Technicaltraining.

Productinformation.
S63TUEngine

BMWService

Generalinformation
Symbolsused
Thefollowingsymbolisusedinthisdocumenttofacilitatebettercomprehensionortodrawattention
toveryimportantinformation:

Containsimportantsafetyinformationandinformationthatneedstobeobservedstrictlyinorderto
guaranteethesmoothoperationofthesystem.
Informationstatusandnational-marketversions
BMWGroupvehiclesmeettherequirementsofthehighestsafetyandqualitystandards.Changesin
requirementsforenvironmentalprotection,customerbenefitsanddesignrendernecessarycontinuousdevelopmentofsystemsandcomponents.Consequently,theremaybediscrepanciesbetween
thecontentsofthisdocumentandthevehiclesavailableinthetrainingcourse.
ThisdocumentbasicallyrelatestotheEuropeanversionofleft-handdrivevehicles.Someoperating
elementsorcomponentsarearrangeddifferentlyinright-handdrivevehiclesthanshowninthegraphicsinthisdocument.Furtherdifferencesmayariseastheresultoftheequipmentspecificationinspecificmarketsorcountries.
Additionalsourcesofinformation
Furtherinformationontheindividualtopicscanbefoundinthefollowing:

Owner'sHandbook

IntegratedServiceTechnicalApplication.

Contact:conceptinfo@bmw.de
2011BMWAG,Munich,Germany
ReprintsofthispublicationoritspartsrequirethewrittenapprovalofBMWAG,Munich
TheinformationcontainedinthisdocumentformsanintegralpartofthetechnicaltrainingoftheBMW
Groupandisintendedforthetrainerandparticipantsintheseminar.RefertothelatestrelevantinformationsystemsoftheBMWGroupforanychanges/additionstothetechnicaldata.
Informationstatus:September2011
VH-23/InternationalTechnicalTraining

S63TUEngine
Contents
1.

Introduction............................................................................................................................................................................................................................................. 1
1.1.
Models..................................................................................................................................................................................................................................... 1
1.2.
Technicaldata............................................................................................................................................................................................................. 1
1.2.1.
Fullloaddiagram ................................................................................................................................................................ 3
1.3.
Newfeatures/Changes/SpecialFeatures.........................................................................................................................5
1.4.
Engineidentification......................................................................................................................................................................................... 6
1.4.1.
Enginedesignation............................................................................................................................................................ 6
1.4.2.
Engineidentification........................................................................................................................................................ 6

2.

EngineComponents................................................................................................................................................................................................................8
2.1.
Enginehousing......................................................................................................................................................................................................... 8
2.1.1.
Crankcase......................................................................................................................................................................................... 9
2.1.2.
Cylinderheadgasket..................................................................................................................................................... 9
2.1.3.
Cylinderhead..............................................................................................................................................................................9
2.1.4.
Cylinderheadcover..................................................................................................................................................... 11
2.1.5.
Oilpan................................................................................................................................................................................................19
2.2.
Crankshaftdrive................................................................................................................................................................................................... 21
2.2.1.
Crankshaftwithbearings..................................................................................................................................... 21
2.2.2.
Connectingrodwithbearing......................................................................................................................... 22
2.2.3.
Pistonwithpistonrings......................................................................................................................................... 23
2.3.
Camshaftdrive....................................................................................................................................................................................................... 24
2.4.
Valvetrain......................................................................................................................................................................................................................... 25
2.4.1.
Design................................................................................................................................................................................................ 25
2.4.2.
Valvetronic................................................................................................................................................................................... 29
2.5.
Beltdrive......................................................................................................................................................................................................................... 32

3.

Oil Supply...............................................................................................................................................................................................................................................34
3.1.
Overview.......................................................................................................................................................................................................................... 34
3.1.1.
S63TUhydrauliccircuitdiagram............................................................................................................. 35
3.2.
Oilpumpandpressurecontrol.................................................................................................................................................... 36
3.2.1.
Oilpump......................................................................................................................................................................................... 37
3.3.
Oilfilteringandcooling............................................................................................................................................................................ 38
3.3.1.
Oilcooling.................................................................................................................................................................................... 38
3.3.2.
Oilfiltering................................................................................................................................................................................... 38
3.4.
Oilmonitoring.......................................................................................................................................................................................................... 39
3.4.1.
Oillevel............................................................................................................................................................................................. 39
3.5.
Oilspraynozzles.................................................................................................................................................................................................39
3.5.1.
Pistoncrowncooling..................................................................................................................................................39
3.5.2.
Chaindrive.................................................................................................................................................................................. 40
3.5.3.
Camshaft........................................................................................................................................................................................42
3.5.4.
Valvetronicservomotor........................................................................................................................................... 43

S63TUEngine
Contents
4.

CoolingSystem........................................................................................................................................................................................................................... 44
4.1.
Systemoverview................................................................................................................................................................................................. 44
4.1.1.
Enginecoolingcircuit................................................................................................................................................45
4.1.2.
ChargeaircoolerandDMEcoolingcircuit ............................................................................ 50
4.2.
Heatmanagement........................................................................................................................................................................................... 53
4.2.1.
Coolantpump........................................................................................................................................................................ 53
4.2.2.
Mapthermostat.................................................................................................................................................................. 53

5.

AirIntake/ExhaustEmissionSystem.................................................................................................................................................. 54
5.1.
Overview.......................................................................................................................................................................................................................... 54
5.2.
Airintakesystem................................................................................................................................................................................................56
5.2.1.
Intakesilencer....................................................................................................................................................................... 57
5.2.2.
Hotfilmairmassmeter..........................................................................................................................................57
5.2.3.
Intakemanifold..................................................................................................................................................................... 57
5.3.
Exhaustturbocharger..................................................................................................................................................................................58
5.3.1.
Function.......................................................................................................................................................................................... 60
5.4.
Exhaustemissionsystem..................................................................................................................................................................... 60
5.4.1.
Exhaustmanifold.............................................................................................................................................................. 60
5.4.2.
Catalyticconverter......................................................................................................................................................... 62

6.

VacuumSystem.......................................................................................................................................................................................................................... 64

7.

FuelPreparation......................................................................................................................................................................................................................... 65
7.1.
Overview.......................................................................................................................................................................................................................... 65
7.2.
Fuelpumpcontrol............................................................................................................................................................................................ 66
7.3.
High-pressurepump.................................................................................................................................................................................... 66
7.4.
Injectors.............................................................................................................................................................................................................................67

8.

Fuel Supply......................................................................................................................................................................................................................................... 68

9.

EngineManagementSystem............................................................................................................................................................................. 69
9.1.
Overview.......................................................................................................................................................................................................................... 69
9.2.
Enginecontrolunit.......................................................................................................................................................................................... 74
9.2.1.
Overallfunction................................................................................................................................................................... 76

S63TUEngine
1.Introduction
TheS63top(S63TU)engineisinstalledinthenewBMWM5andM6.Itisafurtherdevelopmentof
theS63enginefromtheBMWX5MandBMWX6M.TheS63top(S63TU)engineintheBMWM5/
M6isthesuccessortotheextremelysuccessfulS85engine.Withthis"downsizing"thisnowbecomesapartoftheBMWdrivestrategyofEfficientDynamicsforMvehicles.Thefurtherdevelopment
oftheS63top(S63TU)enginetothepreviousS63engineisthelatestfuel-mixturegenerationtechnologyTurbo-ValvetronicDirectInjection(TVDI).TherearestrongsimilaritiesheretotheN20and
N55engines.TheaiminthedevelopmentoftheS63top(S63TU)enginewasnottoachieveapower
greaterthanthatoftheS63engine,buttoincreasetheresponseandrevcharacteristics,whileatthe
sametimereducingthefuelconsumption.
InthisdocumentationthedifferencestotheS63enginearedescribed.

