13 53 310 Removing and installing or replacing an injector

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

WARNING: Observe warning on cylinder head cover.
Disconnect BATTERY NEGATIVE TERMINAL (risk of fire due to short-circuiting on removal).
Electric fuel pump starts up automatically each time door is opened!
Carry out installation work on fuel system only with coolant temperature below 40 °C.

WARNING: Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high velocity from the fuel injectors!
To reduce the fuel pressure, place rag over fuel injector and carefully tap against the fuel injector with a spanner.
There is a risk of injury if the fuel pressure is not reduced!

IMPORTANT: The tightening sequences and tightening torques of the screw connections must be adhered to when reassembling!
Disregard of these requirements may result in leaks!

IMPORTANT: Adhere to conditions of absolute cleanliness when working on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the system!

Do not allow any dirt particles or foreign bodies to get into the system.
Remove all traces of dirt before removing pipes or individual components.
Use only fluff-free cloths.
Seal all fuel system openings with protective caps or plugs.
High-pressure lines may be rescrewed a maximum of 10 times.

IMPORTANT: Injectors are not waterproof!
Carry out engine cleaning/washing only with ignition coil cover fitted.

Necessary preliminary tasks:

Remove IGNITION COIL of corresponding cylinder.

NOTE:

Ignition coils must not be fouled by fuel!
The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots!
Before installing ignition coils, clean spark plug slots with compressed air.
Make sure the spark plug slot is absolutely clean.
Remove PRESSURE LINE of corresponding cylinder

NOTE: The following description applies to all injectors.

Unlock plug (1) and remove.

Release screw and remove holding-down element (2).

Remove injector (3).

NOTE: If several injectors are removed, ensure that each injector is reinstalled in its original location (cylinder).

Mark injectors.

Fig 1: Identifying Plug, Holding-Down Element And Injector

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Procedure in event of stuck injector:

Mount special tool 13 0 180 on injector (1).

Fig 2: Identifying Injector With Special Tool 13 0 180

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Mount special tool 13 5 250 .

Carefully knock out injector (1) with special tools 13 0 180 and 13 5 250 .

Fig 3: Knocking Out Injector With Special Tools 13 0 180 And 13 5 250

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After removing, fit protective caps (1 and 3) to injector tip and fuel line connection.

Fig 4: Identifying Protective Caps

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Installation:

When reusing fuel injector:

Replace uncoupling element (2).
Replace PTFE sealing ring (1).

A PTFE seal which has been heated once by engine operation must be replaced before the fuel injector is reinstalled.

Fig 5: Identifying Uncoupling Element And PTFE Sealing Ring

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Installation:

When installing a new injector:

Use a new uncoupling element (2).
Remove protective cap (1) from injector tip max. 10 min. before installation (PTFE sealing ring swells up).

Fig 6: Identifying Uncoupling Element And Protective Cap
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Replacing PTFE sealing ring:

Before replacing PTFE sealing ring (1), make sure hands and work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

Fig 7: Identifying PTFE Sealing Ring And Injector Tip

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Remove PTFE sealing ring (1) with special tool 13 0 191 from injector (2).

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other tools/agents).

Do not clean injector tip.

Fig 8: Removing PTFE Sealing Ring With Special Tool 13 0 191 From Injector

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Fig 9: Identifying PTFE Sealing Ring With Taper 13 0 195

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Slide new PTFE sealing ring (1) onto mounting taper 13 0 195 .

Use fingers and mounting taper 13 0 195 to slide PTFE sealing ring (1) onto injector (2).

NOTE:

Do not use fingernails to slide PTFE sealing ring on.
Do not use any lubricating agents.
The sealing ring is expanded when slid on.

Fig 10: Sliding PTFE Sealing Ring Onto Injector With Taper 13 0 195
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To bring the expanded PTFE sealing ring to its installation dimension, slide three mounting sleeves with decreasing diameters onto the injector.

Slide mounting sleeve (1) with large opening first onto injector (1).

Do not use any lubricating agents.

Fig 11: Sliding Mounting Sleeve

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First slide mounting sleeve 13 0 192 (large diameter) onto injector (1).

Then slide mounting sleeve 13 0 193 (medium diameter) onto injector (1).

Fig 12: Sliding Mounting Sleeve 13 0 192 Onto Injector

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Finally, press injector (1) into mounting sleeve 13 0 194 (small diameter).

Installation:

Install injector within 10 minutes or slide on protective cap (Fig 4) (PTFE sealing ring swells up).

Fig 13: Pressing Injector Into Mounting Sleeve 13 0 194

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Installing injector:

Installation of injector is described separately from removal.

Before installing injector in engines that have been run:

Clean contact surfaces of uncoupling elements (2) in cylinder head.
Clean injector bore: To do so, preferably slide injector without uncoupling element (2) but with new PTFE sealing ring (1) in and out of injector bores several times.
The PTFE sealing ring must then be replaced.
Replace uncoupling element (2).

Fig 14: Identifying Uncoupling Element And PTFE Sealing Ring
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IMPORTANT: Injector adjustment!

An injector adjustment must be carried out if an injector is replaced or changed on the cylinder side.

Injector adjustment is carried out with the aid of a so-called adjustment value.

The adjustment value is printed in two blocks of three digits on the injector.

The adjustment value must be read off before installation!

Fig 15: Identifying Injector Adjustment Value

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Enter the adjustment value according to the installation position (cylinder) of the injector.

If injector adjustment is not carried out, the engine may run roughly or fail to start.

Description of injector adjustment at end of instruction.

Fig 16: Identifying Injector Adjustment Value

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Installing injector:

Installation note:

Install hold-down device (1) with curvature facing upwards.

Fig 17: Installing Hold-Down Device With Curvature

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Install injector (3).

Install holding-down element (2).

IMPORTANT: Tighten screw hand-tight only so that holding-down element (2) is slack and if necessary injector can still be turned.

Connect contact plug (1).

Fig 18: Identifying Plug, Holding-Down Element And Injector

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NOTE: Make sure holding-down element (1) is correctly seated.

Fig 19: Identifying Holding-Down Element

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Copper seals (1) that may be fitted on the pressure lines are no longer needed and must be removed.

If using the pressure line, apply a light coating of gear oil to the thread. New lines are already pretreated.

Fig 20: Identifying Copper Seals

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Connect pressure line (1), tightening nuts hand-tight only in the process.

IMPORTANT: Connect pressure line (1) without tension only.
To ensure distortion-free installation of the pressure line and to avoid damaging the thread, it must be possible for both nuts to be screwed on easily by hand!
If the nuts cannot be screwed on easily by hand, the injector must if necessary be turned a little.

Fig 21: Connecting Pressure Line

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Turn injector (2) if necessary in direction of arrow until nuts on pressure line can be easily screwed on by hand.

Tighten nuts on pressure line hand-tight.

Then tighten down screw for holding-down element (1).

Tightening torque 13 53 5AZ .

Fig 22: Turning Injector

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Adhere to tightening sequence:

First tighten down nut (1) on injector.
Then tighten down nut (2) on high-pressure rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151 .

Tightening torque 13 53 8AZ .

Fig 23: Identifying Nuts And Wrench

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Carrying out injector adjustment:

Connect DIS Tester
Identify car
Select "Function selection"
Select "Service functions"
Select "Engine electronics"
Select "Adjustment programs"
Select "Adjust injectors"
Change "Test schedule"
For each replaced injector, the adjustment value must be entered according to the installation position (cylinder).

Fig 24: Identifying Injector Adjustment Value
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Clean spark plug slot.

Assemble engine.

Check fuel system for leaks.

Check function of DME.