Parts Catalog Accessories Catalog Tech Info Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
M54 6 Cylinder Engine Fuel Injectors Replacement
 
Bookmark and Share

Pelican Technical Article:

M54 6 Cylinder Engine Fuel Injectors Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$300

Talent:

****

Tools:

Set of sockets, 10mm, flathead screwdriver

Applicable Models:

BMW 525i/xi Sedan (2004-06)
BMW 530i/xi Sedan (2004-06)
BMW 530xi Wagon (2006)

Parts Required:

Fuel injectors, fuel injector O-rings

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 with a M54 6-cylinder engine 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. The ECM supplies constant power to the injectors; the injector opening is controlled by the groundside of the circuit. Since fuel pressure at the injectors is (relatively) constant, the length of time (in milliseconds) of a 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. This way you maintain an even flow from all the injectors.

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 injectors attached to it. Individual injectors are then separated from the fuel rail, as needed. If you remove the fuel injectors for any reason (for example, to replace the intake manifold) and you plan to reuse the fuel injectors, replace all the fuel injector sealing O-rings.

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 pump fuse and run the vehicle until the engine stalls. This is described below.

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.

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

Remove fuse F72 in the engine electrical box (check that this fuse applies to your vehicle).
Figure 1

Remove fuse F72 in the engine electrical box (check that this fuse applies to your vehicle). Start and run the engine until it stalls. Once the engine stalls, attempt to start it again. If it does not start, the fuel system pressure has been relieved. Keep in mind, this does not remove all the fuel from the fuel lines, only the pressure. So you still need to be prepared to catch leaking fuel when the fuel lines are disconnected. Disconnect the negative (-) battery cable. See our tech article on battery connection notes. Working at the fuel rail, remove the fuel test port cap (green arrow). Then place a rag over the Schrader valve and open the valve with a flathead screwdriver (yellow arrow) to relieve any remaining pressure.

Working at the top of the intake manifold, locate the oxygen sensor connectors.
Figure 2

Working at the top of the intake manifold, locate the oxygen sensor connectors. Slide (green arrows) both connectors out of the mounting bracket and lay them aside. Then lift the other two oxygen sensor connectors (yellow arrows) up and out of the mounting brackets and lay the harness aside.

Working at the fuel rail, remove the oxygen sensor connector mounts (green arrows) by squeezing and pulling them toward the left side of the engine.
Figure 3

Working at the fuel rail, remove the oxygen sensor connector mounts (green arrows) by squeezing and pulling them toward the left side of the engine.

In this step I am removing the plastic mount for the front oxygen sensor connectors.
Figure 4

In this step I am removing the plastic mount for the front oxygen sensor connectors. You can skip this and leave it on if you are only replacing the injectors. If you are replacing the fuel rail, you will have to remove them and swap this over. Using a flathead screwdriver (yellow arrow) unclip the retaining tabs (green arrows) to remove the plastic mount.

Working at the front of the intake manifold, squeeze the crankcase vent hose (green arrow) release tabs and pull them off the intake manifold.
Figure 5

Working at the front of the intake manifold, squeeze the crankcase vent hose (green arrow) release tabs and pull them off the intake manifold.

Then, rotate the hose toward the wiper cowl to move it out of the way.
Figure 6

Then, rotate the hose toward the wiper cowl to move it out of the way.

Working at the intake VANOS solenoid, disconnect the VANOS solenoid electrical connector by releasing the wire (green arrow) and pulling it off.
Figure 7

Working at the intake VANOS solenoid, disconnect the VANOS solenoid electrical connector by releasing the wire (green arrow) and pulling it off.

Then release the fuel injector harness strip from the fuel injectors and remove it.
Figure 8

Then release the fuel injector harness strip from the fuel injectors and remove it. I find the easiest way to do this is to use a 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. If stuck, try a swift prying action to detach the connector.

Work your way down the injectors while disconnecting the injector harness.
Figure 9

Work your way down the injectors while disconnecting the injector harness. Lay the fuel injector harness aside.

Next, remove the four 10mm fuel rail fasteners (green arrows).
Figure 10

Next, remove the four 10mm fuel rail fasteners (green arrows).

Working at the left strut tower, disconnect the fuel line.
Figure 11

Working at the left strut tower, disconnect the fuel line. Remove the gray safety collar (green arrow) by pulling it straight off the line. Then press and hold the release collar (blue arrow) while pulling it apart. Have a rag handy to catch any dripping fuel. Follow the fuel line behind the intake manifold, near the firewall. You can see the line, but will have to do this part mostly by feel. Reach behind the intake manifold. Repeat these steps used to disconnect the line near the strut tower.

Then pull the fuel rail straight up and out of the intake manifold.
Figure 12

Then pull the fuel rail straight up and out of the intake manifold. Be careful not to damage a fuel injector when removing it. If the O-rings are stuck, you can lightly lever (green arrow) the fuel rail up using a flathead screwdriver. I like to lever between the edge of the valve cover and the fuel rail. Spray lubricant around the O-rings (inset). This will make removing them much easier. If there is dirt in this area, remove it before spraying the lubricant.

When removing the fuel rail, feed the inlet (green arrow) out of the rear of the intake manifold.
Figure 13

When removing the fuel rail, feed the inlet (green arrow) out of the rear of the intake manifold. Note the routing through the wiring harness for reinstalling.

To remove the individual fuel injectors, remove the retaining clip (green arrows) by sliding it off the fuel rail using a flathead screwdriver.
Figure 14

To remove the individual fuel injectors, remove the retaining clip (green arrows) by sliding it off the fuel rail using a flathead screwdriver. Then pull the fuel injector straight out of the fuel rail in the direction of the yellow arrow. When reinstalling the fuel injectors, replace the sealing O-rings and be sure that the retaining clips are properly seated. Press the fuel rail with the injectors into the intake manifold until the fuel rail is fully seated. Then install the fuel rail fasteners and tighten them. Reassemble the remaining items and check that there are no fuel leaks.


Bookmark and Share
Comments and Suggestions:
rajr222 Comments: thank you for helping me with my car problems, thank you! It is so mucheasier to fix my car with your help.
November 15, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
DASH Comments: My car is idling good and I keep getting misfire code to have to replace the spark plugs, and all the coil and also replaced the air flow meter but the car is popping when I give the car gas. Do you have any idea what this McKinley if so please let me know when I'm on the parts from you'll
February 11, 2015
  Followup from the Pelican Staff: A misfire can be caused by many things. I would check spark, fuel and compression on all cylinders. - Nick at Pelican Parts  

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Privacy Statement]
 [Contact Us] [About Us] [Shipping] [Map to our Location] [Careers]

Copyright © Pelican Parts Inc.

Page last updated: Sat 12/3/2016 02:24:48 AM