1.1.Models
Modeldesignation

Enginedesignation

Seriesintroduction

BMWM5/M6

S63B44T0

F12M6ConvertibleJune
2012
F10M5SedanandF13M6
CoupeAugust2012

1.2.Technicaldata
Unit
Series
Modeldesignation
Design
Displacement

[cm]

Firingorder

S85B50O0

S63B44O0

S63B44T0

E60

E70/E71

F10/F12/F13

BMWM5

BMW
X5M/X6M

BMWM5/M6

V10

V8

V8

4999

4395

4395

1-6-5-10-27-3-8-4-9

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

Bore/Stroke

[mm]

92/75.2

89/88.3

89/88.3

Poweroutput
atenginespeed

HP
[rpm]

500
7750

555
6000

560
6000-7000

Cutoffspeed

[rpm]

8250

6800

7200

HP

100

125

127

[Nm/lb-ft]
[rpm]

520/383
6100

680/500
1500-5650

680/500
1500-5750

[]

12.0to1

9.3to1

10.0to1

Poweroutputperliter
Torque
atenginespeed
Compressionratio
Valvespercylinder
Fuel

[RON]

95-98

95-98

95-98

CO2emissions

[g/km]

344

325

232

MSS65

MSD85.1

MEVD17.2.8

DigitalEngineElectronics(DME)

S63TUEngine
1.Introduction
Unit

S85B50O0

S63B44O0

S63B44T0

ULEVII

LEVII

LEVII

km/h
mph

250
155*

250
155*

250
155*

Acceleration060mph

[s]

4.5

4.5

4.1**

VehiclecurbweightDIN

kg
lbs

1,870
4,114

2,305
5,071

1,870
4,114

Exhaustemissionslegislation
Maximumspeed

*Electronicallylimited
**F13M64.1s,F13M64.3sandF10M54.2s

S63TUEngine
1.Introduction
1.2.1.Fullloaddiagram
BMWF10M5/E60M5

FullloaddiagramcomparingS63B44T0enginewithS85B50O0engine

S63TUEngine
1.Introduction
BMWM5/BMWX5M

FullloaddiagramcomparingS63B44T0enginewithS63B44O0engine

S63TUEngine
1.Introduction
1.3.Newfeatures/Changes/SpecialFeatures
System
Enginemechanics

Oilsupply

Cooling

Airintakeandexhaust
emissionsystems

Vacuumsystem

Fuelpreparation

Engineelectricalsystem

Comment

NewcylinderheadduetouseoftheTurbo-Valvetronicdirect
injection(TVDI)procedure

3rdgenerationValvetronic

NewValvetrain

Newvariablecamshafttimingcontrol(VANOS)

Newcylinderheadcoverwithadaptedcrankcaseventilation

Newpistons

Newconnectingrodswithevenpitch

Newcrankshaft

Optimizedbeltdriveforhigherspeed

Oilpumpwithintakeandcompressionstage(Grotorand
pendulumslidecellpump)

Newoilspraynozzles.

Modifiedcoolantpumpforincreasedflowrate

Electriccoolantpumpsforexhaustturbocharger,chargeair
coolingandDME(DigitalEngineElectronics)

optimizedairintakesystem

TwinScrollexhaustturbochargerwithmulti-bankexhaust
manifold

Hotfilmairmassmeter7.

Two-stagevacuumpumpwithnewarrangementofthe
screwconnection

Vacuumreservoirforthewastegatevalvesbelowtheoilpan.

High-pressureinjection(likeN55engine)

Solenoidvalveinjectors

Boschhigh-pressurepump.

Twoenginecontrolunits,mountedtotopofengineand
cooledbycoolant.

S63TUEngine
1.Introduction
1.4.Engineidentification
1.4.1.Enginedesignation
TheenginedesignationS63B44T0isusedtoensureproperidentificationoftheengine.
Explanation
Index

Explanation

BMWMGmbHdevelopment

V8engine

Enginewithexhaustturbocharger,Valvetronic
anddirectfuelinjection(TVDI)

Gasengine,longitudinallyinstalled

44

4.4litersdisplacement

Topperformanceclass

Newdevelopment

IntheenginedesignationS63B44T0theTstandsforTopperformanceclassthussomematerial
mayrefertothisengineastheS63topanditalsomaybereferredtoasS63TU(inmarketingterms).
ThisdocumentcontainstheshortformoftheenginedesignationS63top(S63TU),whichonlyindicatestheenginetype.

1.4.2.Engineidentification
Theengineshaveanidentificationmarkonthecrankcasetoensureproperidentificationandclassification.Thefirstsixpositionsoftheengineidentificationcorrespondtotheenginedesignation.
Theenginenumbercanbefoundontheengineabovetheengineidentification.Thisconsecutive
number,inconjunctionwiththeengineidentification,allowsproperidentificationofeachindividualengine.

S63TUEngine
1.Introduction

S63top(S63TU)engineidentificationandenginenumber

Index

Explanation

20054919

Individualconsecutiveenginenumber

BMWMGmbHdevelopment

V8engine

Enginewithexhaustturbocharger,Valvetronicanddirectfuelinjection(TVDI)

Gasengine,longitudinallyinstalled

44

4.4litersdisplacement

Typetestconcerns,standard

S63TUEngine
2.EngineComponents
2.1.Enginehousing
Theenginehousingconsistsoftheengineblock,cylinderheads,cylinderheadcovers,oilpanandthe
gaskets.

S63top(S63TU)engine,structureofenginehousing

Index

Explanation

Cylinderheadcover

Cylinderheadcovergasket

Cylinderhead

Cylinderheadgasket

Crankcase

Gasketforupperpartofcrankcase

Upperpartofoilpan

Gasketforlowerpartofoilpan

Lowerpartofoilpan

10

Gasketforchaincase

11

Chaincasecover

S63TUEngine
2.EngineComponents
2.1.1.Crankcase
Thecrankcaseismanufacturedfromdie-castaluminiumGL-AlSi917Cu4MG,similartotheS63engine.ThecylinderwallsaremadefromAlusil.ThecrankcasewasoptimizedforthespecificMrequirements.

2.1.2.Cylinderheadgasket
Athree-layerspringsteelgasketisusedforthecylinderheadgasket.Thereisastopperplate(2)inthe
areaofthecylinderboresinordertoachievesufficientcontactpressureforsealing.Thecontactsurfacesforthecylinderheadandtheengineblockarelayeredandhaveapartialfluorocaoutchouccoatingwithanti-stickcoating.

Cylinderheadgasket

Index

Explanation

Topspringsteellayerwithanti-stickcoating

Stopperplate

Bottomspringsteellayerwithanti-stickcoating

2.1.3.Cylinderhead
ThecylinderheadoftheS63top(S63TU)engineisanewdevelopmentwithintegratedairductsfor
thecrankcaseventilation.
3rdgenerationValvetronicisalsousedintheS63top(S63TU)engine,similartotheN55engine.The
Valvetronicservomotorisconnectedontheoutsideofthecylinderhead.

Thecombinationofexhaustturbocharger,ValvetronicanddirectfuelinjectionisknownasTurbo
ValvtronicDirectInjection(TVDI).

S63TUEngine
2.EngineComponents

Cylinderhead

Index

Explanation

VANOS,intakeside

VANOS,exhaustside

Rollertappet,high-pressurepump

Eccentricshaft

Spring

Guideblock

Intermediatelever

Valvetronicservomotor

10

S63TUEngine
2.EngineComponents
2.1.4.Cylinderheadcover
Design
Thecylinderheadcoverisanewdesignwithintegratedcrankcaseventilationandlinerouting.The
operatingprincipleofthecrankcaseventilationisfromtheN63engine.Anseparatelinefromthe
crankcaseventilationsystemtotheairintakesystemisnotusedontheS63top(S63TU)engine.Separateboreholesfortheindividualintakeportsareintegratedinthecylinderhead.Everybankhasits
owncrankcaseventilationducts.
Thecamshaftsensorsarepositionedonthefrontofthecylinderheadcover.
Toseparatetheoilintheblow-bygasses,alabyrinthoilseparatorisused.Apre-separator(5)anda
impactplatewithsmallairvents(4)areintheflowdirection.Theoildropsareseparatedatthesebarriersandreturntothecylinderheadviathereturnline(7+8).Animpactsurface(3)withanupstream
filterensuresfurtherseparationofoilparticles.Theoilreturn(8)isequippedwithanon-returnvalve
inordertopreventdirectintakeofblow-bygasseswithoutseparation.Iftheoillevelincreasesinthis
pipe,thenon-returnvalveopenstheoildropsintothecylinderhead.Finallythecleanedblow-bygasesarere-fedintotheintakesystemdependingontheoperatingconditionoftheengineviathenon-returnvalve(1)orviathevolumecontrolvalve(10).

