BMW 7 Series: Start Valves

Removing And Installing/Replacing An Injector (N63)

Notes

WARNING: Observe warning on cylinder head cover.

There is a risk of injury if the fuel pressure is not reduced!

IMPORTANT: Observe without fail the tightening sequences and tightening torques when reassembling.

Disregard of these requirements 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 pipes or individual components.
• Use only fluff-free cloths.
• Seal all fuel system openings with protective caps or plugs.
• High-pressure lines may be rescrewed a maximum of 10 times.

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

Necessary preliminary tasks

• Remove IGNITION COIL of corresponding cylinder

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.
• Remove PRESSURE LINES on corresponding injectors

NOTE: The following description applies to all injectors.

Release bolt (1) and remove holding-down element (2).

Fig. 102: Identifying Injector Holding Down Element With Mounting Bolt

Remove injector (1).

Fig. 103: Removing Injector

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

Mark injectors.

After removing, fit protective caps (1 and 3) to injector tip and fuel line connection.

Protective caps are available from BMW Parts Service.

Fig. 104: Identifying Fit Protective Caps With Uncoupling Element

Installation: When installing a new injector:

• Use a new uncoupling element (2).
• Remove protective cap (1) from injector tip max. 10 min. before installation (PTFE sealing ring swells up).

Fig. 105: Identifying Fit Protective Caps With Uncoupling Element

Installation:

When reusing fuel injector:

• Replace uncoupling element (2).
• Replace PTFE sealing ring (1).

A PTFE seal which has been heated once by engine operation must be replaced before the fuel injector is reinstalled.

Fig. 106: Identifying PTFE Sealing Ring And Uncoupling Element

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).

Fig. 107: Identifying PTFE Sealing Ring And Injector Tip

Remove PTFE sealing ring (1) with special tool 13 0 191 from injector (2).

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.

Fig. 108: Removing PTFE Sealing Ring From Injector Using Special Tool (13 0 191)

Slide new PTFE sealing ring (1) onto mounting taper 13 0 195.

Fig. 109: Identifying PTFE Sealing Ring Onto Mounting Taper 13 0 195

Use fingers and mounting taper 13 0 195 to slide PTFE sealing ring (1) onto injector (2).

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.

Fig. 110: Sliding PTFE Sealing Ring Onto Injector Using Mounting Taper (13 0 195)

To bring the expanded PTFE sealing ring to its installation dimension, slide three mounting sleeves with decreasing diameters onto the injector.

Slide mounting sleeve (1) with large opening first onto injector (1).

Do not use any lubricating agents.

Fig. 111: Sliding Mounting Sleeve Onto Injector

First slide mounting sleeve 13 0 192 (large diameter) onto injector (1).

Then slide mounting sleeve 13 0 193 (medium diameter) onto injector (1).

Fig. 112: Sliding Mounting Sleeve 13 0 192 (Large Diameter) Onto Injector

Finally, press injector (1) into mounting sleeve 13 0 194 (small diameter).

Installation: Install injector within 10 minutes or slide on protective cap (Fig. 105) (PTFE sealing ring swells up).

Fig. 113: Identifying Injector Into Mounting Sleeve 13 0 194 (Small Diameter)

Installing injector

Installation of injector is described separately from removal.

Before installing injector in engines that have been run

• Check injector bore for dirt.

  Clean only dirty injector bores.

  Important - do not damage injector!

• Clean injector bore: To do so, preferably slide injector without uncoupling element (2) but with new PTFE sealing ring (1) in and out of injector bores several times.

  The PTFE sealing ring must then be replaced.

• Clean contact surfaces of uncoupling elements (2) in cylinder head.
• Replace uncoupling element (2).

Fig. 114: Identifying PTFE Sealing Ring And Uncoupling Element

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 in two blocks of three digits on the injector.

The adjustment value must be read off before installation!

Fig. 115: Identifying Adjustment Value Printed In Blocks Of Digits On Injector

Enter the adjustment value according to the installation position (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 instruction.

Fig. 116: Identifying Adjustment Value On Cylinder

Installing injector

Install injector (1).

Install holding-down element (2).

NOTE: Make sure holding-down element (2) is correctly seated.

IMPORTANT: Tighten bolt (3) hand-tight only so that holding-down element (2) is slack and if necessary injector (1) can still be turned.

Fig. 117: Identifying Injector With Holding Down Element And Mounting Bolt

Connect pressure line (2), tightening nuts (1) handtight only in the process.

IMPORTANT: 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 to be screwed on easily by hand! If the nuts cannot be screwed on easily by hand, the injector must if necessary be turned a little.

Fig. 118: Identifying Pressure Lines With Mounting Nuts

Turn injector (1) if necessary in direction of arrow until nuts on pressure line can be easily screwed on by hand.

Tighten nut (2) of pressure line hand-tight.

Then tighten down bolt for holding-down element (3).

Tightening torque 13 53 5AZ.

Fig. 119: Turning Injector

Adhere to tightening sequence:

• First tighten down pressure line on injector.

Tighten down nut on injector with special tool (1) 13 0 161 and to torque (2). In so doing, grip hexagon head of injector with wrench (3).

Tightening torque 13 53 2AZ.

Fig. 120: Tightening Nut On Injector Using 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. 121: Tightening Pressure Line Using Crowfoot Wrench

• Then tighten down pressure line on rail.

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.

Fig. 122: Tightening Down Pressure Line On Rail With Torque Wrench And Special Tool (00 1 440)

Carrying out injector adjustment

• Connect DIS Tester
• Identify car
• Select "Function selection"
• Select "Service functions"
• Select "Engine electronics"
• Select "Adjustment programs"
• Select "Adjust injectors"
• Change "Test schedule"
• For each replaced injector, the adjustment value must be entered according to the installation position (cylinder).

Fig. 123: Identifying Adjustment Value Printed In Blocks Of Digits On Injector

Assemble engine.

Vent fuel system with BMW diagnosis system.

Check fuel system for leaks.

Check function of DME.

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