13 53 310 Removing and installing/replacing an injector (N20)
Special tools required:
Observe warning on cylinder head cover.
Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short-circuiting on removal).
Electric fuel pump starts up automatically when door is opened!
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!
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!
Before removing the injectors, clean or vacuum off injector shafts.
Injectors may be pulled out with a maximum tensile force of 2000 N and twisted only to 6 Nm (torsion movement). If these values are exceeded, the injectors must be replaced!
When assembling, it is essential to adhere to screwing sequences and tightening torques!
Failure to comply with this requirement may result in leaks!
Adhere to conditions of absolute cleanliness when carrying out repair work 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 contamination before removing lines or separate components.
- Use only lint-free cloths.
- Seal all fuel system openings with protective caps or plugs.
Wear safety goggles.
Oil and dirt particles may get into your eyes!
Carry out engine cleaning/washing only with ignition coil cover fitted.
No water may penetrate into injector slots and corrosion between injectors and cylinder head must be prevented.
- Ignition coils must not become coated with 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.
After removing the ignition coils, blow on the silicone material (1) of the ignition coils using a compressed air gun (2) in order to remove oil or fuel residues from the ignition coils, if necessary.
Before installing the ignition coils, blow out the spark plug shafts (2) using a compressed air gun (1).
Necessary preliminary tasks:
- Remove IGNITION COILS .
- Release PRESSURE LINE at high pressure pump and rail (do not remove ).
Removal and installation of injectors are described separately from each other.
Observe screw fastening sequence without fail.
Injector removal:
Unlock connector (1) and pull off.
Unscrew nuts (2).
Release screws (3) a few threads until rail (4) is loose.
Turn rail (1) counter clockwise until injectors can be removed.
Unlock and disconnect the connectors (2) from the injectors with a small slotted screwdriver (1).
Unlock the lock in the direction of the arrow with a small slotted screwdriver (1). Disconnect the connector (2) on the connector housing from the injector.
Unlock connector (1) from injectors and detach.
Slacken nut (2).
Tightening torque 12 52 2AZ .
Remove ground cable (3).
Attention!
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.
Mark injectors.
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 illustration) before using the special tool.
Attention!
Pull-out thread (1) is a left-hand thread.
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 8AZ .
Attention!
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!
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.
Installing injector:
When reusing a running injector:
- Replace decoupling element (1) without fail!
- Replace Teflon ring (2) without fail!
A Teflon ring that has already been installed once in the cylinder head must be replaced before the injector is reinstalled.
When installing a new injector:
- Install decoupling element (1) without fail!
Failure to comply with this requirement may result in line breaks and fuel discharge!
Replace Teflon ring:
Before replacing the Teflon ring (1), make sure your hands and the support areas are clean and free of oil.
Avoid mechanical contact with injector tip (2).
Dismount Teflon ring (2) from injector (1) with special tool (3) 13 0 191 .
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.
Push new Teflon ring (1) onto installation cone (2) 13 0 283 .
Mount Teflon ring (1) with installation cone (2) 13 0 283 on injector tip (3).
- Do not use fingernails to slide Teflon ring on.
- Do not use any lubricating agents.
- The sealing ring is expanded when slid on.
Using special tool (1) 13 0 281 push Teflon ring into groove (3) on injector.
To bring the widened Teflon ring to installation dimension, special tool (1) 13 0 282 must be pushed up to the limit position at injector (2).
Do not use any lubricating agents.
Attention!
Injection quantity compensation!
An injection quantity compensation must be carried out if an injector is replaced or changed on the cylinder side.
Injection 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!
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.
Insert injectors in injector bores.
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 8AZ .
Attention!
Set torque wrench (1) to 2 Nm counter-clockwise 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.
Installation note:
Install hold-down device (1) with curvatures (black arrows) downward.
Fit hold-down device (3) on injectors.
Attention!
Only hand-tighten screw (1). Screw the screw (2) in by only a few threads.
Otherwise, the hold-down device may tilt.
Install (4) rail, manually tightening nuts (3) and bolts (2) only.
- Rail must still be displaceable on cylinder head.
- Nuts (2) must be able to be screwed on easily by hand.
Firstly tighten screw (1).
Tightening torque 13 53 5AZ .
Then tighten down screw (2).
Tightening torque 13 53 5AZ .
First tighten screws (3).
Tightening torque 13 53 4AZ .
Then tighten nuts (2) on the injectors.
Tightening torque 13 53 6AZ .
Connect the connector (1) to the rail pressure sensor.
Noticeably connect connector (1) to the injectors.
Mount the ground cable (3).
Tighten nut (2).
Tightening torque 12 52 2AZ .
Check all connectors (1) on the injectors again for correct fit and make sure that all connectors have noticeably engaged.
Install pressure line (2).
Tighten nut (1) manually only.
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 (1) to be screwed on easily by hand!
Observe screwing sequence:
- First tighten nut on high pressure pump.
Tightening torque 13 53 7AZ .
- Then tighten the nut on the rail.
Tightening torque 13 53 7AZ .
Perform an injection quantity compensation:
The adjustment value is printed in three digits on the injector body.
- Connect BMW diagnosis system
- Identify vehicle
- Select "Function selection"
- Select "Service functions"
- Select "Engine electronics"
- Select "Adjustment function"
- Select "Adjust injectors"
- Select "Test plan"
- For each replaced injector, the adjustment value must be entered according to the installation location (cylinder). If no value exists, then enter dummy value 2.15 .
Clean spark plug slot.
Assemble engine.
Check fuel system for leak tightness.
Check function of DME.