11

S63TUEngine
2.EngineComponents

Cylinderheadcoverwithcrankcaseventilation

Index

Explanation

Non-returnvalveforthecleanairpipewithleakhole

Linetocleanairpipe

Impactsurfacewithupstreamfilter

Fineimpactplatewithsmallairvents

Pre-separator

Intakeforblow-bygases

12

S63TUEngine
2.EngineComponents
Index

Explanation

Oilreturn

Oilreturnwithnon-returnvalve

Connectinglineviablow-by-gaschannelfortheintakeport

10

Volumecontrolvalvefortheairintakesystemwiththrottlefunction

11

Oilseparator

Crankcaseventilationinnaturallyaspiratedengineoperation
Inthenaturallyaspiratedengineoperationthereisavacuumintheairintakesystem(2).Thevolume
controlvalve(15)isopenedandthecleanedblow-bygasesmaketheirwaytotheintakeportsviabore
holesinthecylinderheadandintotheairintakesystem.Asthereisariskthatoilmaybedrawninby
thecrankcaseventilationinthecaseofanincreaseofvacuum,thevolumecontrolvalve(15)hasa
throttlefunctionwhichlimitstheblow-bygasflowalongwiththepressurelevelinthecrankcase.
Thevacuuminthecrankcaseventilationkeepsthenon-returnvalve(12)closed.Additionalfresh
airflowsintotheoilseparatorviaanoverlyingleakhole(13).Thisdoesnotallowthevacuuminthe
crankcasetogoaboveamaximumof100mbar.

13

S63TUEngine
2.EngineComponents

Crankcaseventilationinthenaturallyaspiratedengineoperation

Index

Explanation

Highpressure

Vacuum

Exhaustgas

Oil

Blow-bygases

Airfilter

Intakemanifold

14

S63TUEngine
2.EngineComponents
Index

Explanation

Oilseparator

Oildischarge

Ventilationduct

Crankchamber

Oilpan

Oilreturnduct

Exhaustturbocharger

10

Cleanairpipe

11

Linetocleanairpipe

12

Non-returnvalveforthecleanairpipe

13

Leakhole

14

Throttlevalve

15

Volumecontrolvalvefortheairintakesystemwiththrottlefunction

16

Channelinthecylinderhead

15

S63TUEngine
2.EngineComponents

Ventilationinthenaturallyaspiratedengineoperation

Index

Explanation

Leakhole

Non-returnvalve

16

S63TUEngine
2.EngineComponents
Crankcaseventilationinboostmode
Inboostmodethepressureintheairintakesystem(2)increasesandclosesthevolumecontrolvalve
(15).Sincethereisavacuuminthecleanairpipe(10),thenon-returnvalve(12)forthecleanairpipe
opensandthecleanedblow-bygasesaredirectedtothecompressorsideoftheexhaustturbocharger
throughthechargeaircoolerandintotheairintakesystem.

Crankcaseventilationinboostmode

17

S63TUEngine
2.EngineComponents
Index

Explanation

Highpressure

Vacuum

Exhaustgas

Oil

Blow-bygases

Airfilter

Intakemanifold

Oilseparator

Oildischarge

Ventilationduct

Crankchamber

Oilpan

Oilreturnduct

Exhaustturbocharger

10

Cleanairpipe

11

Linetocleanairpipe

12

Non-returnvalveforthecleanairpipe

13

Leakholeinthehousingofthenon-returnvalve

14

Throttlevalve

15

Volumecontrolvalvefortheairintakesystemwiththrottlefunction

16

Channelinthecylinderhead

18

S63TUEngine
2.EngineComponents

Crankcaseventilationinboostmode

2.1.5.Oilpan
Theoilpanismadefromaluminium.LiketheS63engine,itismadeupoftwoparts.Theoilfilterisintegratedintheupperoilpansection.
Theoilpumpisboltedtotheupperoilpansectionanddrivenbyachainbythecrankshaft.Toavoid
engineoilfoaming,thedrivechainandtheshaftsprocketareseparatedfromtheoilbytheoilpan.The
oildeflectorisintegratedintheupperoilpansection.Theoildrainplugisnotusedintheoilfiltercover.

19

S63TUEngine
2.EngineComponents

Upperoilpansectionwithoilpump

Index

Explanation

Oilreturnpipe

Intakepipeforthepressurepump

Grotorandpendulumslidecellpump

Thermostat

Chaindriveofthecrankshaft

Oilfiltercoverwithoutoildrainplug

Connectionfromoilcooler

Connectiontooilcooler

20

S63TUEngine
2.EngineComponents
2.2.Crankshaftdrive
2.2.1.Crankshaftwithbearings
Crankshaft
ThecrankshaftoftheS63top(S63TU)enginehasastrokeof88.3mmandisforgedsteel(C38)witha
hardenedsurfacelayerand6balanceweights.

S63top(S63TU)crankshaft

Crankshaftbearings
Thecrankshaftissupportedbyfivebearings.Thetwo-materialthrustbearingislocatedinthemiddle
atthethirdbearingposition.Lead-freethree-materialbearingsareused.

S63top(S63TU)crankshaftbearings

21

S63TUEngine
2.EngineComponents
Index

Explanation

Upperbearingshellwithgrooveandoilhole

Thrustbearingwithgrooveandoilhole

Lowerbearingshellwithoutgroove

Theidentificationmarkingsforthebearingsarestampedonthecrankcaseandonthecrankshaft.Refertotherepairinstructionsifthecrankshaftistobefittedwithnewbearings.

2.2.2.Connectingrodwithbearing
Connectingrod
TheconnectingrodoftheS63top(S63TU)enginehasbeenredesigned.Itisacrackedandforged
connectingrodwithatrapezoidaldesign.Inthesmallendoftheconnectingrodwithaformedholeis
usedlikeintheN20andN55engine.Theforceisevenlydistributedoveralargerareaandtheloadon
theedgesoftherodbushingsisreducedconsiderably.

22

S63TUEngine
2.EngineComponents

Connectingrod

Bearings
Lead-freeconnectingrodbearingshellsareused.Abearingpairwiththecolorsred/blueareusedas
standard.Thebluebearingisontherodside,theredbearingonthecapside.

2.2.3.Pistonwithpistonrings
Mahlecastpistonsareused.Thepistoncrownshapeisadaptedaccordinglytothecombustionprocesses,thevalvereliefsinthepistoncrownandtheuseoftheinjectorswithmultiplenozzles.

23

S63TUEngine
2.EngineComponents

Castpiston

Pistonrings

Index

Explanation

Plainrectangularcompressionringwithball-shaped(B-ring)

Taperfacedpistonring(NM-ring)

Oilscraperringwithspiralexpander(DSF-ring)

2.3.Camshaftdrive
Thecamshaftdrivehasbeenredesigned.Thedrivechainusesatoothedroller-typechain.
24

S63TUEngine
2.EngineComponents

Camshaftdrive

Index

Explanation

VANOS,exhaustside

VANOS,intakeside

Chaintensioner

Tensioningrail

Tooth-typechain

Crankshaftgear

2.4.Valvetrain
2.4.1.Design
IntheS63top(S63TU)enginethefullyvariablevalveliftcontrol(VVT)isnowusedinadditiontodoubleVANOS.Thevalvetrainitselfcomprisesofalreadyknowncomponents.Aroller-typechainisused
perbankforthedriveofthecamshafts.Thechaintensionerandsliderailsarecommonpartsforboth
banks.Theoilspraynozzlesareintegratedinthechaintensioner.Forservicingthecamsoranypartof
thevalvetrain,theS63top(S63TU)engineisnotpinnedatTDCofthecylinder,butat150beforefiringTDCofcylinder#1.Forlockingtheengineinthispositionaspecialtoolispositionedonthetorsionalvibrationdamper,whichisusedasareferenceforthealignmentpinforthecrankcase.

