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NG6 Engine Fuel Injectors Replacement
 
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Pelican Technical Article:

NG6 Engine Fuel Injectors Replacement

Nick Czerula

Time:

2.5 hours

Tab:

$400

Talent:

*****

Tools:

Set of sockets (10mm), flathead screwdriver, clean rags

Applicable Models:

BMW 525i Sedan (2006-07)
BMW 528i/xi Sedan (2008-10)
BMW 530i Sedan (2006-07)
BMW 530xi Sedan/Wagon (2006-07)
BMW 535i/xi Sedan (2008-10)
BMW 535xi Wagon (2008)

Parts Required:

Fuel injectors, fuel injector O-rings, fuel injector Teflon seals, steel fuel lines

Hot Tip:

Work with a cool engine and relieve fuel system pressure

Performance Gain:

Clean and even flowing fuel injectors

Complementary Modification:

Replace with performance injectors

BMW E60 models equipped with the NG6 6-cylinder engine (starting with 2006 models) utilize one fuel injector per cylinder. Each fuel injector is an electrically controlled solenoid which, when triggered by a pulse from the engine control module, sprays a precisely metered amount of atomized fuel directly into the cylinder head intake port or combustion chamber. The ECM supplies constant power to the injectors. The injector opening is controlled by the ground side of the circuit. Since fuel pressure at the injectors is (relatively) constant, the length of time (in milliseconds) of the grounding pulse from the ECM determines the amount of fuel injected.

Over time fuel injectors can become restricted or fail electrically. If you have an injector giving you a problem, I suggest replacing them in sets of six. This way you maintain an even flow from all the injectors. If you are removing fuel injectors to replace the intake manifold and you plan to reuse the fuel injectors, replace all the fuel injector sealing O-rings.

Normally aspirated E60 engines utilize standard style fuel injectors that mount in the intake manifold runner and spray fuel on the backside of the intake valves. The injectors' shared fuel supply is a steel fuel rail. To remove an injector, you have to disconnect the electrical connectors to all the injectors. Then remove the fuel rail with all the injectors attached to it. The individual injectors are then separated from the fuel rail, as needed.

Turbocharged E60 engines utilize a direct injection style injector. This style injector sprays fuel directly into the cylinder and is mounted in the center of the cylinder head between the camshafts. These require a few steps and special tools to replace that you may not be familiar with. Be sure to read through the entire procedure before beginning.

In this tech article, I will describe how to replace each style of fuel injector.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Disconnect the negative (-) battery cable. See our tech article on Battery Connection Notes.

Remove the engine covers. See our tech article on removing the engine covers.

Normally aspirated engine:
Normally aspirated engine: It's a good idea to relieve fuel system pressure before beginning.
Figure 1

Normally aspirated engine: It's a good idea to relieve fuel system pressure before beginning. This will minimize the amount of fuel spilled. The best way to relieve fuel system pressure is to remove the fuel pressure test port cap (red arrow) and press the Schrader valve to drain the fuel rail.

Normally aspirated engine: Remove the fuel rail pressure testing cap.
Figure 2

Normally aspirated engine: Remove the fuel rail pressure testing cap. Then place a rag under the port. Use a small flathead screwdriver and press the Schrader valve to relieve fuel pressure. When you press it, have the rag wrapped around your screwdriver to minimize fuel spillage.

Normally aspirated engine: Working at the center of the fuel rail, you will have to remove the fuel supply line (red arrow).
Figure 3

Normally aspirated engine: Working at the center of the fuel rail, you will have to remove the fuel supply line (red arrow).

Normally aspirated engine: To release it, press the plastic collar (green arrow) toward the fuel line.
Figure 4

Normally aspirated engine: To release it, press the plastic collar (green arrow) toward the fuel line. Then slide the fuel line off the fuel rail. If the collar will not press in far enough to release the fuel line, pull the fuel line toward the front of the vehicle and hold it there. Then press and hold the collar while you slide the fuel line off the fuel rail. I like to place the disconnected fuel line on the valve cover, wrapped in a rag. This will help to collect any excess fuel in the line and also keep dirt from entering the fuel line.

Normally aspirated engine: Then release the fuel injector harness strip from the fuel injectors.
Figure 5

Normally aspirated engine: Then release the fuel injector harness strip from the fuel injectors. I find the easiest way to do this is to use a large flathead screwdriver and gently pry up at each fuel injector (green arrows). This will release the spring clips that hold the electrical harness to the fuel injectors. When you do this, be sure to lever straight up and be sure the flathead is next to the fuel injector connector you are releasing. Work your way down the injector electrical harness and disconnect each fuel injector.

Normally aspirated engine: Next, remove the four 10mm fuel rail fasteners (green arrows).
Figure 6

Normally aspirated engine: Next, remove the four 10mm fuel rail fasteners (green arrows). Then pull the fuel rail straight up and out of the cylinder head. Be careful not to damage a fuel injector when removing it. If the O-rings are stuck, you can lightly pry the fuel rail up using a flathead screwdriver. I like to pry between the edge of the intake manifold and the fuel rail.

