Special Tools Required

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13 5 160
13 5 162

See FUEL SYSTEM - SPECIAL TOOLS .

WARNING: Clamp off battery negative terminal (risk of fire due to short-circuiting on removal). Electric fuel pump starts up automatically when door is opened! Carry out installation work on fuel system only with coolant temperature below 40°C. See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD .

Wear protective goggles.

Wear protective gloves.

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.

IMPORTANT: 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! Cover ignition coil with suitable means.

Necessary preliminary tasks:

Remove left intake filter housings

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Release clamps (1) and (2).

Replace clamps (2).

Detach both charge-air ducts (3) and remove.

Check gaskets on turbocharger, replacing if necessary.

Fig 1: Identifying Charge-Air Ducts & Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

Picture shows the left side, the procedure for the right side is identical.

Detach hoses (1) from clean-air pipe.

Release screw (2).

Tightening torque, see 13 71 1AZ in 13 71 AIR INTAKE DUCT .

Detach clean-air pipe (3) in direction of travel from turbocharger.

Check seal on clean-air pipe, replacing if necessary.

Fig 2: Checking Seal On Clean-Air Pipe

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock and disconnect fuel feed line (1).

Seal fuel lines with special tools 13 5 160 and 13 5 162 .

Unlock and disconnect plug (2) on fuel low-pressure sensor.

Release fuel feed line (3) on high-pressure pump.

Tightening torque, see 13 53 4AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .

Release bolts (4).

Tightening torque, see 13 53 6AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .

Catch and dispose of escaping fuel.

Fig 3: Releasing Fuel Feed Line On High-Pressure Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Seal fuel lines with special tools (1) 13 5 160 and (2) 13 5 162 .

Fig 4: Sealing Fuel Lines With Special Tools

Courtesy of BMW OF NORTH AMERICA, INC.

Release fuel feed line (1) on high-pressure pump.

Tightening torque, see 13 53 4AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .

Catch and dispose of escaping fuel.

Fig 5: Releasing Fuel Feed Line On High-Pressure Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) on retaining clips.

Tightening torque, see 13 53 7AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .

Feed out and remove fuel feed line (2).

Fig 6: Releasing Screws On Retaining Clips

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

Observe tightening sequence .

Fit fuel feed line.
In so doing, tighten screw connections hand-tight only .
Tighten down fuel feed line (1) on high-pressure pumps to torque (2) and with crowfoot wrench (3).
Tightening torque, see 13 53 4AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .
Tighten down lugs on fuel low-pressure sensor.
Tightening torque, see 13 53 6AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .
Tighten down retaining clips.
Tightening torque, see 13 53 7AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .

Fig 7: Tightening Down Fuel Feed Line On High-Pressure Pumps

Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

Check fuel system for leaks.

Check function of DME.