25

S63TUEngine
2.EngineComponents

Valvetrain

Index

Explanation

Exhaustcamshaft

Intakecamshaft

Guideplate

Intermediatelever

Spring

Valvetronicservomotor

Valvespring,intakevalve

VANOS,intakeside

Intakevalve

10

Exhaustvalve

11

Valvespring,exhaustvalve

12

VANOS,exhaustside

26

S63TUEngine
2.EngineComponents
Camshafts
TheS63top(S63TU)enginehasthesamelightweightcamshaftsasintheS63engine.Allcomponentsarefixedtotheshaftbytheinnerhigh-pressuremetalforming.

S63top(S63TU)camshafts

Index

Explanation

Exhaustcamshaft

Intakecamshaft

27

S63TUEngine
2.EngineComponents

S63top(S63TU)camliftandduration

Index

Explanation

Valvelift[mm]

Crankshaftdegrees[KW]

Exhaustvalveopen

Intakevalveopen

Openingperiodofexhaustvalve

Exhaustvalvecloses

Intakevalvecloses

Openingperiodofintakevalve

Technicaldataofvalvetrain
S85B50O0

S63B44O0

S63B44T0

Intakevalvediameter/stemdiameter

[mm]

35/5

33.2/6

33.2/6

Exhaustvalvediameter/stemdiameter

[mm]

30.5/5

29/6

29/6

Maximumvalvelift,intake/exhaustvalve

[mm]

11.7/11.5

8.8/9.0

8.8/9.0

VANOSadjustmentrange,intake

[crankshaft
degrees]

66

50

70

VANOSadjustmentrange,exhaust

[crankshaft
degrees]

37

50

55

28

S63TUEngine
2.EngineComponents
Spread,intakecamshaft

[crankshaft
degrees]

79145

70120

55125

Spread,exhaustcamshaft

[crankshaft
degrees]

91128

73.5123.5

60115

Openingperiod,intakecamshaft

[crankshaft
degrees]

268

231

260

Openingperiod,exhaustcamshaft

[crankshaft
degrees]

260

252

252

Intakeandexhaustvalves
Theinletandexhaustvalvesbothhaveastemdiameterof6mm.Theexhaustvalvesarehollowand
filledwithsodium.Thisresultsinimprovedandquickerheatdissipation.

2.4.2.Valvetronic

TheValvetronicisfullyvariablevalveliftcontrolandvariablecamshaftcontrol(doubleVANOS),which
makestheclosingtimeoftheintakevalvesadjustable.
Valveliftcontrolisperformedontheintakeside,whilecamshaftcontrolisperformedonboththeintakeandexhaustsides.
Throttle-freeloadcontrolisonlypossibleif:

theliftoftheintakevalve

andcamshaftadjustmentoftheintakeandexhaustcamshaftsarevariablycontrollable.

Result:
Theopeningandclosingtimesandtheopeningperiodandtheliftoftheintakevalveareadjustable.
VANOS
TheVANOS(variablecamshafttimingcontrol)componentsoftakenfromtheN55engine.ThedifferencesbetweentheS63andS63TUengineare:

Theadjustmentrangeofthevariablecamshafttimingcontrol(VANOS)wasincreasedfrom
50to70throughtheuseoffourinsteadoffiveflanks.

Theweightwasreducedfrom1050gto650g(2.31lbsto1.43lbs)throughtheuseofaluminiuminsteadofsteel.

29

S63TUEngine
2.EngineComponents

Variablecamshafttimingcontrol(VANOS)withoilsupply

Index

Explanation

Oilductfortimingadvance

Rotor

Oilductfortimingretard

VANOS,exhaustside

VANOS,intakeside

VANOSsolenoidvalve,intakeside

VANOSsolenoidvalve,exhaustside

Valveliftcontrol
TheValvetronicservomotorisattachedattheintakesidetothecylinderhead.Theeccentricshaft
sensorisintegratedintheValvetronicservomotor.
ThesystemusesValvetronicIII,whichisalreadyusedintheN55engine.

30

S63TUEngine
2.EngineComponents
Therollercamfollowersontheintakesidearemadefromsheetmetalandsubdividedintofiveclasses,
Class1toClass5.Theintermediateleversarealsomadefromsheetmetalandsubdividedintosix
classes,Class00toClass05.

Valveliftcontrol

Index

Explanation

VANOS,exhaustside

Exhaustcamshaft

Rollercamfollower

HydraulicvalveclearancecompensationHVCC

Valvespringonexhaustside

Exhaustvalve
31

S63TUEngine
2.EngineComponents
Index

Explanation

Intakevalve

HydraulicvalveclearancecompensationHVCC

Valvespringonintakeside

10

Rollercamfollower

11

Valvetronicservomotor

12

Eccentricshaft

13

Spring

14

Intermediatelever

15

Intakecamshaft

16

VANOS,intakeside

2.5.Beltdrive
Thebeltdrivedoesnothaveanymajorchanges,onlythedrivebeltandthebeltpulleyonthe
crankshafthaveasmallerdiameterduetothehigherenginespeed.
Thebeltdriveincludesamainbeltdrivewithanalternator,coolantpumpandpowersteeringpump.
Themainbeltdriveusesamechanicaltensioningpulley.
Thesecondarybeltdriveincludestheairconditioningcompressorandisequippedwithanelasticbelt.
ThecrankshaftpulleytensioningsystemfromtheS63engineisusedforreplacingtheelasticbelt.

32

S63TUEngine
2.EngineComponents

S63top(S63TU)beltdrive

Index

Explanation

Beltpulley,alternator

Belt

Coolantpumpbeltpulley

Beltpulley,powersteeringpump

Belttensioner

Beltpulley,crankshaft

Beltpulley,A/Ccompressor

33

S63TUEngine
3.OilSupply
ExtremelyhighdecelerationvaluescanoccurwhilebrakingwiththeM5/M6.Thiscanpushtheengine
oiltothefrontareaoftheoilpan.
Inthiscase,thependulumslidecellpumpcannolongerguaranteetheoilsupplyoftheenginedueto
nooilavailableattheinletsideofthepump.
Forthisreasonanoilpumpwithanintakeandpressurestage(G-rotorandpendulumslidecellpump)
areusedfortheS63top(S63TU)engine.
ThespecialfeaturesoftheoilsupplyintheS63top(S63TU)engineare:

Two-stageoilpump

Tensioningrailfortheoilpumpdrive

Additionalintakepipe.

3.1.Overview
Thefollowinggraphicprovidesanoverviewoftheoilsupplyandshowsthehydraulicoilcircuitdiagram
andtheactuallayoutoftheoilductsintheengine.

34

S63TUEngine
3.OilSupply
3.1.1.S63TUhydrauliccircuitdiagram

S63top(S63TU)hydrauliccircuitdiagram

Index

Explanation

Oilpan

Crankcase

Cylinderhead2x

Chaintensioner
35

S63TUEngine
3.OilSupply
Index

Explanation

VANOS,intakeside

VANOS,exhaustside

Oilpan

Oilpanintheoilpumparea

Volume-flow-controlledpendulumslidecellpump

G-rotoroilpump

Pressure-limitingvalve

Oilfilter

Filterbypassvalve

Thermostat

Oilcooler(oil-airheatexchanger)

10

Oilpressureswitch

11

Oilspraynozzlesforpistoncrowncooling

12

Lubricationpointoncrankshaftmainbearing

13

Lubricationpointsonexhaustturbocharger

14

Non-returnvalve,cylinderhead

15

Lubricationpointsoncamshaftbearing

16

Oilspraynozzlefortimingchain

17

Chaintensioner

18

Hydraulicvalveclearancecompensatingelements(16x)

19

Non-returnvalve

20

Strainer

21

Solenoidvalve

22

Swivelmotor

23

Non-returnvalve

24

Strainer

25

Solenoidvalve

26

Swivelmotor

3.2.Oilpumpandpressurecontrol
TheS63top(S63TU)enginehasanvolume-flow-controlledoilpumpwithintakeandpressurestage
intheonehousing.Theoilpumpisfixedtotheupperoilpansection.
Arotorstylepumpisusedasanintakestage,whichtransferstheengineoilfromthefrontareaofthe
oilpantotherearareaoftheoilpanbyanadditionalintakepipe.

36

S63TUEngine
3.OilSupply
Tosupplytheenginewithoilpressuretheknownvolume-flow-controlledpendulumslidecellpumpis
used.Theintakepipeispositioneddeepintherearareaoftheoilpantoguaranteeadefiniteoilsupply.
Informationontheoperatingprincipleofavolume-flow-controlledoilpumpcanbefoundintheST501
NewEngineTechnology"N63Enginetrainingmaterial"availableonICPandTIS.

