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BMW E39 Fuel Injector Removal
 
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Pelican Technical Article:

BMW E39 Fuel Injector Removal

Kerry Jonsson

Time:

4 hours4 hrs

Tab:

$400

Talent:

*****

Tools:

10mm socket with ratchet, small thin pick

Applicable Models:

BMW 525i Sedan/Wagon (2001-03)
BMW 528i Sedan/Wagon (1997-00)
BMW 530i Sedan (2001-03)
BMW 540i Sedan/Wagon (1997-03)

Parts Required:

Fuel rail, fuel injectors

Hot Tip:

Use a rag to cover the fuel line when you disconnect them

Performance Gain:

Replace clogged or leaking injectors,

Complementary Modification:

Replace all injector O-rings

The fuel tank stores the fuel for the car. The fuel pump supplies pressurized fuel to the fuel rail. The fuel rail distributes the fuel to the individual fuel injectors. The DME control unit opens the injectors to feed fuel to the engine. If and injector fails or becomes clogged that cylinder will not fire properly. This will lead to a misfire. Your check engine light will flash to let the driver know the engine is misfiring. This will cause your engine to run rough and you will lose power. The sophisticated electronics of the DME control unit will identify the cylinder that is misfiring and stop firing that injector. Many components can cause a misfire and the injector is one of them. In this tech article we will go over replacing your injectors.

Fuel Rail Removal Six Cylinder:
On the top of the fuel rail cover use a pick to remove the mounting bolt covers (green arrows).
Figure 1

On the top of the fuel rail cover use a pick to remove the mounting bolt covers (green arrows).

Remove the two 10mm fasteners (green arrows) that hold down the fuel rail cover.
Figure 2

Remove the two 10mm fasteners (green arrows) that hold down the fuel rail cover.

Pull up on the O2 sensor connectors to release them from their hold down clips and move out of the way.
Figure 3

Pull up on the O2 sensor connectors to release them from their hold down clips and move out of the way.

Remove the two 10mm fasteners (green arrows) that mount the fuel rail to the intake manifold.
Figure 4

Remove the two 10mm fasteners (green arrows) that mount the fuel rail to the intake manifold.

At the front of the fuel rail unplug the electrical connector by pushing the retaining clip (green arrow) in and pushing the connector down in the direction of the blue arrow.
Figure 5

At the front of the fuel rail unplug the electrical connector by pushing the retaining clip (green arrow) in and pushing the connector down in the direction of the blue arrow.

In between the number one and two cylinder intake runner push in the retaining clip (green arrow) on the solenoid and pull up on the electrical connector.
Figure 6

In between the number one and two cylinder intake runner push in the retaining clip (green arrow) on the solenoid and pull up on the electrical connector.

Pull up on the injector connector housing to start unplugging each injector.
Figure 7

Pull up on the injector connector housing to start unplugging each injector. You may have to gently lever at each connector using a flathead screwdriver, be careful not to damage the fuel injector when removing the electrical connectors.

Move the injector connector housing out of the way.
Figure 8

Move the injector connector housing out of the way.

Lift up the fuel rail to expose the fuel line connections at the back of the rail.
Figure 9

Lift up the fuel rail to expose the fuel line connections at the back of the rail. Mark the lines so you know which one goes where during installation. Push the black plastic retaining clips (green arrows) in the direction of the blue arrow. The fuel lines (red arrows) will also disconnect from the fuel rail in the direction of the blue arrows). Wrap this area with a rag to absorb any fuel that leaks out.

Remove the fuel pressure regulator vacuum line by twisting it and then pulling it off of the rail.
Figure 10

Remove the fuel pressure regulator vacuum line by twisting it and then pulling it off of the rail. You can now remove the fuel rail from the car. Make sure to plug the open injector ports with a clean shop rag or towel. Installation is the reverse of the removal procedure. Fit the vacuum line to the fuel pressure regulator and the fuel lines just snap on to the fuel rail. Position the fuel rail in the intake manifold and bolt it down. Plug in the solenoid connection in between the number one and number two cylinder runners and fit the injector connector housing to the top of the injectors and plug them in. Install the oxygen sensor connectors and bolt down the fuel rail cover. Cycle the ignition key several times to pressurize the fuel system and check for leaks before you start the engine.

