13 53... Installing/removing/replacing an injector (N55) from engine number 02167649 (top 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 . See 13 53 192 REMOVING AND INSTALLING/REPLACING A PRESSURE LINE (CONTINENTAL HIGH-PRESSURE PUMP) (N55) or 13 53 192 REMOVING AND INSTALLING/REPLACING A PRESSURE LINE (BOSCH HIGH-PRESSURE PUMP) (N55) of corresponding cylinder.

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

Unlock connector (1) from injectors and detach.

Slacken nut (2).

Tightening torque: 12 90 5AZ .

Remove ground cable (3).

Fig 1: Identifying 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

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Procedure in event of stuck injector:

Use special tool 13 0 320 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 Pull-Out Thread

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Fit special tool (1) 13 0 320 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 Screw Threaded Sleeves On Injectors

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IMPORTANT: Set torque wrench (1) to 5 Nm clockwise rotation. Together with special tool 13 0 320 this corresponds to a tensile force of max. 2000 N. The injector must be replaced if the torque wrench clicks when the injector is pulled out!

Fig 5: Turning Torque Wrench Clockwise

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Fit torque wrench (1) and special tool (2) 00 9 170 on hexagon head (3) of special tool 13 0 320 .

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 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 With Injector Tip

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Remove Teflon 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 9: Removing Teflon Ring From Injector

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Push new Teflon ring (1) onto the installation cone (2) 13 0 283 .

Fig 10: Identifying PTFE Sealing Ring And Mounting Taper

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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 With Installation Cone On Injector Tip

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

Fig 12: Pushing Teflon Ring Into Injector Groove

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To bring the widened Teflon 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 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 mounting taper (2) 13 0 281 .

Fig 14: Pulling Mounting Tip Of Special Tool (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!

Fig 15: Identifying Teflon Ring And Decoupling Element

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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 (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.

Tighten down screws (2).

Tightening torque: 13 53 13AZ .

Fig 17: Identifying Screw Threaded Sleeves On Injectors

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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 13 0 320 .

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 With Curvatures

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Fit hold-down device (3) on injectors.

IMPORTANT: Only hand-tighten screw (1). Screw the screw (2) in by only a few threads. The screw head (2) may not touch; otherwise, the hold-down device (3) may tilt!

Fig 20: Identifying Hold-Down Device On Injectors

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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 21: Identifying Pressure Lines On Injectors And Rail

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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 Hold-Down Device On Injectors

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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 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 24: 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 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.