13 53 721 Replacing one injector, cylinders 1-4 (N63)

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Special tools required:

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

IMPORTANT: Observe without fail the tightening sequences and tightening torques when reassembling.
Disregard of these requirements may result in leaks!

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste disposal regulations.

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 lines or separate 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.

Necessary preliminary work:

Remove ignition coils . See 12 13 511 REPLACING IGNITION COILS (N63) or 12 13 511 REPLACE THE IGNITION COILS (N63 B40/B44 O 1) , cylinders 1-4
- 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! It is therefore essential to protect the spark plug slot against ingress of fuel with a cloth!
- Before installing ignition coils, clean spark plug slots with compressed air.
- Make sure the spark plug slot is absolutely clean.
Drain off AIR CONDITIONING SYSTEM
Remove right intake port. Refer to 13...... REMOVING INTAKE DUCT (N63) or 13...... REMOVE THE INTAKE PORT (N63 B40/B44 O 1) .
Remove REAR RIGHT SUSPENSION CROSS-BRACE
Remove REAR UNDERBODY PROTECTION
In all-wheel-drive vehicles:
Remove STIFFENING PLATE

Unlock and detach plug connections (1 and 2).

Release transmission wiring harness (3) from marked clamps.

Fig 1: Locating Transmission Wiring Harness

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Unfasten plug connection (1) and disconnect.

Slide transmission wiring harness as far as possible in an upward direction.

Fig 2: Identifying Plug Connection

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Pull gasket (1) in the operating range off in an upward direction.

Unfasten screws (2).

Release screws (3).

Tightening torque 51 71 3AZ .

Remove right bulkhead side section (4) upwards.

Fig 3: Identifying Bulkhead Side Section, Gasket And Screws

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Release screws (1).

Tightening torque 12 90 4AZ .

Release clamp (2).

Remove lid (3) from auxiliary box.

Fig 4: Identifying Electronics Box Clamp And Screws

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Unclip grommet hold-down device (1).

Release wiring harness (2) from bulkhead.

Unlock connector (3) and remove.

Fig 5: Identifying Grommet Hold-Down Device, Wiring Harness And Connector

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Release screws (1).

Tightening torque 12 90 2AZ .

Remove electronics box cover (2).

Fig 6: Identifying Electronics Box Cover And Screws

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Unlock all connectors (1) from control unit and disconnect.

Unclip grommet hold-down device (2) and remove.

Detach rubber grommets (3) from electronics box. Place wiring harnesses to the side.

Installation note:

Make sure grommets are correctly seated (watertightness).

Fig 7: Identifying Rubber Grommets, Grommet Hold-Down Device And Connectors

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Slacken nut (1).

Tightening torque 12 51 1AZ .

Detach earthing cable (2).

Fig 8: Identifying Grounding Cable And Nut

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Release screw (1).

Lay filler neck (2) for windscreen washer fluid to one side.

Fig 9: Identifying Windscreen Washer Fluid Filler Neck And Screw

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Release screws (1).

Tightening torque 12 90 1AZ .

Unclip coolant lines at clamp (2) from electronics box.

Fig 10: Identifying Electronics Box, Clamp And Screws

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Carefully feed out the electronics box (1) complete with control unit upwards and place to one side.

IMPORTANT: Risk of damage! Do not under any circumstances kink or bend coolant lines (2).

Fig 11: Identifying Electronics Box And Coolant Lines

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Installation note:

When installing the electronics box (1), insert guide (3) on engine support.

Open cover.

Release screw (1).

Tightening torque 12 42 3AZ .

Remove positive battery cable lead (2) from positive battery connection point.

Release positive battery cable (2) from clamps (3).

Fig 12: Identifying Positive Battery Cable, Clamp And Screws

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Release screw (1).

Tightening torque 64 53 3AZ .

Detach A/C line (2) and place to one side.

Replace sealing ring on A/C line.

Fig 13: Identifying Refrigerant Line And Screws

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Slacken nut (1).

Tightening torque 12 42 7AZ .

Remove positive battery cable (2) and place to one side.

Fig 14: Identifying Positive Battery Cable And Screw

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Release clamp (1).

Tightening torque 13 71 8AZ .

Release clamp (2).

Replace clamp (2).

Remove right charge-air duct (3).

Check the gasket on the exhaust turbocharger. replacing if necessary.

Fig 15: Identifying Right Charge Air Duct And Clamp

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

Detach hoses (1) from clean air pipe.

Release screw (2).

Tightening torque 13 71 1AZ .

