13 53 310 Removing and installing/replacing an injection (N55 hybrid)

Special tools required:

WARNING: High-voltage system - danger to life!
The following points must be strictly observed prior to starting work :

Observe SAFETY INFORMATION for handling hybrid cars.

It is of vital importance to adhere to the WARNINGS ON REMOVING THE INJECTORS !

Necessary preliminary work:

Disconnect negative battery terminal . See 61 20 900 DISCONNECTING AND CONNECTING BATTERY NEGATIVE LEAD or 61 20 900 DISCONNECTING AND CONNECTING BATTERY EARTH LEAD (risk of fire due to short-circuiting on dismantling).
Disconnect NEGATIVE BATTERY TERMINAL OF THE AUXILIARY BATTERY (risk of fire due to short-circuiting on dismantling).
Remove IGNITION COIL of corresponding cylinder.
Disconnect PRESSURE LINES of corresponding cylinder.

NOTE: The following description applies to all injectors in cylinders 1-6.

Unlock connector (1) from injectors and detach.

Slacken nut (2).

Tightening torque 12 90 5AZ .

Remove ground cable (3).

Fig 1: Identifying Injector, Ground Cable And Nut

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IMPORTANT: First, release screw (2). The, release screw (1).
Otherwise, the hold-down device may tilt.

Remove holding-down element (3).

Pull injectors upward out of cylinder head and remove.

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

Fig 2: Identifying Holding-Down Element And Screw

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Procedure in event of stuck injector:

Use special tool 0 496 885 to remove injectors that are stuck.

Lightly oil pull-out thread (1) and unscrew completely (see Fig 3) before using the special tool.

IMPORTANT: Pull-out thread (1) is a left-hand thread!

Fig 3: Identifying Oil Pull-Out Thread

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Fit special tool (1) 0 496 885 on injector slot. Join screws (2) to injector slot by a few threads. Screw in pull-out thread (4) until it is possible to screw the threaded sleeves (3) onto the injectors. Screw threaded sleeves (3) onto injectors and tighten down.

Tighten down screws (2).

Tightening torque 13 53 13AZ .

Fig 4: Identifying Threaded Sleeves And Screws

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IMPORTANT: Set torque wrench (1) to 5 Nm clockwise rotation. Together with special tool 0 496 885 this corresponds to a tensile force of max. 2000 N. The injector must be replaced if the torque wrench is activated when the injector is pulled out!

Fit torque wrench (1) and special tool (2) 00 9 170 on hexagon head (3) of special tool 0 496 885.

Fig 5: Turning Torque Wrench

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Turn torque wrench (1) in clockwise direction until the injector is pulled out.

After removing, fit protective caps (1 and 2) to injector tip and fuel line connection.

Installation note:

When installing a new injector:

Replace decoupling element (3).

Fig 6: Identifying Injector Protective Caps
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Installation note:

When reusing fuel injector:

Replace decoupling element (1).
Replace Teflon ring (2).
A Teflon ring that has already been installed once in the cylinder head must be replaced before the injector is reinstalled.

Fig 7: 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 8: Identifying Teflon Ring And Injector Tip

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Remove Teflon ring (2) using special tool (3) 13 0 191 from the set of special tools 13 0 190 from the injector (1).

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 9: Removing Teflon Ring From Injector

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Push new Teflon ring (1) onto installation cone (2) 13 0 283 from the set of special tools 13 0 280 .

Fig 10: Identifying Teflon Ring And Cone

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Mount Teflon ring (1) with installation cone (2) 13 0 283 onto injector tip (3).

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 11: Identifying Teflon Ring, Cone And Injector Tip

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Using special tool (1) 13 0 281 from the set of special tools 13 0 280 push Teflon ring into injector groove (3).

Fig 12: Pushing Teflon Ring Into Injector Groove Using Special Tool

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To bring the widened Teflon ring to installation size, push special tool (1) 13 0 282 from the set of special tools 13 0 280 as far as it will go onto injector (2).

Do not use any lubricating agents.

Fig 13: Pushing Special Tool (13 0 282) Onto Injector

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NOTE: Pull mounting tip (1) of special tool 13 0 282 towards rear to release installation cone (2) 13 0 281.

Fig 14: Pulling Special Tool Mounting Tip (13 0 282)

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Installing injector:

Before installing injector in engines that have been run:

IMPORTANT: Injectors must not be twisted to 6 Nm!
The injector must be replaced if this value is exceeded!

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

Important - do not damage injector!

Fig 15: Identifying Teflon Ring And Decoupling Element
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Clean injector bore: To do so, preferably slide injector without decoupling element (1) but with new Teflon ring (2) in and out of injector bores several times.
The Teflon ring must subsequently be replaced.
Clean contact surfaces of decoupling elements (1) in cylinder head.
Replace decoupling element (1).

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 three digits on the injector body.

The adjustment value must be read off before installation!

Fig 16: 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.

Injection quantity compensation is described at the end of these instructions.

Insert injectors in injector bores.

Fit special tool (1) 0 496 885 on injector slot. Join screws (2) to injector slot by a few threads. Screw in the pull-out thread (4) until the threaded sleeves (3) can be screwed onto the injectors. Screw threaded sleeves (3) onto injectors and tighten down.

Tighten down screws (2).

Tightening torque 13 53 13AZ .

Fig 17: Identifying Threaded Sleeves And Screws

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IMPORTANT: Set torque wrench (1) to 2 Nm counterclockwise rotation.

Fit torque wrench (1) and special tool (2) 00 9 170 on hexagon head (3) of special tool 0 496 885.

Turn torque wrench (1) in counterclockwise direction until 2 Nm are reached.

Fig 18: Turning Torque Wrench Counterclockwise

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Installation note:

Install hold-down device (1) with curvatures (black arrows) downward.

Fig 19: Installing Hold-Down Device

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Fit hold-down device (3) on injectors.

Fit screws (1) hand-tight.

Only fit the screw (2) loosely to prevent the hold-down device from tilting.

Fig 20: Identifying Holding-Down Element And Screw

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Fit pressure lines with rubber mount (3) on injectors and rail. Tighten nuts (1) and (2) manually only.

Fig 21: Identifying Pressure Lines On Injectors And Nuts

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Firstly tighten screw (1).

Tightening torque 13 53 6AZ .

Then tighten down screw (2).

Tightening torque 13 53 6AZ .

Fig 22: Identifying Holding-Down Element And Screw

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Tighten down pressure lines on injectors (1).

Tightening torque 13 53 9AZ .

Then tighten down pressure lines (2) on the rail.

Tightening torque 13 53 9AZ .

Installation note:

Reinstall line damper (3).

Fig 23: Identifying Pressure Lines On Injectors And Nuts

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Perform an injection quantity compensation:

The adjustment value is printed with three digits - depending on the version - on the injector body.

Connect BMW diagnosis system.
Identify vehicle.
Select "Function selection."
Select "Service functions."
Select "Engine electronics."

Fig 24: Identifying Injector Adjustment Value
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Select "Adjustment functions."
Select "Adjust injectors."
Select "Test plan"
For each replaced injector, the adjustment value must be entered according to the installation location (cylinder).

Clean spark plug slot.

Assemble engine.

Check fuel system for tightness.

Check function of DME.