13 53 315 Removing and installing/replacing all injectors in diesel injection system (M57T2)

Special tools required:

13 5 250

Necessary preliminary tasks:

Read out the fault memory of the DDE control unit.
Switch off ignition.
Remove acoustic cover. See 13..... REMOVE THE ACOUSTIC COVERS (M57T2 WITH AND WITHOUT SCR) .
Pull off LEAKAGE OIL LINE .
DISCONNECT all pressure lines.

IMPORTANT: It is essential to adhere to conditions of absolute cleanliness when carrying out repair work on the fuel system.

Do not allow any dirt particles or foreign bodies to get into the system
Use only fluff-free cloths
Remove all traces of dirt contamination before dismantling lines or separate components
Seal all fuel system openings with protective caps.

NOTE: Following description applies to all injectors:

Unlock connector (1) and remove.

Unscrew nuts.

Remove injector (2).

Installation note:

Tightening torque: 13 53 4AZ .

Fig 1: Locating Injector Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

If the injectors have seized up, assemble special tools 13 5 251, 13 5 252 and 13 5 253 (from the set of special tools 13 5 250 ) and fit on the injector connection.

Drive out injector with impact weight of special tool.

Installation note:

Replace sealing rings (1 and 2).

Replace gasket (3).

Lightly lubricate injector slot with highly heat-resistant grease (refer to CONSUMABLES 4.5 ).

Prior to installation of injectors, CLEAN INJECTOR SOCKETS .

Fig 2: Identifying Injector Sealing Rings And Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Only for vehicles with a production date between 27/01/2012 and 05/10/2012:
Several cylinder heads were installed with an additional injector shim underneath the injector.
If during disassembly an injector shim (2) was removed in addition to a copper gasket (1), it is imperative that it is reinstalled.
If the injector shim is not installed or two injector shims are installed, a malfunction of the engine may occur (e.g. irregular engine running, exhaust fumes).

IMPORTANT: If the injector spacer shim is lost, the entire cylinder head has to be replaced!

Fig 3: Identifying Injector Shim And Copper Gasket

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 4: Measuring Depth Of Injector Shaft Using Depth Gauge

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Several cylinder heads were installed with an additional injector shim underneath the injector.
Before installing the injector it is imperative that the depth of the injector shaft is measured using a depth gauge.

The depth of the injector shaft is 126.25 mm.

Ensure that an injector shim is installed if one is needed.

If the injector shim is not installed or two injector shims are installed, a malfunction of the engine may occur (e.g. irregular engine running, exhaust fumes).

IMPORTANT: Risk of breakage of pressure line on injector. Observe tightening torque without fail.
Tightening torque: 13 53 1AZ .

Hand-tighten all union nuts on pressure lines.
Tighten union nuts on injectors and pressure accumulator to specified torque.
Perform visual inspection for tightness of all common rail system components.

NOTE: In the case of piezo injectors, the seven-digit adjustment value must be stored in the control unit after replacement of an injector.

Read off adjustment value (1) on new injector (2).

Fig 5: Identifying Injector Adjustment Value

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: If injectors have been replaced, "injector characteristic map adjustment" must be performed:

Connect BMW diagnosis system
Identify vehicle
Select "Function selection"
Select "Service functions"
Select "Digital Diesel Electronics (DDE)"
Select "Injectors adjustment"
Select "Test plan"
Start "Service" function with right arrow button.

NOTE: Clear diagnostic fault entries from fault memory.