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

Check seal on clean air pipe and renew if necessary.

Fig 16: Identifying Clean-Air Pipe, Hoses And Screw

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IMPORTANT: Screw back on all screw points of cable channels without fail! Some screw points are also ground points . If the wiring harnesses are not correctly screwed tight and secured, this may cause DME malfunction and failure!

Release screw (1).

Tightening torque 12 51 2AZ .

Fig 17: Identifying Injectors Wiring Harness Screws

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Unlock plug connections for oxygen sensor and disconnect.

Release screws (1).

Tightening torque 12 51 2AZ .

Release wiring harness (2).

Release wiring harness (3) and place to one side.

IMPORTANT: Screw back on all screw points of cable channels without fail. Some screw points are also ground points .

Fig 18: Identifying Wiring Harness And Screws

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Release screw (1).

Tightening torque 12 51 2AZ .

Raise cable duct (2).

Fig 19: Identifying Cable Channel And Screw

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Lay positive battery cable (1) and wiring harness for injectors (2) forwards.

Slightly raise engine wiring harness (3).

Fig 20: Identifying Positive Battery Cable, Injector And Engine Wiring Harness

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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!

Only for injector, cylinders 5 and 6:

Remove pressure line between high pressure pump and rail .

Graphic shows the left side. Procedure on right side identical.

Release union nuts (1).

Disconnect pressure line (2).

Fig 21: Identifying Pressure Line And Union Nut

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Removing all pressure lines, cylinders 1-4 between injector and rail:

NOTE: The following description applies to all pressure lines.
First disconnect the pressure line from the rail. To reduce existing fuel pressure if necessary. Fuel must not get into the spark plug slot. Then disconnect the pressure line from the injector.

Tighten down pressure line on rail with special tools (2) 00 1 440 , (3) 13 0 162 and (4) 13 0 161 .

Fig 22: Tightening Pressure Line On Rail Using Torque Wrench

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Secure injector against twisting with spanner (2).

Release union nut (1).

Remove pressure line.

IMPORTANT: If several pressure lines are removed, ensure that each pressure line is reinstalled in its original location (cylinder).
Mark pressure lines.

Fig 23: Releasing Union Nut

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IMPORTANT: Wear safety goggles.
Oil and dirt particles may get into your eyes!

Before removing the injectors, clean or vacuum off injector slots.

Removing injector:

NOTE: The following description applies to all injectors.

Release bolt (1) and remove holding-down element (2).

Fig 24: Identifying Holding-Down Device And Bolt

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Pull out injector (1).

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

Fig 25: Pulling Injector

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Procedure in event of stuck injectors:

Mount special tool 13 0 301 or 13 0 302 (from set of special tools 13 0 300 ) on the stuck injector. In so doing, attach the special tool at the bottom to the injector and secure at the top with the knurled screw to the injector feed.

Fig 26: Installing Special Tool (13 0 301) On Injector

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Mount special tool 13 0 300 over the stuck injector with special tool 13 0 301 or 13 0 302. In so doing, insert screws (1) in the designated holes and screw down.

Tightening torque 13 53 10AZ .

Fig 27: Identifying Special Tool (13 0 300)

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Twist bolt (1) through special tool 13 0 300 into special tool 13 0 301 or 13 0 302 on the stuck injector. Tighten down bolt (1) until the injector is pulled out.

Fig 28: Identifying Injector Screws

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

Protective caps are available from BMW Parts Service.

Fig 29: Identifying Injector Protective Caps

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Installation note:

When installing a new injector:

Use a new uncoupling element (2).
Pull protective cap (1) off of injector tip maximum 10 min. before installation (Teflon ring swells).

Fig 30: Identifying Injector Protective Caps
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Installation note:

When reusing fuel injector:

Replace decoupling element (2).
Replace Teflon ring (1).
A Teflon ring which has been heated once by engine operation must be replaced before the injector is reinstalled.

Fig 31: Identifying Teflon Ring And Decoupling Element
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Replace Teflon ring:

Before replacing the Teflon ring (1), make sure your hands and the work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

Fig 32: Identifying Teflon Ring And Injector Tip

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Remove Teflon 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 33: Removing Teflon Ring Using Special Tool (13 0 191) From Injector

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Push new Teflon ring (1) onto the installation cone 13 0 195 .

Fig 34: Identifying Teflon Ring And Cone

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Push Teflon ring (1) with fingers assisted by the installation cone 13 0 195 onto the injector (2).

