
These power plants are very demanding on the quality of the fuel fluid. If you use low-quality diesel fuel, which is of dubious origin, it can lead to failure of the fuel pump, injectors and other elements of the fuel system. These parts are very expensive, so if they break down, the owner will have to fork out well to repair the engine. Under normal operating conditions, the average life of the injectors is 100,000 km. The high-pressure fuel pump is made quite well, compared with the unit installed on the M51 engines. Turbine plants have a very high resource, which often exceeds 450,000 km. However, if low-quality lubricants are used, then the life of the main engine elements can be significantly reduced. Oil change must be carried out in conjunction with the plastic cover of the filter element housing, since it is most often deformed during filter replacement.
Also, the engines of this series are very sensitive to overheating, especially the M57D30UL version. This can lead to a lot of trouble, including costly repairs. The weak point is the exhaust gas recirculation valve. Air mixture flow sensors and electro-vacuum hydraulic engine mounts break a little less. These elements must be replaced at approximately 200,000 km. You can often see oil marks on the pipes leading from the turbo element to the intercooler, as well as from the vent valve to the turbine. Despite the fact that many sin on the turbine and replace it, however, the reason lies elsewhere. Oil separator does not provide cut-off of crankcase gases. As a result, oil vapors settle on the surface of the nozzles. To ensure the frequency of the supplied air, it is necessary to replace the roller that cleans the crankcase gases, together with the oil in the engine. Also, we must not forget to flush the cyclone, which is also designed to clean oil.
As well as in the engines of the M47 series, unreliable swirl flaps are installed here. In the worst case, they can come off and get into the motor cavity. The consequences of this can be very serious. In order to protect themselves from such a situation, the owners remove the dampers by installing special plugs and flashing the electronic control unit, after which the engine can function without these elements. Also, with a run of more than two hundred thousand, problems with the crankshaft damper may appear. Signs of damper failure are the appearance of extraneous noise and knocks.
Problems with the exhaust manifold appear among car owners with the M57D30OLTU engine. If it malfunctions in the engine compartment, you can hear the smell of exhaust gases. You can also feel the deterioration of the car's traction. Many replace the manifold with cast iron units installed on other M57 engines.
Summing up, we can say that the BMW M57 in-line six-cylinder engines are reliable units if you treat them with care and use high-quality lubricants and consumables. Contract engines are quite easy to find, since a huge number of cars have been produced with these power plants under the hood. Estimated price is about 60 thousand rubles. For a long engine life, the best option is: 5W40.
Over the entire period of production, engines from the M57 series were installed on the following BMW cars: 3 (E46 (sedan, touring, coupe, convertible, compact), E90, E91, E92, E93), 5 (E39, E60, E61), 6 (E63 , E64) and 7 series (E38, E65, E66), as well as X3 (E83), X5 (E53, E70) and X6 (E71) crossovers.
Specifications
| Modification | Volume | Power, torque @ revolutions | Maximum turns | Year |
|---|---|---|---|---|
| M57D25 | 2497 | 163 HP(120 kW)@4000, 350 Nm@2000-2500 | 4750 | 2000 |
| M57TUD25 | 2497 | 177 HP(130 kW)@4000, 400 Nm@2000-2750 | 4750 | 2004 |
| M57D30 | 2926 | 184 HP(135 kW)@4000, 390 Nm@1750-3200 | 4750 | 1998 |
| 2926 | 184 HP(135 kW)@4000, 410 Nm@2000-3000 | 4750 | 1998 | |
| 2926 | 193 HP(142 kW)@4000, 410 Nm@1750-3000 | 4750 | 2000 | |
| M57TUD30 | 2993 | 204 HP(150 kW)@4000, 410 Nm@1500-3250 | 4750 | 2003 |
| 2993 | 218 HP(160 kW)@4000, 500 Nm@2000-2750 | 4750 | 2002 | |
| 2993 | 245 HP(180 kW)@4000, 500 Nm@2000-2250 | 4750 | 2008 | |
| 2993 | 272 HP(200 kW)@4000, 560 Nm@2000-2250 | 5000 | 2004 | |
| M57TU2D30 | 2993 | 231 HP(170 kW)@4000, 500 Nm@2000-2750 | 4750 | 2005 |
| 2993 | 286 HP(210 kW)@4000, 580 Nm@2000-2250 | 4750 | 2004 |
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Features of the BMW M57 engine
The BMW M57 engine has a cast-iron body, an aluminum cylinder head, a centrally vertical Common Rail injector, a 4-valve mechanism (as on), exhaust ports in the cylinder head (as on the M47) and glow plugs that are located on the intake side.
