13 53... Installing/removing/replacing an injector (N55) up to engine number 02167648 (bottom hold-down device concept)

Special tools required:

Observe WARNINGS ON REMOVAL OF THE INJECTORS without fail!

Necessary preliminary tasks:

Disconnect NEGATIVE BATTERY TERMINAL (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 cylinder 1-6.

Slacken nut (1).

Tightening torque: 12 90 5AZ .

Remove earth cable.

Unlock connector (2) from injectors and detach.

Release screw plug (3) and remove.

Fig 1: Identifying Injectors Connector And Nut

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Release screws (1).

Remove clamping plate (2) and counter support bridge (3).

Clamping plate (2) is a disposable part and must be replaced following removal.

Remove EMC plate (4).

Fig 2: Identifying EMC Plate, Counter Support Bridge And Screws

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Release screw (1).

Feed out hold-down device (2) and remove.

Lift injectors (3) 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 3: Identifying Injectors, Hold-Down Device And Screw

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Procedure in event of stuck injector:

Use special tool 13 0 270 to remove injectors that are stuck.

Lightly oil pull-out thread (1) and unscrew completely (see Fig 4) before using the special tool.

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

Fig 4: Identifying Oil Pull-Out Thread

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Fit special tool (1) 13 0 270 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 5: Fitting Special Tool On Injector Slot

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IMPORTANT: Set torque wrench (1) to 5 Nm clockwise rotation. Together with special tool 13 0 270 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!

Fig 6: Turning Torque Wrench Clockwise

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Fit torque wrench (1) and special tool (2) 00 9 170 on square head (3) of special tool 13 0 270 .

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

Make sure that retaining pin (4) does not touch the cylinder head cover; if necessary, press the retaining pin back.

Risk of damage!

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 7: Identifying Protective Caps
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Installation note:

When reusing fuel injector:

Replace decoupling element (1).
Replace PTFE sealing ring (2).
A PTFE sealing ring which has been installed in the cylinder head must be renewed before the injector is reinstalled.

Fig 8: Identifying PTFE Sealing Ring And Decoupling Element
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Renew the PTFE sealing ring:

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

Avoid mechanical contact with injector tip (2).

Fig 9: Identifying PTFE Seal With Injector Tip

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Remove PTFE sealing ring (2) with special tool (3) 13 0 191 from 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 10: Removing PTFE Sealing Ring From Injector

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Slide new PTFE sealing ring (1) onto mounting taper (2) 13 0 283 .

Fig 11: Identifying PTFE Sealing Ring And Mounting Taper

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Mount PTFE sealing ring (1) with mounting taper (2) 13 0 283 onto injector tip (3).

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 12: Identifying PTFE Sealing Ring With Mounting Taper On Injector Tip

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Using special tool (1) 13 0 281 push PTFE sealing ring into injector groove (3).

Fig 13: Pushing PTFE Sealing Ring Into Injector Groove

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To bring the widened PTFE sealing ring to installation size, push special tool (1) 13 0 282 as far as it will go onto injector (2).

Do not use any lubricating agents.

Fig 14: 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 mounting taper (2) 13 0 281 .

Fig 15: Pulling Mounting Tip Of Special Tool (13 0 282)

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Installing injector:

Installation of injector is described separately from removal.

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.

Fig 16: Identifying PTFE Sealing Ring And Decoupling Element
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Clean only dirty injector bores.

Important - do not damage injector!
Clean injector bore: To do so, preferably slide injector without decoupling element (1) but with new PTFE sealing ring (2) in and out of injector bores several times.
The PTFE sealing ring must then 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 with three digits - depending on the version - on the injector body.

Fig 17: Identifying Injector Adjustment Value

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The adjustment value must be read off before installation!

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.

Fig 18: Identifying Injector Adjustment Value

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Installing injector:

Tighten down screws (2).

Tightening torque: 13 53 13AZ .

Fig 19: Fitting Special Tool On Injector Slot

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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 square head (3) of special tool 13 0 270 .

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

Fig 20: Turning Torque Wrench Counterclockwise

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Make sure that retaining pin (4) does not touch the cylinder head cover; if necessary, press the retaining pin back.

Risk of damage!

Install injectors (3).

Install hold-down device (2).

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

Fig 21: Identifying Injectors, Hold-Down Device And Screw

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Align injectors.

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

Install EMC plate (1).

Insert counter support bridge (2).

Fig 22: Identifying EMC Plate And Counter Support Bridge

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Replace clamping plate (1).

Insert clamping plate (1). Ensure correct installation position (see Fig 23).

Insert screws (2) and tighten down hand-tight only.

Fig 23: Identifying Clamping Plate And Screws

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Install pressure lines on injectors and rail. Tighten nuts (1) and (2) manually only.

Installation note:

Reinstall line damper (3).

Fig 24: Identifying Pressure Lines On Injectors And Rail

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Tighten down hold-down screw (1) through EMC plate.

Tightening torque: 13 53 6AZ .

Fig 25: Identifying Hold-Down Screw Through EMC Plate

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Tighten down screws (1) of EMC plate uniformly.

Tightening torque: 13 53 11AZ .

Fig 26: Identifying EMC Plate Down Screws

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Tighten down screw plug (1) on EMC plate.

Tightening torque: 13 53 12AZ .

Fig 27: Identifying Down Screw Plug On EMC Plate

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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 28: Identifying Pressure Lines On Injectors And Rail

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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.

Fig 29: Identifying Injector Adjustment Value

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Connect BMW diagnosis system.
Identify vehicle.
Select "Function selection."
Select "Service functions."
Select "Engine electronics."
Select "Adjustment functions."
Select "Adjust injectors."
Select "Test schedule"
For each replaced injector, the adjustment value must be entered according to the installation location (cylinder).

Fig 30: Identifying Injector Adjustment Value
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Clean spark plug slot.

Assemble engine.

Check fuel system for tightness.

Check function of DME.