Fuel System - Repair Instructions (m54) BMW X3 E83

13 00 002 Checking function of Digital Engine Electronics (DME)

Diagnostic connector in engine compartment

Connect up MoDiC or BMW DIS.

Interrogate DME fault memory.

Note down fault messages stored in memory.

Further information on troubleshooting in line with DIS or MoDiC instructions.

Scheme 13

OBD socket (1) in driver's footwell

Same procedure as above.

Scheme 14

13 31 ... Notes on fuel pressure check (reference pressure: environment)

Feature of this version with ambient pressure

The connection for the vacuum hose of the fuel pressure regulator is located between the throttle and the air cleaner or on the air cleaner.

Test precondition

The correct fuel pressure regulator is fitted.

1. Using the EPC, check whether the fuel pressure regulator suitable for the car is fitted
2. Connect test adapter. Refer to «CHECKING FUEL PUMP DELIVERY PRESSURE (M54)»(/bmw/x3/e83-2003-2006/remont/fuel-system/#fuel-system-repair-instructions-m54__13-31-029-checking-fuel-pump) .

Description of operation

The control function of the fuel pressure regulator must be guaranteed under all operating conditions. The fuel pump must always be able to generate a higher fuel pressure than the pressure regulated by the pressure regulator.

The injection rate is adjusted by means of the injection time; the injection time is controlled by the DME.

Description of operation: fuel return line

When the engine is at a standstill and the ignition key is in position 0, the fuel return line after the pressure regulator is at zero pressure. Description of operation: pressure retaining function

The pressure regulator closes when the engine is at a standstill and the ignition key is in position 0. The fuel pressure in the delivery line is retained over an extended period. A non-return valve closes in the fuel pump. These measures help to retain the fuel pressure in the fuel system. Extended starting times are thus avoided.

Complaint: drive characteristic faults, lack of power

1. Run engine at idle speed and measure fuel pressure.

If the measured value is less than the nominal value - 0.2 bar

1. Line cross-sections in fuel feed are constricted or fuel filter is clogged, or
2. Fuel pump voltage supply is not O.K.: e.g. as a result of high contact resistance (corrosion) in plug connection between wiring harness and fuel pump.

If the measured value is greater than the nominal value + 0.2 bar

1. Turn off engine stop and then observe measured value.
2. If measured value drops to nominal value, then line cross-sections in fuel return are constricted or clogged.
3. Check the fuel lines for kinks. If no kinks are visible: Replace return lines

If measured value remains too high, then pressure regulator is in all probability faulty.

Complaint: starting problems

1. Run engine briefly at idle speed and switch off.
2. Note down measured value while engine is stopped.
3. Read off measured value again after approx. 20 to 30 minutes while engine is stopped.

Special tool 13 3 010 (hose clamp) is required for the following test.

If the measured value has dropped by more than 0.5 bar

1. Start engine and wait briefly for a stable pressure increase.
2. Switch off the engine and immediately pinch off the delivery line just before the pressure gauge with the special tool 13 3 010.
3. Note down measured value
4. Read off measured value again after approx. 20 to 30 minutes while engine is stopped

If the measured value has now dropped by less than 0.5 bar, the following faults can be present

1. Fault in delivery lines
2. Fault in in-tank delivery hose
3. Faulty pressure-holding non-return valve in fuel pump

Check components. Replace faulty components.

If the measured value has dropped by more than 0.5 bar again

1. Replace pressure regulator

Note. All the fuel hoses and hose clips which were detached within the framework of the checks must be replaced. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Now clear the fault memory.

13 31 029 Checking fuel pump delivery pressure (M54)

Special tools required

1. 13 3 010
2. 13 5 220
3. 61 3 050

Switch off ignition.

Remove cover from fuel injectors.

Remove dust cap (1) from measuring valve on fuel rail.

Scheme 15

Prepare special took kit 13 5 220 (consisting of 13 5 221 and 13 5 222).

Scheme 16

Unscrew check valve (1) on special tool kit 13 5 220.

Scheme 17

Fit special tool kit 13 5 220 on measuring valve and tighten knurled nut until hand-tight.

Start engine.

Screw in check valve (1) until a pressure reading is indicated on DIS Tester.