3.2.1.Oilpump

Oilpumpwithcounterbalanceshafts

Index

Explanation

Returnline

O-ringgasket

Inlettorotorpump

Pendulumslidecellpump

Drivechainforoilpump

Oilpumpoutlet

Oilpumpsprocket

Chaintensioner

Intakepipeforpressurepump
37

S63TUEngine
3.OilSupply
3.3.Oilfilteringandcooling
TheS63top(S63TU)engineusesafull-flowoilfilterfamiliartotheN63engine.Itisboltedintothe
oilpanfrombelow.Theoilfilterdrainplugisnotused.Afilterbypassvalveisintegratedintheoilfilter
housing.

Oilfiltermodule

Index

Explanation

Thermostat

Connectionforoilcooler

Oilcooler

3.3.1.Oilcooling
TheS63top(S63TU)enginehasanoil-airheatexchangerforcoolingtheengineoilwhichisattached
belowthecoolingmoduleinthefrontbumper.Toallowquickheatingoftheengineoil,athermostatis
integratedintheoilpan.Thethermostatopensfromanengineoiltemperatureof100Candallows
theoiltoflowthroughthecooler.

3.3.2.Oilfiltering
TheS63top(S63TU)enginehasafilterbypassvalvewhichcanopenabypassaroundthefilterifthe
engineoiliscoldandthick.Thisoccursifthepressuredifferencebetweenbeforeandafterthefilter
exceedsapprox.2.5bar.Thepermissiblepressuredifferencehasbeenincreasedfrom2.0to2.5bar
38

S63TUEngine
3.OilSupply
inordertoprotectthelead-freecrankshaftandconnectingrodbearings.Thisensuresthatthefilteris
bypassedmuchlessfrequentlyandanydirtparticlesarefilteredout.Thefilterbypassvalveisintegratedintheoilfilterhousing.

3.4.Oilmonitoring
3.4.1.Oillevel
Formonitoringtheoilleveltheknownoilconditionsensor(QLT)isused.Thereisnoevaluationofthe
oilcondition.

3.5.Oilspraynozzles
IntheS63top(S63TU)enginesomecomponentswhichcannotbereacheddirectlybyanoilductare
lubricatedand/orcooledbyoilspraynozzles.

3.5.1.Pistoncrowncooling
Theoilspraynozzlesforpistoncrowncooling,asusedintheS63top(S63TU)engine.Theyincorporateanon-returnvalvetoallowthemtoopenandcloseonlyfromaspecificoilpressure.Eachcylinder
hasitsownoilspraynozzle,whichobtainsthecorrectinstallationpositionthroughitsdesign.Inadditiontothepistoncrowncooling,thesearealsoresponsibleforthelubricationofthepistonwristpins.

39

S63TUEngine
3.OilSupply

Oilspraynozzlesforthepistoncrowncooling

Index

Explanation

Oilspraynozzle

Openingpressure

2.25bar2.65bar

Closingpressure

2.0bar

3.5.2.Chaindrive
ThechaindriveintheS63top(S63TU)engineisdividedintoanuppersection,thecamshaftdrive,
andalowersection,theoilpumpdrive.
Camshaftdrive
Theoilspraynozzlesforthelubricationofthetimingchainsareintegratedinthechaintensionerofthe
specificbanks.Theyspraytheoildirectlyontothetimingchain.Thetimingchainofthecamshaftdrive
isdesignedasatoothedroller-typechain.
40

S63TUEngine
3.OilSupply

Chaintensionerwithoilspraynozzleforthetimingchain

Oilpumpdrive
Theoilpumpisdrivenviaaroller-typechainbythecrankshaft.Theroller-typechainistensionedbya
tensioningrail.Thesecondarydriveislubricatedviatheoilpan.

41

S63TUEngine
3.OilSupply

S63top(S63TU)oilpumpdrive

Index

Explanation

Crankshaft

Drivechainforoilpump

Gear,oilpump

Oilpump

Chaintensioner

3.5.3.Camshaft
Theoilsupplyofthechaintensioner,thehydraulicvalveclearancecompensatingelementsandthe
camshaftmountsinthecylinderheadisdonebyarisingpipefromtheengineblockinthecylinder
head.Anon-returnvalveinthecylinderheadpreventstheoilfromdrainingfromthecylinderhead.

42

S63TUEngine
3.OilSupply
3.5.4.Valvetronicservomotor
Thewormgearforadjustingtheeccentricshaftislubricatedusingtheoilsprayfromthecamshaft.

43

S63TUEngine
4.CoolingSystem
ThecoolingsystemintheS63top(S63TU)engineissimilartotheS63engine.Theengineand
chargeaircoolingbothhaveseparatecoolingcircuits.TheDMEhasnowbeenintegratedintothe
coolingcircuitofthechargeaircoolingthecooling.

4.1.Systemoverview

S63top(S63TU)completeengine,coolingsystem

44

S63TUEngine
4.CoolingSystem
Index

Explanation

Radiatorforthechargeaircooling

Additionalradiatorforthechargeaircooling

Electriccoolantpump,bank1

Chargeaircooler,bank1

Expansiontank,chargeaircooling

DigitalEngineElectronics,bank1

DigitalEngineElectronics,bank2

Chargeaircooler,bank2

Electriccoolantpump,bank2

Additionalradiatorforthechargeaircooling

Radiator

Heatercoil

Expansiontank

Mapthermostat

Electriccoolantpump

Exhaustturbocharger

Heatexchanger

Coolantvalve

Electriccoolantpump,exhaustturbocharger

10

Electriccoolantpump,heatingforpassengercompartment

11

Coolanttemperaturesensor

12

Expansiontank

13

Electricfan

4.1.1.Enginecoolingcircuit
Theenginecoolingisdonebyaconventionalcoolantpump.IntheS63top(S63TU)engine,ahighercoolantflowrateisachievedbythemodifiedimpellergeometryofthecoolantpump.Thecylinder
headcoolinghasalsobeenoptimized.Thecoolingmoduleonlycomesinonevariant.
Theelectricfanhasanominalpowerof850W.
Thefollowinggraphicsshowtheinstallationlocationsandlayoutofthecomponents.

45

S63TUEngine
4.CoolingSystem

Coolingsystemforengine

Index

Explanation

Radiator

Heatercoil

Expansiontank

Mapthermostat

Electriccoolantpump

Exhaustturbocharger

Heatexchanger

Coolantvalve

Electriccoolantpump,exhaustturbocharger

46

S63TUEngine
4.CoolingSystem
Index

Explanation

10

Electriccoolantpump,heatingforpassengercompartment

11

Coolanttemperaturesensor

12

Expansiontank

13

Electricfan

Componentsofthecoolingcircuitforenginewithoutexhaustturbocharger

S63top(S63TU)engine,componentsforcoolingsystemofenginewithoutexhaustturbocharger

Index

Explanation

Expansiontank

Coolantfillerpipe

Coolantvalve

Coolantpump

Electricfan

Radiator

Plugconnectionforelectricfan

Coolanttemperaturesensoratradiatoroutlet

Mapthermostat

10

Coolanttemperaturesensoratengineoutlet
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S63TUEngine
4.CoolingSystem
Index

Explanation

11

Inletforhotcoolantfromengineincoolantpump

12

Inletforcoldcoolantintheengine

13

Electricauxiliarycoolantpumpforpassengercompartmentheating

14

Heatexchanger

15

Coolantlevelsensor

Componentsofexhaustturbochargercoolingcircuit
Theconventionalcoolantpumpisdrivenbyabeltandcannotbeusedforcoolingtheexhaustturbochargeraftertheenginehasshutdown.Forthisreasonthereisanelectriccoolantpump,which
worksatapowerof20W.Thisisdonebyaseparatecoolingcircuit.Thiscircuitcanalsobeactivated
duringengineoperation,theelectriccoolantpumpcanbeswitchedontakingintoaccountthefollowingfactors:

Coolanttemperatureatengineoutlet

Engineoiltemperature

Injectedfuelquantity.

