13 53 170 Removing and installing/replacing all pressure lines (N63)

WARNING: This page does not describe the selected car, but rather 21 other vehicles, including the 2017 BMW 550i GT xDrive, 2017 BMW 535i GT xDrive, 2017 BMW 535i GT, 2016 BMW 550i GT xDrive, and 2016 BMW 535i GT xDrive. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

WARNING: Electric fuel pump starts up automatically when door is opened!
Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short-circuiting on dismantling).
Observe warning on cylinder head cover.

WARNING: Carry out installation work on fuel system only with coolant temperature below 40 °C.
Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the high pressure line is released!

IMPORTANT: Adhere to conditions of absolute cleanliness when working on the high-pressure fuel system.
Introduced dirt contamination 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 32 1 270 .
High pressure lines may be rescrewed a maximum of 10 times.

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable collecting vessel.

Observe country-specific waste disposal regulations.

NOTE:

Ignition coils must not be fouled by fuel!
The durability of the silicone material is greatly reduced by contact with fuel, which can lead to failure of the ignition coil. 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.

Necessary preliminary tasks

Remove IGNITION COILS
Drain off AIR CONDITIONING SYSTEM
Remove INTAKE PORT on left and right
Remove REAR RIGHT SUSPENSION CROSS-BRACE
Remove REAR UNDERBODY PROTECTION
Release COOLANT EXPANSION TANK and place to one side
Remove WATER VALVE for heater/air conditioner and lay coolant hoses to one side.
In all-wheel-drive vehicles:
Remove STIFFENING PLATE

Unlock and detach plug connections (1 and 2).

Release transmission wiring harness (3) from marked clamps.

Fig 1: Identifying Wiring Harness And Connectors

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Unfasten plug connection (1) and disconnect.

Slide transmission wiring harness as far as possible in the upward direction.

Fig 2: Identifying Connector

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Pull gasket (1) in the operating range off in an upward direction.

Unfasten screws (2).

Release screws (3).

Tightening torque 51 71 3AZ .

Remove right bulkhead side section (4) upwards.

Fig 3: Identifying Right Bulkhead Side Section, Gasket, And Screws

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Release screws (1).

Tightening torque 12 90 4AZ .

Release clamp (2).

Remove lid (3) from auxiliary box.

Fig 4: Identifying Auxiliary Box Lid, Clamp, And Screws

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Unclip grommet hold-down device (1).

Release wiring harness (2) from bulkhead.

Unlock connector (3) and remove.

Fig 5: Identifying Grommet Hold-Down Device, Wiring Harness And Connector

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Release screws (1).

Tightening torque 12 90 2AZ .

Remove electronics box cover (2).

Fig 6: Identifying Electronics Box Cover And Screws

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Unlock all connectors (1) from control unit and disconnect.

Unclip grommet hold-down device (2) and remove.

Detach rubber grommets (3) from electronics box. Place wiring harnesses to the side.

Installation note:

Make sure grommets are correctly seated (watertightness).

Fig 7: Identifying Grommet Hold-Down Device, Rubber Grommets, And Connectors

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Slacken nut (1).

Tightening torque 12 51 1AZ .

Detach earthing cable (2).

Fig 8: Identifying Earthing Cable And Nut

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Release screw (1).

Lay filler neck (2) for windscreen washer fluid to one side.

Fig 9: Identifying Washer Fluid Filler Neck And Screw

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Release screws (1).

Tightening torque 12 90 1AZ .

Unclip coolant lines at clamp (2) from electronics box.

Fig 10: Identifying Clamp And Screws

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Carefully feed out the electronics box (1) complete with control unit upwards and place to one side.

IMPORTANT: Risk of damage! Do not under any circumstances kink or bend coolant lines (2).

Fig 11: Identifying Electronics Box And Coolant Lines

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Installation note:

When installing the electronics box (1), insert guide (3) on engine support.

Open cover.

Release screw (1).

Tightening torque 12 42 3AZ .

Remove positive battery cable lead (2) from positive battery connection point.

Release positive battery cable (2) from clamps (3).

Fig 12: Identifying Positive Battery Cable, Clamps, And Screw

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Release screw (1).

Tightening torque 64 53 3AZ .

Detach A/C line (2) and place to one side.

Replace sealing ring on A/C line.

Fig 13: Identifying A/C Line And Screw

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Slacken nut (1).

Tightening torque 12 42 7AZ .

Remove positive battery cable (2) and place to one side.

Fig 14: Identifying Positive Battery Cable And Nut

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Release clamp (1).

Tightening torque 13 71 8AZ .

Release clamp (2).

Replace clamp (2).

Remove right charge-air duct (3).

Check the gasket on the exhaust turbocharger. replacing if necessary.

Fig 15: Identifying Right Charge-Air Duct And Clamps

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Picture shows the left side, the procedure for the right side is identical.

Detach hoses (1) from clean air pipe.

Release screw (2).

Tightening torque 13 71 1AZ .

Detach clean-air pipe (3) in direction of travel from exhaust turbocharger.

Check seal on clean air pipe and renew if necessary.

Fig 16: Identifying Clean Air Pipe And Screw

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IMPORTANT: Screw back on all screw points of cable channels without fail! Some screw points are also ground points . If the wiring harnesses are not correctly screwed tight and secured, this may cause DME malfunction and failure!

Release screw (1).

Tightening torque 12 51 2AZ .

Fig 17: Identifying Screw

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Unlock plug connections for oxygen sensor and disconnect.

Release screws (1).

Tightening torque 12 51 2AZ .

Release wiring harness (2).

Release wiring harness (3) and place to one side.

IMPORTANT: Screw back on all screw points of cable channels without fail. Some screw points are also ground points .