Measuring fuel pressure

1. Connect pressure sensor to DIS Tester
2. Start engine.
3. Select Measurement.
4. Multimeter function appears
5. Select Pressure test
6. Read off fuel pressure

Compare actual value of test pressure with specified value. Refer to FUEL SYSTEM - TECHNICAL DATA .

Switch off engine.

Checking fuel pump

Detach fuel pump relay.

Note. Check whether fuel pump no longer starts up during engine starting procedure (engine fails to start).

Connect special tool 61 3 050 to terminal (87) and terminal (30). Press button and read off fuel pump delivery pressure on DIS Tester.

Scheme 18

Compare actual value with specified value of delivery pressure.

Keep special tool 13 3 010 ready for further tests.

Scheme 19

Further tests are described in the section "Fuel pressure check". Refer to NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: ENVIRONMENT) .

Note. Interrogate fault memory of DME control unit.

Check stored fault messages.

Rectify faults.

Then clear fault memory.

13 32 051 Replacing fuel filter (M62, M54)

Special tools required

1. «13 3 010»(/bmw/x3/e83-2003-2006/remont/fuel-system/#fuel-system-special-tools__13-3-010-hose-clip)

Switch off ignition.

Recycling

The fuel in the fuel lines is under pressure (approx. 3 to 5 bar)!

Fuel emerges when the fuel lines are disconnected from the fuel filter.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

REMOVE FUEL PRESSURE REGULATOR .

Seal fuel feed line before and after fuel filter with two special tools 13 3 010.

This prevents excessive discharge of fuel from the fuel lines.

Scheme 20

Note. Mark fuel lines on fuel filter. This prevents the fuel lines from being installed incorrectly on the fuel filter.

Release clips (1).

Detach fuel lines (2) from fuel filter.

Installation

Replace clips.

Scheme 21

Release screws.

Remove fuel filter (1) from holders (2).

Scheme 22

13 41 500 Replacing idle speed control valve (M52TU, M54)

Necessary preliminary tasks

1. Switch off ignition.
2. Disconnect battery ground wire.
3. Observe instructions for disconnecting and connecting battery. Refer to «INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/x3/e83-2003-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair-m54__12-00-instructions-for-disconnecting-and) .

M52TU only

Remove intake filter housing.

Pull Bowden cable upwards out of holder (1) and suspend from throttle.

Scheme 23

Loosen hose clamps (1).

Scheme 24

Detach air intake hose section from throttle assembly and idle actuator.

Installation

To facilitate installation, fit air-mass flow sensor with intake hose (1). Coat intake hose (1) with antiseize agent.

Scheme 25

M54 E46/E53 only

Remove complete intake hose (between intake filter housing and throttle assembly).

M54 E60/E61/E65/E66 only

Remove intake hose.

M52TU and M54

Unfasten following plug connections

Scheme 26

1. Resonance flap
2. Idle speed control valve

Installation location

Idle actuator (2) is fitted below intake air manifold, directly above throttle (1).

Scheme 27

Release screw (1) on cable duct mounting.

Scheme 28

Release screws (2) on holder of idle actuator (3).

Remove idle actuator with holder from intake air manifold.

Detach idle actuator (2) from rubber retainer (4).

Scheme 29

Always replace gasket (1) from idle actuator (2) to intake air manifold. However, during reinstallation, do not fit gasket on idle actuator but install first in intake air manifold.

Installation

Replace seal (1).

Scheme 30

Coat gasket (1) on inside with antiseize agent.

Note. Interrogate fault memory of DME control unit.

Check stored fault messages.

Rectify faults.

Then clear fault memory.

13 51 630 Replacing fuel pressure regulator (M62, M54)

FOLLOW INSTRUCTIONS FOR FUEL PRESSURE TESTING

Recycling

The fuel in the fuel lines is under pressure (approx. 3 to 5 bar)!

Fuel emerges from the fuel filter when the fuel pressure regulator is removed.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Removing fuel tank underbody protection on left

Release metal screws (1).

Release screws (2).

Scheme 31

Release screws (1) on wheel arch trim, rear left.

Scheme 32

Bend wheel arch trim open.

Release screw (1).

Scheme 33

Release screws (1).

Scheme 34

Release screws (1) and (2).

Release nuts (3).

Scheme 35

Lower fuel tank underbody protection (1) only until access to fuel filter/pressure regulator is unhindered.

Scheme 36

Installation

Check routing of handbrake cable on tank.