Theheatinputintotheengineiscalculatedusingthesevalues.Theafter-runoftheelectriccoolant
pumpcanlastupto30minutes.Toimprovethecoolingeffect,theelectricfanisactivatedandcanrun
foruptoamax.of11minutes.

48

S63TUEngine
4.CoolingSystem

Coolingcircuitoftheexhaustturbochargerwithelectricalauxiliarywaterpump

Index

Explanation

Cooledcoolant

Returnofhotcoolantfromexhaustturbocharger

Hotcoolantfromengine

Supplylinetotheexhaustturbochargersfromtheelectriccoolantpump

Returnlinefromexhaustturbochargerstoconventionalcoolantpump

Electriccoolantpump

Coolanttemperaturesensoratengineoutlet

Returnofhotcoolantfromenginetoradiator

Intakepipeofelectriccoolantpump

49

S63TUEngine
4.CoolingSystem
4.1.2.ChargeaircoolerandDMEcoolingcircuit
Toguaranteesufficientcoolingofthechargeair,thecoolant-airheatexchangershaveincreasedinsize
fortheS63TUengineincomparisontotheS63engine.Thesearesuppliedwithcoolantbyanindependentcoolingsystemwithtwo(50W)electriccoolantpumps.Thecoolingcircuitforthechargeair
coolingiscombinedwiththeDigitalEngineElectronics(DME)andcontainaradiatorandtwoauxiliary
coolersinthefrontbumperontheleftandrightsides.

Chargeair/DMEcooling

50

S63TUEngine
4.CoolingSystem
Index

Explanation

Radiatorforthechargeaircooling

Additionalradiatorforthechargeaircooling

Electriccoolantpump,bank1

Chargeaircooler,bank1

Expansiontankforthechargeaircooling

DME,bank1

DME,bank2

Chargeaircooler,bank2

Electriccoolantpump,bank2

Additionalradiatorforthechargeaircooling

Components
Both50Wpumpshaveaself-diagnosisanddry-runprotection.Ifthepumpspeedincreasesby15
rpmsoverapredeterminedperiod,theauxiliarywaterpumpsareswitchedoffandanfaultcodeis
storedintheDME.Theexpansiontankdoesnothaveacoolantlevelswitchanddoesnotautomaticallydetectwhenthefluidlevelistoolow.Inthecaseofalackoffluidinthecoolingcircuitofthecharge
aircoolerandDME,awarninglightintheinstrumentpanelsignalseithertoohighanintakeairtemperaturewithaparallelreductioninpowerorinsufficientDMEcooling.ACheckControlmessagealsoappears.

51

S63TUEngine
4.CoolingSystem

CoolingcircuitforchargeairwithDME

Index

Explanation

Radiatorforthechargeaircooling

Auxiliarycoolerforthechargeaircooling(rightside)

Electriccoolantpump,bank1

Chargeaircooler,bank1

Expansiontankforthechargeaircooling

DME,bank1

DME,bank2

Chargeaircooler,bank2

Electriccoolantpump,bank2

Auxiliarycoolerforthechargeaircooling(leftside)

52

S63TUEngine
4.CoolingSystem
4.2.Heatmanagement
TheS63top(S63TU)enginehasthesameheatmanagementfunctionintheDigitalEngineElectronics(DME)asintheN55engine.Thisincludesindependentcontroloftheelectriccoolingcomponents
ofelectricfan,mapthermostatandcoolantpumps.

4.2.1.Coolantpump
TheS63top(S63TU)enginehasatotaloffourelectriccoolantpumpsinadditiontothemechanicalpumps.Oneforthepassengercompartmentheating,anotherforthecoolingoftheexhaustturbochargerandtwoadditionalelectriccoolantpumpsforcoolingthechargeaircoolerandDME.

Ifthecoolantpumpisremovedandthentobereused,itisimportanttoensurethatitissetdownstill
filledwithcoolant.Dryingoutmaycausethebearingstostick.Thereasonforthisisthatthecoolant
pumpmaynotrun,whichinturnmayresultindamagetotheengine.
Beforeinstalling,turnthepumpimpellermanuallytoensurethatitmovesfreely.

4.2.2.Mapthermostat
TheS63top(S63TU)engineisfittedwithamapthermostatwhichhasthefollowingtechnicaldatain
non-electricallycontrolledmode:

Openingstartat105C

Completeopeningat120C.

Inaddition,anelectricheaterinthemapthermostatcanbeusedtomakethethermostatopenata
lowercoolanttemperature.

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
TheairintakeandexhaustemissionsystemsareinprinciplecomparablewiththoseintheS63engine.
Thelistbelowshowsthemostimportantchangestotheairintakeandexhaustemissionsystems:

Flow-optimizedairintakesystem

Hotfilmairmassmeter7

AdaptationoftheairintakesystemwithregardtotheValvetronicservomotor

Enlargedair-coolantheatexchangerforincreasingthecoolingpowerandreducingthepressurelosses

Optimizedexhaustmanifold.

5.1.Overview

Intakeairandexhaustemissionsystem

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
Index

Explanation

Throttlevalve

Charge-airtemperaturesensorandpressuresensor

Chargeaircooler

Intakesilencer

Hot-filmairmassmeter

Exhaustturbocharger

Wastegatevalve

Electropneumaticpressureconverter

Oxygensensorbeforecatalyticconverter(controlsensor)

10

Oxygensensoraftercatalyticconverter(monitoringsensor)

11

Catalyticconverter

12

DigitalEngineElectronics(DME)

13

Intakemanifoldpressuresensor

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
5.2.Airintakesystem

Airintakesystem

Index

Explanation

Intakeair

Compressed,hotchargeair

Cooledchargeair

Intakesnorkel

Intakesilencer

Hotfilmairmassmeter

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
Index

Explanation

Connectionforcrankcaseventilationforcleanairpipe

Exhaustturbocharger

Chargeaircooler

Chargingpressuresensor

Throttlevalve

Intakemanifold

10

Chargeairtemperatureandintake-manifoldpressuresensor

5.2.1.Intakesilencer
TheS63top(S63TU)enginehasitsownintakesilencerforeachbank.Thesealsoholdthehotfilmair
massmeters.

5.2.2.Hotfilmairmassmeter
TheS63top(S63TU)engineisfittedwiththehotfilmairmassmeter7,whichisverysimilartotheone
intheN20engine.

Failureordisconnectionofthehotfilmairmassmeterdoesnotimmediatelyresultinemergencyengineoperation.However,impairedmixturepreparationandthereforeincreasedemissionlevelsare
possible,whichiswhytheemissionswarninglamplightsup.

5.2.3.Intakemanifold
Thevolumeoftheairintakesystemhasbeenoptimizedandithasaflow-optimizedconnectionforthe
throttlebody.IncomparisontopreviousturbochargedBMWenginestheS63TUdoesnotuseablowoffvalve.TheuseofValvetronicandspecialtuningrendereditunnecessary.

Intakesystemwiththrottlevalve

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
Index

Explanation

Intakemanifold

Airtemperatureandintake-manifoldpressuresensor

Throttlevalve

Connectionfromtankventvalve

5.3.Exhaustturbocharger
TheS63top(S63TU)enginefeaturestwoexhaustturbochargerswithTwinScrolltechnology.Itincludesattheturbineinlettwoseparateductsinwhichtheexhaustgasisroutedfromtwocylindersto
theturbinevanes.Theturbinesandcompressorhavebeenslightlyredesigned,withthisdesignthe
exhaustturbochargerisnotsensitivetopump.WiththeseupgradesandtheuseofValvetronicalong
withspecialprogramingtheblow-offvalveisnolongernecessarythustheyarenotinstalled.

S63top(S63TU)TwinScrollexhaustturbocharger

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
Index

Explanation

Turbine

Bearingseat

Compressor

Vacuumunit

Wastegatevalve

Properpositioningofexhaustturbochargerduringinstallationisnecessary.
TheS63TUturbochargersrequireaspecialtooltoalignthemintheirproperinstallationlocation.Alwaysfollowproperrepairinstructions.