Fuel Rail Removal Eight Cylinder: Remove the engine covers to access the top of the engine. Also the coil covers need to be removed as well. See our tech articles on removing the engine covers.
Remove the four 10mm fasteners (green arrows) that hold down both the fuel rail and engine cover mounting brackets.
Figure 11

Remove the four 10mm fasteners (green arrows) that hold down both the fuel rail and engine cover mounting brackets.

Unplug the knock sensor connector on the left side of the injector connector housing.
Figure 12

Unplug the knock sensor connector on the left side of the injector connector housing.

Unplug the knock sensor connector on the right side of the injector connector housing.
Figure 13

Unplug the knock sensor connector on the right side of the injector connector housing.

Unplug the additional electrical connector on the front of the right side wiring injector connector housing by squeezing the electrical connector retaining clip and pulling the connector off the housing.
Figure 14

Unplug the additional electrical connector on the front of the right side wiring injector connector housing by squeezing the electrical connector retaining clip and pulling the connector off the housing.

Loosen the two 10mm fasteners (green arrows) that hold the left side injector connector housing to the intake manifold.
Figure 15

Loosen the two 10mm fasteners (green arrows) that hold the left side injector connector housing to the intake manifold. You do not have to remove them just loosen them.

Loosen the two 10mm fasteners (green arrows) that hold the right side injector connector housing to the intake manifold.
Figure 16

Loosen the two 10mm fasteners (green arrows) that hold the right side injector connector housing to the intake manifold. You do not have to remove them just loosen them.

Pull out the coil retaining clip on each coil connection on both sides of the engine.
Figure 17

Pull out the coil retaining clip on each coil connection on both sides of the engine.

Pull up on each coil connection to unplug each coil on both sides of the engine.
Figure 18

Pull up on each coil connection to unplug each coil on both sides of the engine.

Unplug the last injector connector on the left side by pushing on the retaining clip (green arrow) and pulling up on the connector.
Figure 19

Unplug the last injector connector on the left side by pushing on the retaining clip (green arrow) and pulling up on the connector.

Lift up on the left side injector connector housing to unplug the rest the injectors on the left side.
Figure 20

Lift up on the left side injector connector housing to unplug the rest the injectors on the left side.

Lift up on the right side injector connector housing to unplug all the injectors on the right side.
Figure 21

Lift up on the right side injector connector housing to unplug all the injectors on the right side.

At the back on the left side of the fuel rail push in the black plastic clip in the direction of the blue arrow and the fuel line will release from the fuel rail.
Figure 22

At the back on the left side of the fuel rail push in the black plastic clip in the direction of the blue arrow and the fuel line will release from the fuel rail.

At the back on the right side of the fuel rail remove the fuel pressure regulator vacuum line (green arrow) by twisting it first then pulling it off the regulator port.
Figure 23

At the back on the right side of the fuel rail remove the fuel pressure regulator vacuum line (green arrow) by twisting it first then pulling it off the regulator port.

Lift up on the fuel rail by pulling up on it in the direction of the blue arrow.
Figure 24

Lift up on the fuel rail by pulling up on it in the direction of the blue arrow. Spray carb spray down at the base of each injection to act as a lubricant and allow the O-rings to slide out easier. Make sure to plug the open injector ports with a clean shop rag or towel. Installation is the reverse of the removal steps. Fit the rail and injectors into the openings on the intake manifold Attach the fuel lines by snapping them in place and attach the fuel pressure regulator hose. Fit the injector connectors housing covers and plug in the final injector on the driver side. Bolt down the housing down to the bracket and plug in the connector on the front of the passenger side injector housing and plug in the knock sensor connectors back into the housings. Plug in the coil connections and cycle the ignition key on several time to pressurize the fuel system and check for leaks before starting the engine.

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Page last updated: Fri 12/2/2016 02:04:35 AM