Fig 18: Identifying Wiring Harness And Screws

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Release screw (1).

Tightening torque 12 51 2AZ .

Raise cable duct (2).

Fig 19: Identifying Cable Duct And Screw

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Lay positive battery cable (1) and wiring harness for injectors (2) forwards.

Slightly raise engine wiring harness (3).

Fig 20: Identifying Engine Wiring Harness, Wiring Harness For Injectors, And Positive Battery Cable

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Release clamp (1).

Tightening torque 13 71 8AZ .

Pull left charge air line (3) off of exhaust turbocharger.

Installation note:

Check the gasket on the exhaust turbocharger. replacing if necessary.

Fig 21: Identifying Left Charge Air Line And Clamp

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Picture shows the left side, the procedure for the right side is identical.

Detach hoses (1) from clean air pipe.

Release screw (2).

Tightening torque 13 71 1AZ .

Detach clean-air pipe (3) in direction of travel from exhaust turbocharger.

Check seal on clean air pipe and renew if necessary.

Fig 22: Identifying Clean Air Pipe And Screw

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Disconnect fuel delivery line. Seal fuel lines with special tools (1) 13 5 160 and (2) 13 5 162 .

Catch and dispose of escaping fuel.

Fig 23: Tightening Fuel Lines With Special Tools (13 5 160 And 13 5 162)

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Release screws (1).

Tightening torque 12 51 2AZ .

Raise cable duct (2).

Fig 24: Identifying Cable Duct And Screws

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Release screws (1).

Tightening torque 12 51 2AZ .

Release screw (2).

Place wiring loom (4) to one side.

Release wiring harness (3) and place to one side.

IMPORTANT: Screw back on all screw points of cable channels without fail. Some screw points are also ground points .

Fig 25: Identifying Wiring Harness, Wiring Loom And Screws

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Disconnect fuel delivery line. Seal fuel lines with special tools (1) 13 5 160 and (2) 13 5 162 .

Catch and dispose of escaping fuel.

Fig 26: Tightening Fuel Lines With Special Tools (13 5 160 And 13 5 162)

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Remove pressure line from injector to rail.

NOTE: The following description applies to all pressure lines.
First disconnect the pressure line from the rail. To reduce existing fuel pressure if necessary. Fuel must not get into the spark plug slot. Then disconnect the pressure line from the injector.

Release union nuts (1).

Disconnect pressure line (2).

Set down pressure lines in order.

Fig 27: Identifying Pressure Line And Union Nuts

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Secure injector against twisting with spanner (2).

Release union nut (1).

IMPORTANT: If several pressure lines are removed, ensure that each pressure line is reinstalled in its original installation location (cylinder).
Mark pressure lines.

Fig 28: Releasing Union Nut And Spanner

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Installation note:

Only if injector has to be rotated in fitted position:

Release bolt a few turns until holding-down device (3) is slackened.
Turn injector (1) in direction of arrow until union nuts (2) on pressure line can be easily screwed on by hand.
To do so, engage spanner on hexagon head of injector if necessary.
Tighten union nuts on pressure line hand-tight.

Fig 29: Identifying Injector, Hold-Down Device, And Union Nuts
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IMPORTANT: Do not under any circumstances pull injector out of bore hole!
If the injector is pulled out of the bore hole, the PTFE sealing ring must be replaced! Replacing PTFE sealing ring, refer to 13 53 315 . See REPLACING ONE INJECTOR, CYLINDERS 1-4 or REPLACING ONE INJECTOR, CYLINDERS 5-8 .

Adhere to tightening sequence:

First tighten down union nut on injector.
Then tighten down union nut on rail.

Tighten pressure lines with special tool 13 0 160 .

Tighten pressure line on injector with torque wrench (2) and special tool (1) 13 0 161 . Secure the injector from turning.

Tighten union nuts with special tool (1) 13 0 161 .

Tightening torque 13 53 2AZ .

Fig 30: Tightening Pressure Line On Injector With Torque Wrench And Special Tool

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For cylinders 4 and 8, tighten pressure line (1) with torque (2) and crowfoot wrench (3). Secure the injector from turning.

Tightening torque 13 53 2AZ .

Fig 31: Tightening Pressure Line With Torque Wrench And Crowfoot Wrench

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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 .

Installation note:

When tightening the pressure line on the rail, ensure that the angle of rotation of special tool 13 0 161 is restricted. Reapply the special tool if necessary.

Distortion of torque possible.

Fig 32: Tightening Pressure Line On Rail With Torque Wrench And Special Tools

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Remove high pressure line from high pressure pump to rail.

Picture shows left side. Procedure for the right side is identical.

Release union nuts (1).

Disconnect pressure line (2).

Fig 33: Identifying Pressure Line And Union Nuts

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Refit high pressure line from high pressure pump to rail.

Tighten down pressure line (1) hand-tight on rail and injector.

First tighten high-pressure line (1) on high-pressure pump using torque wrench (2) and special tool (3) 00 1 440 .

Tightening torque 13 53 3AZ .

Fig 34: Tightening Pressure Line On High Pressure Pump Using Torque Wrench

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Installation note:

When tightening the pressure line on the rail, ensure that the angle of rotation of special tool 13 0 140 is restricted. Reapply the special tool if necessary.

Fig 35: Tightening Pressure Line On Rail

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Tighten high-pressure line (1) on rail using torque wrench (2), long crowfoot spanner (3) and special tool (4) 13 0 140 .

Tightening torque 13 53 3AZ .

Fig 36: Tightening High-Pressure Line On Rail Using Torque Wrench, Long Crowfoot Spanner, And Special Tool

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Assemble engine.

Bleed fuel system with BMW diagnosis system.

Check fuel system for tightness.

Check function of DME.