13 53 310 Removing and installing/replacing an injector (N63)

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Special tools required:

WARNING: Observe warning on cylinder head cover.
Clamp off 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.

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!

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

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

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

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.

IMPORTANT: Injectors are not waterproof!
Carry out engine cleaning/washing only with ignition coil cover fitted.

Necessary preliminary work:

Remove IGNITION COIL of corresponding cylinder

NOTE:

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.
Remove PRESSURE LINES on corresponding injectors.

NOTE: The following description applies to all injectors.

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

Fig 1: Identifying Injector Holding-Down Element And Bolt

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Remove injector (1).

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

Fig 2: Removing 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 3: Mounting Special Tool (13 0 301) On Stuck 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 4: Mounting Special Tool (13 0 300) Over Stuck Injector

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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 5: Identifying Stuck Injector Bolt

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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 6: Identifying Protective Caps And Uncoupling Element

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Installation note:

When installing a new injector:

Use a new uncoupling element (2).
Remove protective cap (1) from injector tip max. 10 min. before installation (Teflon ring swells up)

Fig 7: Identifying Protective Caps And Uncoupling Element

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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 8: Identifying Teflon Ring And Uncoupling 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 9: 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 10: Removing Teflon Ring From Injector Using Special Tool (13 0 191)

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

Fig 11: Identifying Teflon Ring Onto Installation Cone (13 0 195)

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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 12: Pushing Teflon Ring Onto Injector Using Fingers And Installation Cone (13 0 195)

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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 13: Sliding Assembly Sleeve Onto 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 14: Sliding Slide Assembly 13 0 192 (Large Diameter) 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 (Fig. 13 14 05) Teflon ring swells up.

Fig 15: Identifying Injector Into Assembly Sleeve 13 0 194 (Small Diameter)

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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.
The Teflon ring must subsequently be replaced.

Fig 16: Identifying Teflon Ring And Uncoupling Element
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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 17: Identifying Adjustment Value Printed In Blocks Of Digits On Injector

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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 18: Identifying Adjustment Value Printed In Blocks Of Digits On Injector

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Installing injector

Installation note:

Install hold-down device (1) with curvature facing upwards.

Fig 19: Installing Injector Hold-Down Device

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Installing injector

Install injector (1).

Install hold-down device (2).

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 20: Identifying Injector, Holding Down Element And Mounting Bolt

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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 21: Identifying High Pressure Fuel Lines And Union 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 22: Turning Injector

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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 23: Tightening High-Pressure Fuel Line Onto Injector Using Torque Wrench And Special Tool (13 0 161)

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For cylinders 4 and 8, 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 24: 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 25: Tightening Pressure Line On Rail Using Torque Wrench And Special Tools (001440, 13 0 162 And 13 0 161)

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Perform an injection quantity compensation

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

Fig 26: Identifying Adjustment Value Printed In Blocks Of Digits On Injector
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Select "Adjustment function"
Select "Adjust injectors"
Change "Test schedule"
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.