EBOOK - Turbocharging Technology - Công nghệ turbo tăng áp | Cộng đồng Kỹ thuật cơ điện Việt Nam EBOOKBKMT

In 2005, the first of the new generation 6-cylinder engines was introduced as the N52.

The engine featured such innovations as a composite magnesium/aluminum engine block, electric coolant pump and Valvetronic for the first time on a 6-cylinder.

To further increase the power and efficiency of this design, three new engines where introduced for the 2007 model year. These engines are the N52 K, the N51 SULEV II and the N54.

The N52K (N52KP) engine is the naturally aspirated version of the new 6-cylinder engines. The ”K” designation indicates that there are various efficiency and cost optimization measures. This engine can also be referred to as the “KP” engine.

The measures include new optimized components such as the consolidation of various items such as the crankcase ventilation system into the cylinder head cover.

The N51 engine is introduced to comply with SULEV II requirements. The N51 features much of the same measures and technology as the previous SULEV engine, the M56.

CONTENTS:

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

New Generation Engine Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

EfficientDynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

istory of Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

BMW Twinpower Turbo: One Term – Three Different Turbo

Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Advanced Turbo Engines Use Less Fuel . . . . . . . . . . . . . . . . . . . . . . .9

Three Technologies – One Effect: Twin-Turbocharging . . . . . . . .10

BMW TwinPower Turbo: one charger, two exhaust gas inlets. . . .11

BMW TwinPower Turbo: two same-size chargers. . . . . . . . . . . . . .11

BMW TwinPower Turbo: two different-sized turbochargers. . . . .11

urbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Turbocharging Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Basic Principles of Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Bi-Turbocharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Twin Scroll Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Function of the twin scroll turbocharger . . . . . . . . . . . . . . . . . . . .19

Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

N54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

N55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

N63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

N74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Air Ducting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Boost-Pressure Control (Wastegates) . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Electropneumatic Pressure Transducers (EPDW) . . . . . . . . . . . . . .33

Blow-off Control (Diverter Valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Controlled Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Intake Boost Pressure and Temperature Sensor . . . . . . . . . . . . . . .42

Boost-pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Intake temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Intake-manifold Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Subject Page

able of Contents

Initial Print Date: 03/11

Charge Air Cooling (Intercoolers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

N54/N55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

N63/N74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

urbocharger Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Golden Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Controlled Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Limp-home Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Turbocharger System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

1. Visual inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

2. Active diagnosis of the turbochargers . . . . . . . . . . . . . . . . . . . . . . .52

3. Check the exhaust flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

4. Check the electropneumatic pressure converters (EPDW) . . . .53

5. Check the intake system for leak-tightness with the diagnosis

device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

6. Check the wastegate and blow off valve (BOV/Diverter Valve) .54

7. Check the catalytic converter and turbo module . . . . . . . . . . . . .54

Intake-air Temperature of Charge-air Pressure Sensor . . . . . . . . . . . .54

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Boost pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Intake-air temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Characteristic Curve and Nominal Values . . . . . . . . . . . . . . . . . . . . . .55

Failure of the Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Intake Air Temperature Sensor (NOT Pressure)

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In 2005, the first of the new generation 6-cylinder engines was introduced as the N52.

The engine featured such innovations as a composite magnesium/aluminum engine block, electric coolant pump and Valvetronic for the first time on a 6-cylinder.

To further increase the power and efficiency of this design, three new engines where introduced for the 2007 model year. These engines are the N52 K, the N51 SULEV II and the N54.

The measures include new optimized components such as the consolidation of various items such as the crankcase ventilation system into the cylinder head cover.

The N51 engine is introduced to comply with SULEV II requirements. The N51 features much of the same measures and technology as the previous SULEV engine, the M56.

CONTENTS: