03 - Air Management PDF
03 - Air Management PDF
Air Management
Subject
Page
Air Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Accelerator Pedal Position (Pedalwertgeber - PWG) . . . . . . . . . . . . . . . .3
Throttle Valve (EDK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Throttle Motor and Feedback Position . . . . . . . . . . . . . . . . . . . . . . . . .6
Failsafe Operation - EDK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Idle Air Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Failsafe Operation - Idle Air Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Hot-Film Air Mass Meter (HFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
HFM on NG6 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Air Measurement with HFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Virtual Air Measurement without HFM . . . . . . . . . . . . . . . . . . . . . . .15
Air Temperature Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Variable Intake Manifold (DISA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Fully Variable DISA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Two Stage DISA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Variable Intake Manifold (DISA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
DISA Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
DISA Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
1st stage - idling/lower engine speed range . . . . . . . . . . . . . . .21
2nd stage - medium engine speed range . . . . . . . . . . . . . . . . . . .21
3rd stage - upper engine speed range . . . . . . . . . . . . . . . . . . . . .21
Workshop Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Air Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Crankcase Ventilation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Accelerator Pedal Position (PWG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Throttle Valve (EDK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Hot-Film Air Mass Meter (HFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Idle Air Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Air Temperature Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Revision Date:
Air Management
Model: All
Production: All
Aftercompletionofthismoduleyouwillbeableto:
Understand how different intake manifolds and air intake systems function
Understand how the Air System influences Engine Management
Be able to test the Mass Air Flow system
Be able to test the throttle assembly and the inputs that affect the throttle
Understand EDK and Idle Air Actuator operation
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Air Management
Air Management
Example of IPO for an Air Management System
INTAKE
AIR TEMP
IDLE
CONTROL
VALVE
AIR
MANAGEMENT
ENGINE THROTTLE WARNING
EML
One of the main purposes of the ECM is Air Management which includes the actuation
of several components. In the following pages you will find a generic explanation on how
this system works. For more detailed information please access BMW Training
Reference Manuals found online.
Air flow into the engine is regulated by the Throttle Valve
and/or the Idle Air Actuator. Both of these air passages
are necessary for smooth engine operation from idle to
full load. The Throttle Valve and the Idle Air Actuator are
electrically controlled. All of the ECM monitoring,
processing and output functions are a result of regulated
air flow.
DME
The ECM monitors the engine idle speed in addition to the accelerator pedal position
and throttle position voltage. If the voltage values have changed (mechanical wear of
throttle plate or linkage), the ECM will adjust the Idle Air Actuator to maintain the correct
idle speed.
The Potentiometers/Hall sensors are non-adjustable because the ECM learns the
throttle angle voltage at idle speed. If the throttle housing/accelerator pedal module is
replaced, the adaptations must be cleared and adaptation procedure must be performed
using ISTA. If this is not performed, the vehicle
[mV]
5000
will not start, or run in fail-safe mode.
A
B
2500
500
0
0%
50%
100%
If the signals are not plausible, the ECM will use the lower of the two
signals as the requested input. The throttle response will be slower
and the maximum throttle response will be reduced.
4
Air Management
The pedal position sensor is monitored by checking each individual sensor circuit
and comparing the two pedal values. Monitoring is active as soon as the sensors receive
voltage (KL15). The ECM decides what operating mode the pedal position sensor is to
assume.
Pedal position sensor fully operable.
Failure of one pedal position sensor
(maximum engine speed is limited).
Failure of both pedal position sensors
(engine speed limited to 1500 rpm).
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Air Management
6
Air Management
U[V]
5V
0V
0%
50%
100%
The EDK is electrically held at the idle speed position, and all of the intake air is drawn
through the Idle Air Actuator. Without a load on the engine (<15%), the EDK will not
open until the extreme upper RPM range. If the engine is under load (>15%), the Idle
Air Actuator is open and the EDK will also open.