Pistons and nozzles in the M57 engine
This technology provides significantly lower fuel consumption, high performance and smooth operation in extreme conditions.
The piston forms the movable bottom wall of the combustion chamber. Its specially designed shape contributes to optimal combustion. Piston rings bridge the gap to the cylinder wall to allow for high compression and gas release into the crankcase.
The rotational movement of the crankshaft is transmitted to the camshaft via a chain drive. Thus, it determines the interaction between the movement of the piston stroke and the movement of the valves.
The oil pan is the lower integral element of the M57 motor and serves as a container for oil. Its position depends on the design of the front axle. The M57 oil sump features an aluminum housing with a built-in thermal oil level sensor and a metal oil sump gasket (same as on the M47, common with E38 and E39).
The M57 belt drive on the BMW E38 and E39 consists of the following components: M57 belt drive on the BMW E38 and E39 
Given the high torque of the M57D30T2 engine, it was paired with an automatic 6-speed gearbox - which was usually used with 8-cylinder gasoline engines.
BMW M57D25 engine
This engine links the engines of the M51 and M57 families. 2.5 liter engine M57D25O0 was equipped with modern innovations and developed a power of 163 hp. It was installed only on and was produced from March 2000 to September 2003.
This engine was also available in a weaker version - 150 hp. and with a torque of 300 Nm. It was made specifically for Opel, which fitted it to an Omega B 2.5 DTI built between 2001 and 2003.
A more powerful, 117 hp version of the M57TUD25 ( M57D25O1) was slightly updated and was produced from April 2004 to March 2007. The cylinder diameter was increased by 4 mm, and the piston stroke was shortened by 7.7 mm, while the volume remained unchanged, and the power increased to 177 hp. The motor was installed on and.
Characteristics of the BMW M57D25 engine
| M57D25 | M57TUD25 | Y25DT | |
| Volume, cm³ | 2497 | 2497 | 2497 |
| The order of operation of the cylinders | 1-5-3-6-2-4 | 1-5-3-6-2-4 | 1-5-3-6-2-4 |
| Cylinder diameter / piston stroke, mm | 80/82,8 | 84/75,1 | 80/82,8 |
| Power, hp (kW)/rpm | 163 (120)/4000 | 177 (130)/4000 | 150 (110)/4000 |
| Torque, Nm/rpm | 350/2000-3000 | 400/2000-2750 | 300/1750 |
| Compression ratio, :1 | 17,5 | 17,0 | 17,5 |
| The engine control unit | DDE4.0 | DDE5.0 | DDE4.0 |
| Engine weight, ∼ kg | 180 | 130 | — |
BMW M57D30 engine
This 3.0-liter engine develops a maximum power of 184 hp. and a torque of 410 Nm. It was installed from 1998 to 2000 only on.
After upgrading the engine M57D30O0 acquired minor changes, namely the adjustment of the maximum torque value, from 390 to 410 Nm. In this configuration, the engine was installed on and on.
In addition, since 2000, another variant of this engine was introduced, which produced a maximum power of 193 hp, while the maximum torque remained unchanged. It installed on .
Characteristics of the BMW M57D30 engine
BMW M57TUD30 engine
This is an evolution of the previous engine, in which the cylinder diameter was increased to 88 mm and the piston stroke to 90 mm, in connection with which the volume increased to 2993 cc. This engine was produced in several versions. The first - M57D30O1, introduced in 2002, had a maximum power of 218 hp. It was installed on, and X5 3.0d E53.
The second option, introduced in 2003, is less powerful, 204 hp, it was installed on the E46 330d / Cd, 530d E60, 730d E65 and.
The third option is M57D30T1, the most powerful, is equipped with a double supercharger with two turbochargers arranged in a row. Thanks to this, the engine produces a maximum power of 272 hp. It was installed only on and on and brought the BMW team in the Paris-Dakar race 4th place in the overall ranking.
BMW M57TUD30 engine parameters
BMW M57TU2D30 engine
The latest evolution of the 3-liter M57 turbodiesel was produced in three versions with a capacity of 197, 231 and 235 hp. and respectively a torque of 400, 500 and 520 Nm.
The M57TU2 engine installed on the E65, in addition to increasing power output and torque, has the following improved technical features: reduced weight due to an aluminum crankcase, 3rd generation Common Rail system, piezo injectors, Euro 4 emissions compliance, diesel diesel particulate filter as standard and an optimized electric boost pressure actuator for the turbocharger with variable turbine geometry.
BMW M57 engine management system
