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M62 8-Cylinder Fuel Injectors Replacement
 
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Pelican Technical Article:

M62 8-Cylinder Fuel Injectors Replacement

Nick Czerula

Time:

2 hours2 hrs

Tab:

$300

Talent:

****

Tools:

Set of sockets, 8mm, 10mm, flathead screwdriver

Applicable Models:

BMW X5 (2000-06)

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

Late model BMW engines utilize electronic fuel injectors. Electronic fuel injectors allow greater control over fuel volume and emissions. However, these can fail the same way as the early injectors.

BMW E53 X5 models with an M62 8-cylinder engine utilize a fuel injector per cylinder. Over time 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. If you're removing fuel injectors 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. See our tech article on fuel pump testing for more information.

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. Never work on your vehicle if you feel the task is beyond your ability.

Disconnect the battery. See our tech article on battery replacing.

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

The fuel rail (red arrow) feeds eight individual injectors (green arrows).
Figure 1

The fuel rail (red arrow) feeds eight individual injectors (green arrows). This photo shows that the engine covers already have been removed.

Remove the wiper cowl seal (red arrow).
Figure 2

Remove the wiper cowl seal (red arrow). Start at the right side and peel it off the cowl.

Working at the cowl, rotate the plastic locks (red arrows) 90 degrees to unlock them.
Figure 3

Working at the cowl, rotate the plastic locks (red arrows) 90 degrees to unlock them.

Once unlocked, remove the cowl trim by sliding it forward and pulling it straight out.
Figure 4

Once unlocked, remove the cowl trim by sliding it forward and pulling it straight out.

At the sides of the cabin filter housing, slide the drain channel up (red arrow) and remove it.
Figure 5

At the sides of the cabin filter housing, slide the drain channel up (red arrow) and remove it. The left side is shown. Repeat this step for the right side.

Working at the sides of the cabin filter housing, remove the two 13mm nuts (red arrows).
Figure 6

Working at the sides of the cabin filter housing, remove the two 13mm nuts (red arrows).

Once the nuts are removed, slide the housing (red arrow) up and out of the mounting grooves to remove it.
Figure 7

Once the nuts are removed, slide the housing (red arrow) up and out of the mounting grooves to remove it.

Working at the fresh air intake, remove four plastic rivets (green arrows).
Figure 8

Working at the fresh air intake, remove the four plastic rivets (green arrows). Use a pair of pliers (inset) to remove the center rivet. Once all the center rivets have been removed, pull the duct up to detach it from the vehicle.

Then lift the duct up on the left side while detaching it from the duct (green arrow) on the right side.
Figure 9

Then lift the duct up on the left side while detaching it from the duct (green arrow) on the right side.

Next remove the fuel line.
Figure 10

Next remove the fuel line. Press the blue tab (red arrow) in and hold it, while you pull the line off the filter. The inset shows the line being removed with a rag to prevent spillage.

Next, you have to remove the secondary air solenoid and vacuum reservoir.
Figure 11

Next, you have to remove the secondary air solenoid and vacuum reservoir. Start by removing the 10mm fastener (yellow arrow). Then disconnect the electrical connector by pressing the release tab and pulling it straight off. Then follow the vacuum hose from the solenoid to the reservoir (green arrow) and disconnect it. Then remove the solenoid from the engine. Remove the 10mm fastener at the vacuum reservoir.

Unplug the camshaft shaft sensor electrical connector (green arrow) by pressing the release tab and pulling it straight out.
Figure 12

Unplug the camshaft shaft sensor electrical connector (green arrow) by pressing the release tab and pulling it straight out. Then disconnect the knock sensor (red arrow) electrical connector by pulling it straight out. Once the connectors are unplugged, remove the vacuum reservoir from the engine. Move to the right side of the engine and disconnect the knock and camshaft sensor electrical connectors.

When removing the vacuum reservoir, detach the hard plastic line from the holder (red arrow).
Figure 13

When removing the vacuum reservoir, detach the hard plastic line from the holder (red arrow). Then lift the reservoir (green arrow) up and pull off the mounting tab (yellow arrow).