Normally aspirated engine: To remove the individual fuel injectors, remove the retaining clip (red arrow) by sliding it off the fuel rail using a flathead screwdriver.
Figure 7

Normally aspirated engine: To remove the individual fuel injectors, remove the retaining clip (red arrow) by sliding it off the fuel rail using a flathead screwdriver. Then pull the fuel injector straight out of the fuel rail. When pulling the fuel rail up and out of the cylinder head, be careful not to damage any of the fuel injectors. If the injectors won't budge, use silicone spray to lubricate the injector holes. Doing this should help them slide out.

Normally aspirated engine: Before reinstalling the fuel injectors, replace the sealing O-rings (green arrows).
Figure 8

Normally aspirated engine: Before reinstalling the fuel injectors, replace the sealing O-rings (green arrows).

Normally aspirated engine: Before reinstalling the fuel injectors, lubricate the sealing O-rings.
Figure 9

Normally aspirated engine: Before reinstalling the fuel injectors, lubricate the sealing O-rings. I like to use silicone grease (red arrow) that is safe for use on rubber. This helps the injectors slide into the cylinder head with ease.

Normally aspirated engine: Evenly press the fuel rail with the injectors into the cylinder head.
Figure 10

Normally aspirated engine: Evenly press the fuel rail with the injectors into the cylinder head. Be sure that all of the injectors are properly seated. You can confirm this by checking if the mounting tabs (green arrows) are sitting flat on the cylinder head. Install the fuel rail fasteners and tighten. Then install the fuel injector retaining clips. Be sure that the fuel injector retaining clips are fully engaged. They should sit in the groove in the fuel injector and snap onto the fuel rail. Reassemble the remaining items and check that there are no fuel leaks.

Turbocharged engines: 
Turbocharged engines: I am going to show how to replace one fuel injector.
Figure 11

Turbocharged engines: I am going to show how to replace one fuel injector. You can use this procedure for replacing any or all of the injectors on a turbocharged engine. Start by disconnecting the fuel injector electrical connector (yellow arrow). Press the release tab and pull the connector straight off. Next, you have to remove the steel fuel line for the injector. First, tap on the line lightly about 20 times to relieve pressure in the line. Then loosen the fuel line connections (green arrows). Then remove the fuel line from the engine. Once this fuel line is removed it cannot be reinstalled. So throw it away immediately.

Turbocharged engines: Working at the base of the fuel injector, remove the E10 fastener (green arrow) from the retainer.
Figure 12

Turbocharged engines: Working at the base of the fuel injector, remove the E10 fastener (green arrow) from the retainer. Then remove the retainer from the fuel injector (yellow arrow). Slide the retainer out of the fuel injectors to remove it. Once the retainer is removed, remove the fuel injector from the engine. To do this, slide the injector straight up and out of the cylinder head. Note: One retainer holds two injectors. If you are reinstalling this fuel injector, be sure to mark the location that it came out of. When replacing injectors on turbocharged engines, I like to use the old injector to clean the injector bore. I slide the injector in and out of the bore a bunch of times to clean the debris from the hole.

Turbocharged engines: Before installing the new injector, note the numbers on the side.
Figure 13

Turbocharged engines: Before installing the new injector, note the numbers on the side. These numbers will need to be entered into the DME using a BMW scan tool.

Turbocharged engines: When installing a new injector, the Teflon seals will come preinstalled and covered with a protective metal cover (green arrow).
Figure 14

Turbocharged engines: When installing a new injector, the Teflon seals will come preinstalled and covered with a protective metal cover (green arrow). Leave this cover on until you are ready to install the injector. Remove the cover and slide the injector into the cylinder head. Install the retainer and retainer fastener. Then install the new fuel line to the injector. When installing the new fuel line, slowly tighten each end until it's snug and then tighten it. This will seat the fuel line. Reassemble the remaining items in the reverse order of the disassembly steps. When done, the fuel injector numbers you wrote down earlier will have to be entered into the DME. If you do not have a BMW scan tool that is capable of this, you can drive the vehicle to a workshop that can program it for you. There may be a slight decrease in drivability until it is programmed, so do not drive it any further than you have to.






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Comments and Suggestions:
Jlforsyth Comments: Fig. 11 a steel fuel lines can be reused
Fig. 13 numbers on side of each injector are for calibration due to manufacturing variations. Calibration codes must be entered for each injector in its respective cylinder so that each delivers the same amount of fuel. The ECU will use the calibration vide to vary the injection pulse width to each injector to accomplish this.
Fig 14 - each new or reinstalled injector must be fitted with a new decoupling element. If reinstalling used injectors, they must be fitted with new Teflon seals. These seals must be compressed in 3 stages using a special tool and the injector must be installed shortly after seal compression before the seal swells to uncompressed dimension. These injectors will slide in with a small amount of force. If this doesn't happen, seals are probably not properly compressed. The seal compression tool is available from manufacturers such as Assenmacher. Their tool also includes a cone that allows the new seals to be slid onto the injector where they sit in a groove similar to an o-ring and a miniature slide hammer that facilitates injector removal.
February 10, 2016
  Followup from the Pelican Staff: Fig 11: No they can not. They are single use lines, as noted by BMW. The flare is single use and can leak or fail if reused.

Fig 13: as noted in step 14.

Fig 14: This depends on the injector type, the decoupling element will come in the parts kit and has to be replaced.

Thanks for the additional info and feedback. We appreciate it.
- Nick at Pelican Parts
 

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Page last updated: Fri 12/9/2016 02:43:03 AM