7
Air Management
All variants of the NG6 engines receive the new EGAS 08 throttle by Siemens/VDO.
The new throttle uses a plastic throttle valve and magneto-resistive feedback to the
ECM.
The previous system used a potentiometer, whereas the new
throttle uses a contactless system featuring magneto-resistive technology which is
familiar from the eccentric shaft sensor on Valvetronic systems.
The magneto-resistive sensors are integrated into the housing cover. The sensors are
also non-wearing.
For plausibility, the one sensor outputs the analog signal in the range from 0.3 to 4.6 V
and the other sensor inverts it again from 4.6 to 0.3 V.
Consequently, the contact force is 10 times greater than that of a conventional plug connector
It is possible to twist the connector before plugging it in.
This can cause damage to the harness and connector.
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Air Management
9
Air Management
10
Air Management
11
Air Management
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Air Management
The N54 engine uses a virtual HFM. The signal is calculated in the
ECM from various parameters such as engine speed, intake air temperature, throttle position etc.
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Air Management
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Air Management
Index
Explanation
Index
Explanation
Residual O2 content in
exhaust gas
Intake manifold
Engine speed
Injection Timing
Index
Explanation
Index
Explanation
Engine speed
Intake manifold
Injection Timing
15
Air Management
16
Air Management
If the drive unit fails, the system remains in its current position.
The driver may notice a loss in power.
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Air Management
Explanation
Index
Explanation
Torque
Index
RPM
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Air Management
The DISA motors are similar in design and operation, but they are not
interchangeable. Each actuator assembly has its own individual part
number.
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Air Management
DISA Actuators
Together with the drive, the DISA valve (flap)
forms one unit. The DISA valve is driven by an
electric motor and a gear mechanism.
The electronic control is integrated in the DISA
actuator. The DISA actuator is driven by a pulse
widthmodulated signal from the DME.
There are only two possible positions: The
valves (flaps) can either be closed or opened, i.e.
when activated, the motor moves the valve to
the respective end position.
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Air Management
DISA Operation
1st stage - idling/lower engine speed range
At idle speed and in the lower engine speed range, actuators 1 and 2 are closed. The
intake air flows past the throttle valve into the resonance pipe. In the resonance pipe, the
intake air mass splits. The air is fed via the collector pipe and resonating pipes into the
individual cylinders. In this way, three cylinders are provided with a comparably high air
mass.
2nd stage - medium engine speed range
In the medium engine speed range, DISA actuator motor 2 is opened. In this case, it is
assumed that the inlet valves of the first cylinder are just closing. The gas motion creates
a pressure peak at the closing inlet valves. This pressure peak is passed on via the resonating and collector pipes to the in next cylinder in the firing order. This improves the
fresh gas filling of the next cylinder to be filled.
3rd stage - upper engine speed range
In the upper engine speed range, both DISA actuator motors are opened. In this case, it
is assumed that the inlet valves of the first cylinder are just closing. The gas motion creates a pressure peak in front of the closing inlet valves. The intake air mass is now fed
via the resonating, overshoot and collector pipes.
1st Stage
2nd Stage
3rd Stage
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Air Management
DISAN52KPandN51
As far as the air management system on the N52KP and N51 engines
is concerned, the previous intake manifold system on the N52 is carried over. Depending upon application, the engines will use the
3-stage DISA or the single stage (no DISA) intake manifold.
For more information on the DISA system refer to the previous
training material in the training course ST501 - New Engine
Technology.
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Air Management
Workshop Hints
Air Management
Unmetered air leaks can be misleading when diagnosing faults causing Malfunction
Indicator Light/driveability complaints. Use the Smoke Machine to help you find leaks.
[mV]
5000
Performance/driveability complaints
B
2500
500
0
0%
50%
100%
U[V]
5V
0V
0%
50%
100%
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Air Management
B+
Two Winding
Rotary
Slide
25
Air Management
NOTES
PAGE
26
Air Management