If necessary, clip handbrake cable into holders on tank.

Note. Fuel pressure regulator is integrated in fuel filter.

Disconnect vacuum hose.

Pull out locking bracket (1) in direction of arrow.

Remove fuel pressure regulator (2).

Scheme 37

Installation

Replace O-rings on fuel pressure regulator (1).

To aid installation, apply a thin coat of petroleum jelly to O-rings (1).

Scheme 38

13 53 240 Replacing complete injection pipe (M54)

Necessary preliminary tasks

1. Switch off ignition
2. Remove cover for fuel injectors

Unclip plug connections (1) from holders and disconnect.

Scheme 39

When replacing injection pipe

Remove both holders for plug connections (1) from injection pipe.

Disconnect plug connection (3) on solenoid valve of VANOS adjustment unit.

Detach terminal strip (4) for fuel injectors from injection pipe.

Recycling

Fuel in fuel lines is under pressure (approx. 3 - 5 bar). Fuel escapes when fuel lines are detached. Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Note. For a better overview, this work step is shown on an engine that has been removed.

Unclip fuel line (1) from holder (2).

Scheme 40

Follow instructions for unlocking fuel line. Refer to REPLACING, SEALING FUEL HOSES .

Unlock fuel line (1) from cylinder head at rear.

Release screws (1) and remove injection pipe with fuel injectors.

Scheme 41

Installation

Coat sealing rings of fuel injectors with anti-seize agent to facilitate fitting of injection pipe.

13 53 540 Replacing, sealing fuel hoses

Recycling

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Version with hose clamps

Release hose clamps.

Scheme 42

Remove hoses (1) and (2).

Installation

Fuel hoses and hose clamps must be replaced each time they are removed!

Version with compressed air connection

Blow fuel back into tank with a short blast of compressed air (max. 3 bar) at compressed air connection (1).

Scheme 43

Version, fuel hoses without integrated unlocking facility

Unlock fuel hoses with special tool 16 1 050 and detach hoses.

Scheme 44

Installation

Check O-ring in fuel hose and sealing surfaces on fuel lines for damage; replace components if necessary.

Coat O-ring for assembly with anti-friction agent.

Version, fuel hoses with integrated unlocking facility

Press fuel hose (1) downwards and keep pressed.

Scheme 45

Press unlocking ring (2) upwards, keep pressed and detach fuel hose (1).

Scheme 46

Installation

Check O-ring in fuel hose and sealing surfaces on fuel lines for damage; replace components if necessary.

Coat O-ring for assembly with anti-friction agent.

M43, M44

Cars with screw-mounted fuel feed line (2)

Follow installation instructions (1) and (2).

Installation instruction 1

Always replace fuel hose (1) and hose clamps once they have been removed.

Scheme 47

Installation instruction 2

Always replace O-ring. Coat O-ring with anti-friction agent.

Scheme 48

Clean sealing faces of fuel feed line.

If necessary, replace fuel feed line.

Tightening Torque, 13 53 4AZ.

Seal off fuel hoses

Fuel hoses with hose clamps

Scheme 49

Seal hoses with special tool 13 3 010.

Installation

Fuel hoses and hose clamps must be replaced each time they are removed!

Fuel hoses with quick-release couplings

Seal fuel hoses (1) with special tool 13 5 281.

Scheme 50

Seal fuel lines (2) with special tool 13 5 282.

Installation

Check O-ring in fuel hose and sealing surfaces on fuel lines for damage; replace components if necessary.

Coat O-ring for assembly with anti-friction agent.

13 54 030 Removing and installing/sealing throttle assembly (M54)

Turn off ignition.

Observe instructions for disconnecting and connecting battery. Refer to INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY .

Disconnect battery negative lead from battery and lay to one side.

Remove intake filter housing.

Remove intake hose completely (between intake filter housing and throttle assembly).

Disconnect following plug connections

Scheme 51

Disconnect following plug connections

Scheme 52

Note. For purposes of clarity, the power steering pump supply tank is not shown.

Unlock plug (1) and detach from tank venting valve.

Scheme 53

Release screws (1) on cable duct mounting.

Scheme 54

E46 only

Unclip fuel lines and cable of oil level sensor out of holder (1) on oil dipstick guide tube.

Scheme 55

Detach oil return line (2) from oil dipstick guide tube.

