BMW 7 Series: Removing And Installing/Replacing All Pressure Lines (N63)

Notes

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

Observe warning on cylinder head cover.

WARNING: Carry out installation work on fuel system only with coolant temperature below 40ºC.

Fuel can emerge spontaneously at high velocity when the high-pressure line is released!

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 pipes or individual 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 container.

Observe country-specific waste-disposal regulations.

NOTE:

• Ignition coils must not be fouled by fuel! The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots!
• 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 intercooler on left and right.
• Partially remove WIRING HARNESS for engine.
• Partially remove WIRING HARNESS for injectors.
• Detach BATTERY POSITIVE LEAD from battery positive terminal, partially remove battery positive lead.
• Remove FLUID RESERVOIR for power steering.
• Remove suction line for power steering.
• Remove coolant EXPANSION TANK.
• Remove ELECTRONICS BOX.
• Remove WATER VALVE for heater/air conditioner and lay water hoses to one side.
• Detach tank vent line from tank venting valve and point of separation.
• Remove suspension cross-braces on left and right.
• Remove ACOUSTIC INSULATION for bulkhead on left and right.
• Drain off AIR CONDITIONING SYSTEM.

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. 43: Identifying A/C Line With Mounting Screws

Slacken nut (1).

Tightening torque 12 42 7AZ.

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

Fig. 44: Identifying Battery Positive Lead With Mounting Nut

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

Catch and dispose of escaping fuel.

Fig. 45: Sealing Off Fuel Lines Using Special Tools (13 5 160 And 13 5 162)

Removing high-pressure fuel line from injector to rail

NOTE: The following description applies to all pressure lines.

First release pressure line on rail to reduce existing fuel pressure if necessary.

Fuel must not get into the spark plug slot. Then release pressure line on injector.

Release union nuts (1).

Disconnect pressure line (2).

Set down pressure lines in order.

Fig. 46: Identifying Pressure Lines With Mounting Nuts

Secure injector against twisting with wrench (2).

Release union nut (1).

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

Mark pressure lines.

Fig. 47: Releasing Union Nut Using Wrench

Installation:

Only if injector has to be rotated in fitted position

• Release bolt a few turns until holding-down element (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 wrench on hexagon head of injector if necessary.
• Tighten union nuts on pressure line hand-tight.

Fig. 48: Turning Injector

IMPORTANT: Do not under any circumstances pull injector out of bore! 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.

Adhere to tightening sequence:

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

Tighten high-pressure fuel lines with special tool 13 0 160.

Tighten high-pressure fuel line on injector with torque wrench (2) and special tool (1) 13 0 161. In so doing, grip hexagon head of injector with wrench (3).

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

Tightening torque 13 53 2AZ.

Fig. 49: Tightening High-Pressure Fuel Line On Injector Using Torque Wrench And Special Tool (13 0 161)

On cylinders 4 and 8 tighten down pressure line (1) to torque (2) and with crowfoot wrench (3). In so doing, grip hexagon head of injector with wrench.

Tightening torque 13 53 2AZ.

Fig. 50: Tightening Down Pressure Line Using Crowfoot Wrench

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: When tightening high-pressure line on rail, note that angle of rotation of special tool 13 0 161 is limited. Reposition special tool if necessary.

Distortion of torque possible!

Fig. 51: Tightening Pressure Line On Rail Using Torque Wrench And Special Tools (001440, 13 0 162 and 13 0 161)

Remove high-pressure line from high-pressure pump to rail.

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

Release union nuts (1).

Disconnect pressure line (2).

Fig. 52: Identifying High Pressure Line With Union Nuts

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. 53: Tightening High-Pressure Line On High-Pressure Pump Using Torque Wrench And Special Tool (00 1 440)

Installation: When tightening high-pressure line on rail, note that angle of rotation of special tool 13 0 140 is limited. Reposition special tool if necessary.

Fig. 54: Identifying Angle Of Rotation For Special Tool (13 0 140)

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. 55: Tightening High-Pressure Line On Rail Using Torque Wrench, Long Crowfoot Spanner And Special Tool (13 0 140)

Assemble engine.

Vent fuel system with BMW diagnosis system.

Check fuel system for leaks.

Check function of DME.

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