Next, you have to disconnect the ignition coils and remove the wiring harness housing on each side of the engine.
Figure 14

Next, you have to disconnect the ignition coils and remove the wiring harness housing on each side of the engine. Start by removing the 10mm mounting nuts (green arrows). The front nuts have already been removed when the solenoid and vacuum reservoir were removed. Remove the remaining rear fasteners. Then remove the 10mm nut for the ignition coil ground (red arrow). Then disconnect each ignition coil (yellow arrows) by sliding the lock up and pulling the connector out of the coil. The left side is shown. Repeat this step for the right side.

The fuel injector harness is part of the housing and has to be removed next.
Figure 15

The fuel injector harness is part of the housing and has to be removed next. The harness is one solid plastic connector with individual connectors for each fuel injector. There are wire clips that hold the harness onto each fuel injector. You can disconnect each wire clip. Then pull the harness up off the fuel injectors. I like to use an alternative method. Use a small pry bar and lever between the harness (red arrows) and the fuel rail. When doing this, you have to use one swift action to disconnect the harness. Lever each connector off in the area of the red arrows. Be careful when using this method. If you lever at an angle or force an injector to move, you may damage a fuel injector. If a clip won't release, use a small pick to remove the wire retainer (inset). The left side is shown. Repeat these steps for the right side.

Move to the rear of the left side electrical housing.
Figure 16

Move to the rear of the left side electrical housing. Locate the battery cable and remove it from the mount (red arrow).

Confirm that the left side of the electrical housing can be lifted and is free from all connections.
Figure 17

Confirm that the left side of the electrical housing can be lifted and is free from all connections. Lift it up and move it to the right side of the engine. Let it rest near the front of the right side of the cylinder head.

Working at the engine cover mounting brackets (blue arrows), remove the four 10mm mounting nuts (red arrows).
Figure 18

Working at the engine cover mounting brackets (blue arrows), remove the four 10mm mounting nuts (red arrows). Then remove the bracket from the engine.

Move to the front of the engine.
Figure 19

Move to the front of the engine. Disconnect the vent line from the intake air duct. Squeeze the collar (red arrows) while you pull the line straight off the duct.

Feed the vent line (red arrow) out from under the fuel rail (green arrow) and lay it aside.
Figure 20

Feed the vent line (red arrow) out from under the fuel rail (green arrow) and lay it aside.

Working at the left valve cover, loosen the hose clamp (red arrow).
Figure 21

Working at the left valve cover, loosen the hose clamp (red arrow). Then remove the breather hose from the valve cover.

Working at the left cylinder head, remove the fuel line by pushing the release collar (red arrow) in toward the fuel line and hold it while pulling the fuel line in the direction of the green arrow.
Figure 22

Working at the left cylinder head, remove the fuel line by pushing the release collar (red arrow) in toward the fuel line and hold it while pulling the fuel line in the direction of the green arrow. Have a rag (yellow arrow) handy to wrap the line. This will help to prevent fuel spillage.

Next, remove the 10mm fastener (red arrow) at the front of the fuel rail.
Figure 23

Next, remove the 10mm fastener (red arrow) at the front of the fuel rail.

Then pull the fuel rail straight up and out of the intake manifold.
Figure 24

Then pull the fuel rail straight up and out of the intake manifold. Be careful not to damage a fuel injector when removing. If the O-rings are stuck, you can lightly lever the fuel rail up using a pry bar. I like to lever at the recessed intake runners on each side (red arrows). Spray lubricant around the O-rings and allow it to soak in. This will make removing much easier. If there is dirt in this area, remove it before spraying the lubricant. It is very important that you lever directly up and not at an angle. If you lever at an angle, the O-rings on the fuel injectors may stick inside the intake manifold.

Once free, lift the fuel rail up and remove it from the engine.
Figure 25

Once free, lift the fuel rail up and remove it from the engine.

To remove the individual fuel injectors, remove the retaining clip (reed arrow) by sliding it off the fuel rail using a flathead screwdriver.
Figure 26

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 in the direction of the green arrow. When reinstalling the fuel injectors, replace the sealing O-rings and be sure the retaining clips are properly seated on the fuel injector before attempting to install them. Press the fuel injectors into the fuel rail until the retaining clip snaps into place. Then press the fuel rail with the injectors into the intake manifold until fully seated. Then install the fuel rail fasteners and tighten. Reassemble the remaining items and check that there are no fuel leaks.

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Comments and Suggestions:
consonaut Comments: Very good description, many thanks. Easy to follow up and a good DIY guide :-
August 9, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 

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Page last updated: Sat 12/3/2016 02:48:32 AM