Release screw (3) and remove oil dipstick guide tube.

Installation

Replace sealing ring for oil dipstick guide tube.

All cars

Unlock plug (1) and detach from throttle assembly (3).

Scheme 56

Release screws (2) and remove throttle assembly (3).

Installation

Replace sealing ring (1) between throttle assembly and intake manifold.

Scheme 57

Note. A faulty throttle adjusts the adaptation values stored in the DME control unit. These adaptation values must be reset after the throttle assembly has been replaced.

Clearing adaptation values

1. Connect DIS Tester
2. Select vehicle type
3. Select "DME Motor Electronics MS43", carry out individual brief test
4. Continue with bottom right arrow
5. The "Fault pattern selection" window appears. Select "Function selection" (bottom left)
6. The "Function and component selection" window appears: Select "Service functions" Select "Drive" Select "Digital Motor Electronics" Select "Reset adaptations" Select "Test schedule" (bottom left)
7. The "Test schedule" window appears. Select "Reset adaptations"
8. Continue with bottom right arrow

For subsequent procedure, follow DIS instructions.

The new adaptation values are stored in the DME control unit after the engine is started for the first time.

Necessary preliminary tasks

1. Switch off ignition
2. Disconnect battery negative lead from battery and lay to one side Follow instructions for disconnecting and connecting battery. Refer to «INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY»(/bmw/x3/e83-2003-2006/remont/gauges-instrument-panels/#engine-electrical-system-repair-m54__12-00-instructions-for-disconnecting-and) .
3. If fitted (E85): remove sound generator
4. Remove air intake hose, refer to «REPLACING AIR INTAKE HOSE (M54)»(/bmw/x3/e83-2003-2006/remont/fuel-system/#fuel-system-repair-instructions-m54__13-54-250-replacing-air-intake)

Release screws (1) of cable duct mounting.

Scheme 58

Place cable channel to one side.

Unlock plug (1) and detach from throttle assembly (3).

Scheme 59

Release screws (2) and remove throttle assembly (3).

Installation

Replace sealing ring (1) on throttle assembly (2).

Scheme 60

13 54 250 Replacing air intake hose (M54)

Switch off ignition.

Release hose clamp (3).

Detach intake hose (5) from air-mass flow sensor.

Scheme 61

Installation

Check sealing ring (1) between air-mass flow sensor and intake hose for damage, replace if necessary.

Coat sealing ring (1) with acid-free grease.

Scheme 62

Detach cable tie (2) of line (1) on intake hose (3).

Scheme 63

Release clips (1).

Pull intake hose (2) out of connecting piece and remove.

Scheme 64

13 54 251 Replacing intake hose (between connecting piece and throttle assembly) (M54)

Switch off ignition.

E53 only

Detach vacuum lines (1 and 2) from intake hose (3).

Scheme 65

Z3, E39 and E53

Release clips (1).

Pull intake hose (2) out of connecting piece.

Release screw.

Remove suction jet pump (1) from intake air manifold.

Scheme 66

Release hose clamps (1).

Detach intake hose from throttle assembly and idle speed control valve.

Scheme 67

13 62 511 Replacing intake air temperature sensor (M52TU, M54)

Turn off ignition.

Remove cover from fuel injectors.

Disconnect plug connection (1) for temperature sensor.

Scheme 68

Press catch and withdraw temperature sensor (1) from intake air manifold.

Installation

Check sealing ring on temperature sensor for damage, replace if necessary.

Coat sealing ring with antiseize agent.

Scheme 69

Note. Read out fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear fault memory.

13 62 531 Replacing coolant temperature sensor (M52TU, M54)

Turn off ignition.

Installation location

Coolant temperature sensor (1) is fitted below intake air manifold in cylinder head of cylinder 6.

Scheme 70

Remove intake air manifold. Refer to REMOVING AND INSTALLING INTAKE AIR MANIFOLD (M54) .

Disconnect plug connection (1).

Scheme 71

Unscrew temperature sensor.

Installation

Tightening torque, 13 62 2AZ. See SENDERS FOR CONTROL UNIT

Check coolant level, top up coolant if necessary.

Note. Read out fault memory of DME control unit.

Check stored fault messages.

Rectify faults.

Then clear fault memory.

13 62 560 Removing and installing/replacing air-mass flow sensor (M54)

Note. Illustrations show E85.

