13 53 310 Removing and installing or replacing an injector (N63O1)

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Special tools required:

WARNING: Observe warning on cylinder head cover.
Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short circuit 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.

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 danger 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: 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!

IMPORTANT: When assembling, it is essential to adhere to screwing sequences and tightening torques!
Failure to comply with this regulation 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.

IMPORTANT: Carry out engine washing only with ignition coil cover fitted.
No water may penetrate into injector slots and corrosion between injectors and cylinder head must be prevented.

NOTE:

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.

Necessary preliminary tasks:

Remove IGNITION COILS .
Remove rail on left and right. See REMOVING LEFT RAIL and REMOVING RIGHT RAIL .

NOTE: Removal and installation of injectors are described separately from each other.

Observe screw fastening sequence without fail.

Injector removal

Release screw (1).

Remove holding-down element (2).

Pull injectors upward out of cylinder head and remove.

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

Mark injectors.

Fig 1: Identifying Holding-Down Element And Screw

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Procedure in event of stuck injector:

Unscrew pull-out threads (1) from special tool 13 0 320 .

Fig 2: Identifying Pull-Out Threads

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Screw pull-out thread (1) from special tool 13 0 320 into special tool 2 249 115 .

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: Screwing Pull-Out Thread From Special Tool (13 0 320) Into Special Tool (2 249 115)

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Fit special tool (1) 2 249 115 on injector slot. Insert screws (2) and (3) in injector slot by a few threads. Screw in pull-out thread (4) until it is possible to screw the threaded sleeves (5) onto the injectors. Screw threaded sleeves (5) onto injectors and tighten down.

Tighten screws (2) and (3).

Tightening torque 13 53 11AZ .

Fig 4: Identifying Special Tool, Screws, Pull-Out Thread, And Threaded Sleeves

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IMPORTANT: Set torque wrench (1) to 5 Nm clockwise rotation. Together with special tool 2 249 115 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 crowfoot spanner (2) on hexagon head (3) of special tool 2 249 115 .

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

Fig 5: Turning Torque Wrench In Clockwise Direction

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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 And Decoupling Element
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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 Injector Tip And Teflon Ring

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Remove Teflon ring (2) from injector (1) using special tool (3) 13 0 191 from special tool set 13 0 190 .

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other auxiliary materials).

Do not clean injector tip.

Fig 9: Removing Teflon Ring From Injector

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Slide new Teflon ring (1) onto installation cone (2) 13 0 283 from special tool set 13 0 280 .

Fig 10: Sliding New Teflon Ring Onto Installation Cone

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Mount Teflon ring (1) onto injector tip (3) using installation cone (2) 13 0 283.

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: Mounting Teflon Ring Onto Injector Tip Using Installation Cone
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Using special tool (1) 13 0 281 from special tool set 13 0 280 , push the Teflon ring into the 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 from special tool set 13 0 280 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 installation cone (2) 13 0 281.

Fig 14: Releasing Installation Cone

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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!

Check injector bore hole for dirt contamination.
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.
Teflon ring must then be renewed.
Clean contact surfaces of decoupling elements (1) in cylinder head.
Replace decoupling element (1).

Fig 15: Identifying Teflon Ring And Decoupling Element
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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.

Description of injector quantity compensation at end of instructions.

Insert injectors in injector bores.

Tighten screws (2) and (3).

Tightening torque 13 53 11AZ .

Fig 17: Identifying Special Tool, Screws, Pull-Out Thread, And Threaded Sleeves

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IMPORTANT: Set torque wrench (1) to 2 Nm counterclockwise rotation.

Fit torque wrench (1) and crowfoot spanner (2) on hexagon head (3) of special tool 2 249 115 .

Turn torque wrench (1) in counter-clockwise direction until 2 Nm are reached.

Fig 18: Turning Torque Wrench In Counter-Clockwise Direction

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Installation note:

Install hold-down device (1) with curvatures (black arrows) downward.

Fig 19: Installing Hold-Down Device With Curvatures Downward

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Fit hold-down device (2) on injectors.

IMPORTANT: Only hand-tighten screw (1).

Fig 20: Identifying Holding-Down Element And Screw

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

First insert the rail at the pump connector (2), then lower to the point where the ball heads are positioned inside the injector cones and the rail is correctly positioned.

Then tighten the nuts (1) on the injectors so they are hand-tight. Next, hand-tighten the nut (2) of the high pressure pump. Lastly, mount screws (3) and hand-tighten.

Tighten down screws (3).

Tightening torque 13 53 1AZ .

Fig 21: Identifying Pump Connector, Screws, And Nuts

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Follow the correct screw connection sequence.

Tighten screws (1) on hold-down device for injectors.
Tightening torque 13 53 5AZ .
Tighten nuts (2) on the injectors.
Tightening torque 13 53 2AZ .
Tighten nut (3) on the high pressure pump.
Tightening torque 13 53 4AZ .

Fig 22: Identifying Screws And Nuts
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Perform an injection quantity compensation:

The adjustment value is printed in three digits on the injector body.

Fig 23: Identifying Adjustment Value

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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).

Clean spark plug slot.

Assemble engine.

Check fuel system for tightness.

Check function of DME.