Turbochargeralignmenttool#2249171

Turbochargeralignmenttool#2249171

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
5.3.1.Function
ThedesignationTwinScrolldenotesanexhaustturbochargerwithatwin-scrollturbinehousing.
TheS63TUisfittedwith2segmentfourintotwoexhaustmanifoldthatconnectsbothcylinderbanks
inanidealconfigurationwheretheexhaustgaspulsesfromcylinders1/6and4/7arefedtotheexhaustturbochargerinstalledovercylinderbank5/8(L)andtheexhaustgasfromcylinders2/8and3/5
isfedtotheexhaustturbochargerinstalledovercylinderbank1-4(R),independentlyfromeachother.
Inthisway,so-calledpulsesuperchargingisusedtogreatereffect.
Thiscreatesaspacingof360ofcrankshaftanglebetweenthetwoexhaustbankcycleswithintheexhaustflutethatfeedseachtwinscrollturbochargerimpeller.Theeffectiveutilizationoftheexhaustgas
energydeliversoptimumde-throttlingandidealresponsecharacteristics.
MoreInformationonthefunctioningprincipleoftheTwinScrollexhaustturbochargercanbefoundin
the"N20Enginetrainingmaterial"availableonTISandICP.

5.4.Exhaustemissionsystem
5.4.1.Exhaustmanifold
TheS63TUexhaustmanifoldhasbeenflow-optimizedincomparisontotheS63engine.Theflow-optimizedmanifoldisafour-into-twotype(twooverlapping),whichisnecessaryforthespecialfunction
oftheTwinScrollturbocharger.ThedoublewalldesignofthepreviousS63exhaustmanifoldhasbeen
discontinuedandreplacedwithanopenpipedesignsothatthegeneratedheatcannowescapeupwardsthroughtheventilatedheatshields.Therearealsocorrugatedelementsmountedattheexhaust
manifoldsinordertobalancethethermomechanicalmovementsintheindividualsectionsoftheexhaustmanifold.

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem

S63top(S63TU)exhaustmanifoldwithexhaustturbochargerindrivingdirection,1stcylinder,topright

Index

Explanation

Exhaustmanifold1combinescylinders2and8tofeedtherightfrontturbo/
scroll

Exhaustmanifold2combinescylinders4and7tofeedtheleftrearturbo/scroll

Exhaustmanifold1combinescylinders3and5tofeedtherightrearturbo/
scroll

Exhaustmanifold2combinescylinders1and6tofeedtheleftfrontturbo/
scroll

Corrugatedelements

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem
TheS63TUcross-bankexhaustmanifoldalsorequiresaspecialtoolstoalignitintoitsproperinstallationlocation.Alwaysfollowproperrepairinstructions.

Forlocatingcross-bankexhaustmanifoldduringinstallationTool#2249161

PleaserefertoRepairInstructionsforF10S63TU,jobitem1840010.

5.4.2.Catalyticconverter
TheS63top(S63TU)enginefeaturesonecatalyticconverterperbank,whichisdouble-walled.The
catalyticconvertersnolongerhaveanydecouplingelements.

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S63TUEngine
5.AirIntake/ExhaustEmissionSystem

Sectionalviewofthecatalyticconverter

Index

Explanation

Connectiontoexhaustsystem

Ceramicmonolith2

Ceramicmonolith1

Controlsensor

Connectiontoturbine

Monitoringsensor

Oxygensensors
Boschoxygensensorsareused:

Control(pre)sensor:LSUADV

Monitoring(post)sensor:LSF4.2.

Thecontrolsensorislocatedaheadoftheprimarycatalyticconverter,ascloseaspossibletotheturbineoutlet.Itspositionhasbeenchosensothatallthecylinderscanberecordedseparately.The
monitoringsensorispositionedbetweenthefirstandsecondceramicmonoliths.

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S63TUEngine
6.VacuumSystem
ThevacuumsystemoftheS63top(S63TU)enginediffersfromtheS63engine.Thevacuumreservoir
andthepressureconverterhaveanewEBOandthevacuumlineshavebeenadapted.

S63top(S63TU)vacuumsystem

Index

Explanation

Vacuumpump

Connection,brakeservo

Connectionforsecondaryconsumer

Vacuumunitsforwastegatevalves

Electropneumaticpressureconverterforwastegatevalves

Vacuumreservoir

Connectionforvacuumlinetotheelectricswitchvalueforvacuumunitsof
exhaustflaps

Thetwostagevacuumpumpisusedsothatthemajorityofthegeneratedvacuumismadeavailable
tothebrakeservo.ThevacuumreservoirisnownolongerpositionedintheVareaoftheengine,butis
attachedatthelowersideoftheoilpan.

64

S63TUEngine
7.FuelPreparation
TheS63top(S63TU)enginemakesuseofhigh-pressureinjection,whichwasintroducedintheN55
engine.Itdiffersfromhigh-precisioninjection(HPI)inthatitusessolenoidvalveinjectorswithmulti-holenozzles.

7.1.Overview
ThefollowingoverviewshowsthefuelpreparationoftheS63top(S63TU)engine.Itcorrespondsto
thesystemswithdirectfuelinjectioninotherBMWmodels.

Fuelpreparation

Index

Explanation

Fuelhose

Fuelquantitycontrolvalve

Injector

High-pressureline,rail-injector

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S63TUEngine
7.FuelPreparation
Index

Explanation

Rail

High-pressureline,high-pressurepump-rail

High-pressurepump

Fuelsupplyline

Boschhigh-pressurefuelinjectorswiththedesignationHDEV5.2areused.Thehighpressurepumpis
alreadyknownfromthe4,8and12-cylinderengines.AninnovationintheS63top(S63TU)engineis
thefactthatthehigh-pressurelinesfromrailtoinjectorarenownolongerthreadedattherailend,but
weldedsimilartotheN20.

Donotopenthefuelsystemifthecoolanttemperatureisabove40C/104F.Theresidual
pressureinthehighpressurefuelsystemcouldcausebodilyinjury.
Itisessentialtoobservetheutmostcleanlinesswhenworkingonthehighpressurefuelsystemandto
followtheproperworkingproceduresdescribedintherepairinstructions.Evenminutesoilingordamageatthethreadconnectionsofthehighpressurelinescouldcauseleaks.
WhenworkingonthefuelsystemoftheS63TUengine,itisimportanttoensurethattheignitioncoils
arenotwetwithfuel.Theresistanceofthesiliconematerialisgreatlyreducedbysustainedcontact
withfuel.Thiscouldresultinarcingatthetopofthesparkplugandmisfiring.

Beforemakinganymodificationstothefuelsystem,alwaysremovetheignitioncoilsandprotectthesparkplugshaftagainsttheingressoffuelbycoveringthemwithacloth

Beforereinstallingthesolenoidvalveinjectors,removetheignitioncoilsandensurethatgreatestpossiblecleanlinessismaintained.

Ignitioncoilsheavilysaturatedwithfuelmustbereplaced.

7.2.Fuelpumpcontrol
Thefuelisdeliveredfromthefueltankthroughtheelectricfuelpumpviathefeedlineataprimary
pressureof5bartothehighpressurepump.Theprimarypressureismonitoredviathelow-pressure
sensor.Thefuelissentfromtheelectricfuelpumpasrequired.Intheeventofmalfunctionofthesensortheelectricfuelpumpcontinuestooperateat100%deliveryratewithterminal15ON.

7.3.High-pressurepump
ABoschhighpressurepumpisused.Thisisasingle-plungerpumpwhichisdrivenfromtheexhaust
camshaftviaatriplecam.Sothatsufficientfuelpressureisguaranteedinalloperatingconditionsof
theengine,ahigh-pressurepumpisusedintheS63top(S63TU)engineforeachbank.
Forfurtherinformationonthehigh-pressurepump,pleaserefertotheN74EngineTrainingmaterial
availableonTISandICP.

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7.FuelPreparation
7.4.Injectors
TheBoschHDEV5.2solenoidvalveinjectorwithaninward-openingmulti-holevalveisused.The
HDEV5.2isconfiguredforasystempressureofupto200bar.
TheseinjectorsarealreadyinuseintheN55andN20engine.
Forfurtherinformationoninjectoractivation,refertothesectionentitledEngineManagementSystem.

Thehousingofthesolenoidvalveinjectorscanonlywithstandacertaintensileforceandacertain
torque.Itisessentialwhenremovingandinstallingtheinjectorstousespecialtoolsandfollowthe
specificproceduresetoutintherepairinstructions,asotherwisetheinjectorswillbedamaged.