NOTE:

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

Fig 35: Pushing Teflon Ring On Injector

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To bring the expanded Teflon ring to its installation dimension, slide three assembly sleeves with decreasing diameters onto the injector.

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

Do not use any lubricating agents.

Fig 36: Sliding Assembly Sleeve On Injector

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

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

Fig 37: Sliding Assembly Sleeve (13 0 192) Onto Injector

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

Installation note:

Install injector within 10 minutes or slide on protective cap (Figure) Teflon ring swells up.

Fig 38: Pushing Injector Into Assembly 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:

Check injector bore for dirt.
Clean only dirty injector bores.

Important - do not damage injector!
Clean injector bore: To do so, preferably slide injector without decoupling element (2) but with new Teflon ring (1) in and out of injector bore several times.

Fig 39: Identifying Teflon Ring And Decoupling Element
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The Teflon ring must subsequently be replaced.
Clean contact surfaces of uncoupling elements (2) in cylinder head.
Replace decoupling element (2).

IMPORTANT: Injection quantity compensation!

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

Injector quantity compensation 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 40: Identifying Injector Adjustment Value

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

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

Description of injector quantity compensation at end of instructions.

Fig 41: Identifying Injector Adjustment Value

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Installation note:

Hold-down device (1) is installed with curvature facing upwards.

Fig 42: Installing Hold-Down Device

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Install injector (1).

Mount hold-down device (2) with the curvature facing upwards.

NOTE: Make sure hold-down device (2) is correctly seated.

IMPORTANT: Tighten bolt (3) hand-tight only so that hold-down device (2) is slack and if necessary injector (1) can still be turned.

Fig 43: Identifying Injector, Hold-Down Device And Screws

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Only for injector, cylinders 5 and 6:

Install pressure line between high pressure pump and rail .

Tighten down pressure line (1) hand-tight on rail and injector.

First tighten high-pressure line (1) on high-pressure pump using torque wrench (2) and special tool (3) 00 1 440 .

Tightening torque 13 53 3AZ .

Fig 44: Tightening High-Pressure Line Using Torque Wrench

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Only for injector, cylinders 5 and 6:

Installation note:

When tightening the pressure line on the rail, ensure that the angle of rotation of special tool 13 0 140 is restricted. Reapply the special tool if necessary.

Fig 45: Tightening Pressure Line On Rail Using Torque Wrench

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Only for injector, cylinders 5 and 6:

Tighten high-pressure line (1) on rail using torque wrench (2), long crowfoot spanner (3) and special tool (4) 13 0 140 .

Tightening torque 13 53 3AZ .

Fig 46: Tightening High-Pressure Line On Rail Using Torque Wrench

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Installation of pressure line between injector and rail:

Install pressure line (2). Tighten nuts (1) manually only.

IMPORTANT: Connect pressure line (2) 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 47: Identifying Pressure Line And Nuts

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Turn injector (1) if necessary in direction of arrow until nuts on pressure line can be easily screwed on by hand.

Tighten nut (2) of pressure line hand-tight.

Then tighten down bolt for hold-down device (3).

Tightening torque 13 53 5AZ .

Fig 48: Turning Injector On Pressure Line

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Adhere to tightening sequence:

First tighten down pressure line on injector.

Tighten down nut on injector with special tool (1) 13 0 161 and to torque (2). In so doing, grip hexagon head of injector with wrench (3).

Tightening torque 13 53 2AZ .

Fig 49: Tightening Pressure Line On Injector With Torque Wrench And Special Tool

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For cylinder 4, tighten pressure line (1) with torque (2) and crowfoot wrench (3). In so doing, grip hexagon head of injector with spanner.

Tightening torque 13 53 2AZ .

Fig 50: Tightening Pressure Line Using Crowfoot Wrench

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After this, tighten pressure line on rail.

Tighten down pressure line on rail with torque wrench (1) and special tools (2) 00 1 440 , (3) 13 0 162 and (4) 13 0 161 .

Tightening torque 13 53 2AZ .

Fig 51: Tightening Pressure Line On Rail Using Torque Wrench

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Perform an injection quantity compensation:

Connect BMW diagnosis system
Identify vehicle
Select "Function selection"
Select "Service functions"
Select "Engine electronics"
Select "Adjustment function"
Select "Adjust injectors"
Change "Test schedule"

Fig 52: Identifying Injector Adjustment Value
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For each replaced injector, the adjustment value must be entered according to the installation location (cylinder).

Assemble engine.

Bleed fuel system with BMW diagnosis system.

Check fuel system for tightness.

Check function of DME.