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Switch off ignition

Unlock plug (1) and remove.

Scheme 72

Release clips (2).

Release clamp (3).

Pull air-mass flow sensor (4) first out of top section of intake filter housing and then out of air intake hose.

Installation

Check sealing ring (1) between air-mass flow sensor and intake filter housing for damage, replace if necessary.

Scheme 73

Coat sealing ring (1) with suitable antiseize agent.

Installation

Check stored fault messages.

Now clear the fault memory.

13 63 590 Replacing fuel pump relay

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Switch off ignition
3. Remove glovebox, refer to «REMOVING AND INSTALLING RIGHT GLOVEBOX»(/bmw/x3/e83-2003-2006/remont/door-locks-anti-theft-systems/#body-equipment-repair-instructions__51-16-360-removing-and-installing)

Pull off fuel pump relay (1).

Scheme 74

Note. After removal of fuel pump relay and during engine starting sequence

1. Fuel pump no longer starts up
2. Engine fails to start.

Installation

Check stored fault messages.

Now clear the fault memory.

13 64 541 Replacing all fuel injectors

Necessary preliminary tasks

1. Switch off ignition
2. Remove complete injection pipe, refer to «REPLACING COMPLETE INJECTION PIPE (M54)»(/bmw/x3/e83-2003-2006/remont/fuel-system/#fuel-system-repair-instructions-m54__13-53-240-replacing-complete-injection)

Detach retainer (1).

Scheme 75

Detach fuel injector from injection pipe.

Installation

Check sealing rings, replace if necessary.

Insert fuel injector fully into injection pipe then pull out until groove is flush with edge of injection pipe.

Push on retainer.

Installation

Coat sealing rings of fuel injectors with anti-seize agent to facilitate fitting of injection pipe.

13 71 000 Removing and installing intake filter housing (M54)

Necessary preliminary tasks

1. Switch off ignition.
2. Remove top section of intake filter. Refer to «REPLACING AIR CLEANER ELEMENT (M54)»(/bmw/x3/e83-2003-2006/remont/fuel-system/#fuel-system-repair-instructions-m54__13-72-001-replacing-air-cleaner) .

Unfasten screws.

Scheme 76

Remove intake filter housing (1).

Installation

Install guide rail (1) on intake filter housing on rubber mount (2).

Scheme 77

13 72 001 Replacing air cleaner element (M54)

Open clips (1).

Scheme 78

Open retainers (2) on air-mass flow sensor.

Remove top section (3) of intake filter housing.

Remove air cleaner element.

Scheme 79

Installation

Clean top and bottom sections of intake filter housing from inside.

Install new air cleaner element.

Check seal between air-mass flow sensor and top section of intake filter housing for damage and replace if necessary.

13 90 500 Replacing tank venting valve (M52TU, M54)

Turn off ignition.

Location

Tank vent valve (2) is fitted at front on intake air manifold (1).

Z3, E39 and E46

Remove intake filter housing.

E53/M54 only

REMOVE INTAKE HOSE .

Scheme 80

Z3, E39, E46 and E53

Disconnect plug connection (1).

Release vent hose (2). To do so, press locking bar and detach vent hose.

Scheme 81

Detach hose (1) from tank venting valve (2).

Note. Illustration shows removed supply tank for power steering.

Scheme 82

Note. Interrogate fault memory of DME control unit. Check stored fault messages. Rectify faults. Then clear the fault memory.

See also:
• FUEL SYSTEM - TECHNICAL DATA
• 13 3 010
• INSTRUCTIONS FOR DISCONNECTING AND CONNECTING BATTERY
• REMOVING AND INSTALLING INTAKE AIR MANIFOLD (M54)
• SENDERS FOR CONTROL UNIT
• REMOVING AND INSTALLING RIGHT GLOVEBOX
• CHECKING FUEL PUMP DELIVERY PRESSURE (M54)
• NOTES ON FUEL PRESSURE CHECK (REFERENCE PRESSURE: ENVIRONMENT)
• REMOVE FUEL PRESSURE REGULATOR
• REPLACING, SEALING FUEL HOSES
• REPLACING AIR INTAKE HOSE (M54)
• REPLACING COMPLETE INJECTION PIPE (M54)
• REPLACING AIR CLEANER ELEMENT (M54)