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8.FuelSupply
Thefuelsupplyisvehicle-specific.ThedifferencetotheF10productionvehiclesistheincreaseofthe
fueltankcapacityby10liters(2.64gallons)toatotalof80liters(21gallons).Theelectricfuelpumpis
adaptedtotheengineatanincreaseddeliveryrate.

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9.EngineManagementSystem
9.1.Overview

DMEIwiringdiagramMEVD17.2.8

Index

Explanation

Engineelectronics(DMEI)ValvetronicdirectinjectionMEVD17.2.8

Ambientpressuresensor

Temperaturesensor

FlexRay

PT-CAN

PT-CAN2

Tankleakdiagnosis

Zero-gearsensor(onlyformanualgearbox)

CarAccessSystem(CAS)

10

Clutchmodule

11

Sportbutton

12

Relayforelectricfan
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9.EngineManagementSystem
Index

Explanation

13

Electricfan

14

Mapthermostat

15

Fueltanknon-returnvalve

16

Tankventvalve

17

VANOSsolenoidvalve,intakecamshaft

18

VANOSsolenoidvalve,exhaustcamshaft

19

Electriccoolantpump,exhaustturbocharger

20

Pressureconverter(EPDW)wastegate

21

Quantitycontrolvalve

2225

Injector

2629

Ignitioncoil

30

Ground

31

Speedsensor,manualgearbox

32

PostOxygensensorLSF4.2

33

PreOxygensensor(LSU)ADV

34

Speedsignal

35

Chargingpressuresensorbeforethrottlevalve

36

Railpressuresensor

37

Chargeairtemperatureandintake-manifoldpressuresensorafterthrottle
valve

38

Knocksensor12

39

Knocksensor34

40

Hotfilmairmassmeter(HFM)7

41

Camshaftsensor,intakecamshaft

42

Camshaftsensor,exhaustcamshaft

43

Crankshaftsensor,signalisforwardedtoDMEII

44

Acceleratorpedalmodule

45

Throttlevalve

46

Enginetemperature

47

Temperature,cooleroutlet

48

Oiltemperature

49

Oilpressureswitch

50

Brakevacuumsensor(manualgearboxonly)

51

Valvetronicservomotor

52

Oillevelsensor

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9.EngineManagementSystem
Index

Explanation

53

Intelligentbatterysensor(IBS)

54

Electriccoolantpump,chargeaircoolerandDigitalEngineElectronics(DMEI)

55

DC/DCconverter

56

Alternator

57

LocalControllerAreaNetworkbetweenDMEIandDMEII

DMEIIwiringdiagramMEVD17.2.8

Index

Explanation

Engineelectronics(DMEII)ValvetronicdirectinjectionMEVD17.2.8

Ambientpressuresensor

Temperaturesensor

FlexRay

PT-CAN

PT-CAN2

CarAccessSystem(CAS)
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9.EngineManagementSystem
Index

Explanation

Servotronicbutton

Tankventvalve

10

VANOSsolenoidvalve,intakecamshaft

11

VANOSsolenoidvalve,exhaustcamshaft

12

Relay,transmissionoilpump(manualgearboxonly)

13

Pressureconverter(EPDW)

14

Quantitycontrolvalve

1518

Injector

1922

Ignitioncoil

23

Ground

24

PostOxygensensorLSF4.2

25

PreOxygensensor(LSU)ADV

26

Fuellow-pressuresensor

27

Chargingpressuresensorbeforethrottlevalve

28

Railpressuresensor

29

Chargeairtemperatureandintake-manifoldpressuresensorafterthrottle
valve

30

Knocksensor56

31

Knocksensor78

32

Hotfilmairmassmeter(HFM)7

33

Camshaftsensor,intakecamshaft

34

Camshaftsensor,exhaustcamshaft

35

Crankshaftsensor(DMEI)

36

DigitalEngineElectronics(DMEI)

37

Throttlevalve

38

Transmissionoiltemperature(manualgearboxonly)

39

Encodingwire

40

Valvetronicservomotor

41

Electriccoolantpump,chargeaircoolerandDigitalEngineElectronics(DMEII)

42

LocalControllerAreaNetworkbetweenDMEIandDMEII

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9.EngineManagementSystem

Vehicleinterface,ofDMEIandDMEII

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S63TUEngine
9.EngineManagementSystem
Index

Explanation

Fuelpressuresensor

Electriccoolantpump,chargeaircoolerandDigitalEngineElectronics(DMEII)

DMEII

Electricfan

Electriccoolantpump,chargeaircoolerandDigitalEngineElectronics(DMEI)

A/Ccompressor

Transmissionspeedsensor

Oillevelsensor

DMEI

10

Junctionbox(JB)

11

Fuse,terminal30B

12

Twin-clutchgearbox,selectorlever(notmanualgearbox)

13

Tankleakdiagnosis

14

Rearrightpowerdistributionbox

15

Relayforelectricfan

16

Fuse,terminal30

17

Intelligentbatterysensor(IBS)

18

Valve,exhaustflaps

19

IntegratedChassisManagement(ICM)

20

Operatingfacility,Servotronicandpowerswitch

21

Acceleratorpedalmodule

22

Couplingswitchmodule(manualgearboxonly)

23

Instrumentcluster

24

CarAccessSystem(CAS)

25

Centralgatewaymodule(ZGM)

26

Footwellmodule(FRM)

27

Startermotor

28

Switchreversinglight(manualgearboxonly)

29

DynamicStabilityControlDSC

9.2.Enginecontrolunit
TheS63top(S63TU)engineusesDigitalEngineElectronicsMEVD17.2.8.manufacturedbyBosch.
ItissimilartotheDigitalEngineElectronicsoftheN55engine.BothDME'sarewater-cooledand
mountedtotheengine.

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9.EngineManagementSystem

DigitalEngineElectronicslocation

Index

Explanation

Carrierplateforfusesandrelay

DMEI,controlunit,bank1

DMEII,controlunit,bank2

Donotattemptanytrialreplacementofcontrolunits.
Becauseoftheelectronicimmobilizer,atrialreplacementofcontrolunitsfromothervehiclesmustnot
beattemptedunderanycircumstances.Animmobilizeradjustmentcannotbereversed.
ThecoolingofthetwocontrolunitsoftheDigitalEngineElectronicsisintegratedtothechargeair
coolingcircuit.Analuminiumcoolingcoilisintegratedinthehousingbaseofthecontrolunitsforthis
system.
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9.EngineManagementSystem
TheplugconceptisidenticaltotheMEVD17.2intheN55engine.Therearesixconnectionsforeach
DME.

DMEconnectionsMEVD17.2.8

Index

Explanation

Module100,vehicleconnection,48pins

Module200,sensorsandactuators,58pins

Module300,sensorsandactuators,58pins

Module400,Valvetronicservomotor,11pins

Module500,DMEsupply,12pins

Module600,fuelinjectionandignition,24pins

9.2.1.Overallfunction
TheDigitalEngineElectronics(DME)isthecomputingandswitchingcenteroftheenginecontrolsystem.Sensorsontheengineandthevehicledelivertheinputsignals.Thesignalsforactivatingtheactuatorsarecalculatedfromtheinputsignals,thenominalvaluescalculatedusingacomputingmodel
intheDMEcontrolunitandthestoredprogrammaps.TheDMEcontrolunitactivatestheactuatorsdirectlyorbyrelays.
TheDMEcontrolunitiswokenupviathewake-upline(terminal15Wakeup)bytheCarAccessSystem(CAS).
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9.EngineManagementSystem
Theafter-runstartsafterterminal15OFF.Theadaptationvaluesarestoredduringtheafter-run.The
DMEcontrolunitusesabussignaltosignalitsreadinesstogotosleep.Whenalltheparticipating
controlunitshavesignalledtheirreadinesstogotosleep,thebusIoutputsabussignalandthecontrolunitsterminatecommunicationfivesecondslater.
ThecircuitboardintheDMEcontrolunithousestwosensors:atemperaturesensorandanambient
pressuresensor.Thetemperaturesensorisusedtomonitorthetemperatureofthecomponentsinthe
DMEcontrolunit.Theambientpressureisrequiredforcalculatingthemixturecomposition.

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