13 53 310 Removing and Installing/Replacing A Fuel Injector

13 53 310 Removing And Installing/Replacing An Injector (N55)







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: 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 contamination 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 re-screwed a maximum of 10 times.







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

Necessary preliminary work:
- Remove ignition coil of corresponding cylinder.







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.
- Disconnect pressure lines of corresponding cylinder.







NOTE: The following description applies to all injectors.

Slacken nut (1).
Tightening torque 12 90 5AZ.

Remove ground cable.
Release connector (2) from injectors and detach.
Release screw plug (3) and remove.







Release screws (1).
Remove clamping plate (2) and counter support bridge (3).
Remove EMC panel (4).







Release screw (1).
Feed out hold-down device (2) and remove.
Lift injectors (3) 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.







Procedure in event of stuck injector:
Use special tool 13 0 270 to remove injectors that are stuck.
Lightly oil pull-out thread before using the special tool.

IMPORTANT:
Pull-out thread (1) is a left-hand thread.
Threaded sleeve (2) is a right-hand thread.







Fit special tool (1) 13 0 270 on injector slot. Join screws (2) to injector slot by a few threads. Screw threaded sleeves (3) onto injectors and tighten down. To do so, screw pull-out thread (4) up or down if necessary.

Tighten down screws (2).

Tightening torque 13 53 13AZ.







IMPORTANT: Set torque wrench (1) to 5 Nm. Together with special tool 13 0 270 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 square head (3) of special tool 13 0 270.

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

Make sure that retaining pin (4) does not touch the cylinder head cover; if necessary, press the retaining pin back. Risk of damage.







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).







Installation note:
When reusing fuel injector:
- Replace decoupling element (1).
- Replace PTFE sealing ring (2).
A PTFE sealing ring which has been heated once by engine operation must be replaced before the fuel injector is reinstalled.







Replacing PTFE sealing ring:
Before replacing PTFE sealing ring (1), make sure hands and work surface are clean and free of oil.
Avoid mechanical contact with injector tip (2).







Remove PTFE sealing 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 auxiliary materials).







Slide new PTFE sealing ring (1) onto mounting taper (2) 13 0 283.







Mount PTFE sealing ring (1) with mounting taper (2) 13 0 283 onto injector tip (3).

NOTE:
- Do not use fingernails to slide PTFE sealing ring on.
- Do not use any lubricating agents.
- The sealing ring is expanded when slid on.







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







To bring the widened PTFE sealing 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.







NOTE: Pull mounting tip (1) of special tool 13 0 282 towards rear to release mounting taper (2) 13 0 281.







Installing injector:
Installation of injector is described separately from removal.







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 PTFE sealing ring (2) in and out of injector bores several times.
The PTFE sealing ring must then be replaced.
- Clean contact surfaces of decoupling elements (1) in cylinder head.
- Replace decoupling element (1).

IMPORTANT: Injector adjustment.







An injector adjustment must be carried out if an injector is replaced or changed on the cylinder side.
Injector adjustment is carried out with the aid of a so-called adjustment value.
The adjustment value is printed with three digits - depending on the version - 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 adjustment is not carried out, the engine may run roughly or fail to start.
Description of injector adjustment at end of instructions.







Installing injector:
Fit special tool (1) 13 0 270 on injector slot. Join screws (2) to injector slot by a few threads.
Screw threaded sleeves (3) onto injectors and tighten down. To do so, screw pull-out thread (4) up or down if necessary.
Tighten down screws (2).
Tightening torque 13 53 13AZ.







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

Fit torque wrench (1) and special tool (2) 00 9 170 on square head (3) of special tool 13 0 270.

Turn torque wrench (1) in counterclockwise direction until 2 Nm are reached.

Make sure that retaining pin (4) does not touch the cylinder head cover; if necessary, press the retaining pin back. Risk of damage.







Install injectors (3).
Install hold-down device (2).

IMPORTANT: Tighten screw (1) hand-tight only so that hold-down device (2) is slack and if necessary injector can still be turned.







Align injectors.

IMPORTANT:
Injectors must not be twisted to 6 Nm.
The injector must be replaced if this value is exceeded.

Install EMC plate (1).
Insert counter support bridge (2).







Insert clamping plate (1). Ensure correct installation position (see graphic).

Insert screws (2) and tighten down hand-tight only.







Install pressure lines on injectors and rail.
Tighten nuts (1) and (2) manually only.

Installation note:
Reinstall line damper (3).







Tighten down hold-down screw (1) through EMC panel.
Tightening torque 13 53 6AZ.







Tighten down screws (1) of EMC panel uniformly.

Tightening torque 13 53 11AZ.







Tighten down screw plug (1) on EMC panel.
Tightening torque 13 53 12AZ.







Tighten down pressure lines on injectors (1).
Tightening torque 13 53 9AZ.
Then tighten down pressure lines (2) on rail.
Tightening torque 13 53 9AZ.

Installation note:
Reinstall line damper (3).







Carrying out injector adjustment:
The adjustment value is printed with three digits - depending on the version - on the injector body.







- Connect BMW diagnosis system
- Identify car
- 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 Digital Engine Electronics.