Fuel System - Repair Instructions - x5 (4.4l) BMW X5 E53

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 1

OBD Socket (1) In Driver's Footwell

Same procedure as above.

Scheme 2

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: Connect test adapter.

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

1. Replace return lines

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

Important

With less likelihood, the return line may be completely blocked. When the pressure regulator is removed, fuel could escape under pressure!

1. Have a cleaning cloth ready and catch and dispose of escaping fuel.
2. Replace the return line but not the pressure regulator.

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 delivery pressure of fuel pump (M62)

Switch off ignition.

Turn fasteners on acoustic cover 90° counterclockwise.

Remove acoustic cover.

Scheme 3

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

Scheme 4

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

Mount special tool kit 13 5 220 on fuel rail and tighten knurled nut until hand-tight.

Start engine.

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

Scheme 5

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

Test pressure

refer to FUEL SUPPLY SYSTEM - TECHNICAL DATA .

Switch off engine.

Checking Fuel Pump

Detach fuel pump relay

refer to 13 63 590 REPLACING 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.

Delivery pressure

refer to FUEL SUPPLY SYSTEM - TECHNICAL DATA .

Scheme 6

Keep special tool 13 3 010 available for further tests.

Further procedure for checks

refer to 13 31 ... FUEL PRESSURE CHECK .

Installation

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

Scheme 7

Special Tools Required

1. 13 3 010

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 8

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 9

Release screws.

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

Scheme 10

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 11

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

Scheme 12

Bend wheel arch trim open.

Release screw (1).

Scheme 13

Release screws (1).

Scheme 14

Release screws (1) and (2).

Release nuts (3).

Scheme 15

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

Scheme 16

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 17

Installation

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

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

Scheme 18

13 53 240 Replacing complete injection pipe (M62)

Interrogate fault memory of DME control unit.

Switch off ignition.

Turn fasteners on acoustic cover 90° counterclockwise.

Remove acoustic cover.

Scheme 19

Detach plug connections (1) of knock sensors from cable strips.

Detach plug (2) from electric changeover valve.

Detach plugs (3) of camshaft sensors from cable strips.

Scheme 20

Remove sealing caps on cover of ignition coils on left.

Release nuts.

Remove cover on ignition coils on left.

Scheme 21

Check profile seal (1) for damage and correct seating, replace if necessary.

Scheme 22

Disconnect plug connection of ignition coils on left cylinder head from ignition coils.

Scheme 23

Screw thin grounding strap (1) and wide grounding strap (2) to ignition coil of cylinder 7.

Scheme 24

Release nuts.

Disconnect cable strip (1) from fuel injectors.

Place electric changeover valve (2) together with holder to one side.

Disconnect vacuum lines from vacuum accumulator (3).

Place vacuum accumulator (3) together with holder to one side.

Disconnect cable strip (4) from fuel injectors and place to one side.

Scheme 25

Recycling

Fuel emerges when fuel line is detached. Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

To unlock fuel line

Press fuel line (1) downwards and keep pressed.

Scheme 26

Press unlocking ring (2) upwards, keep pressed and disconnect fuel line (1).

Scheme 27

Disconnect fuel line (1).

Release clamp (2).

Detach hose (3).

Scheme 28

Release nuts.

Remove both retaining brackets (1 and 2).

Pull out injection pipe (3) with fuel injectors towards top.

Remove injection pipe with fuel injectors.

Scheme 29

Lever out fuses (1).

Pull fuel injectors (2) out of injection pipe.

Scheme 30

Check O-rings on fuel injectors for damage and replace if necessary.

Coat O-rings with anti-friction rubber coating (e.g. petroleum jelly).

Scheme 31

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

13 53 540 Replacing, sealing fuel hoses

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Version With Hose Clamps

Release hose clamps.

Remove hoses (1) and (2).

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

Scheme 32

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 33

Version, Fuel Hoses Without Integrated Unlocking Facility

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

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.

Scheme 34

Version, Fuel Hoses With Integrated Unlocking Facility

Press fuel hose (1) downwards and keep pressed.

Scheme 35

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

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.

Scheme 36

13 54 030 Removing and installing/sealing throttle assembly (M62)

Switch off ignition.

Remove intake hose

refer to 13 54 250 REPLACING INLET HOSE (BETWEEN MASS AIR FLOW SENSOR AND THROTTLE BODY) (M62) .

Disconnect plug (1).

Release screws (2).

Remove throttle assembly.

Check sealing ring (3) on throttle assembly for correct seating and damage and replace if necessary.

To assist installation, coat sealing ring (3) with anti-friction rubber coating (e.g. petroleum jelly).

Scheme 37

Check sealing ring (1) on throttle assembly (2) for damage and replace if necessary.

Scheme 38

13 54 250 Replacing inlet hose (between mass air flow sensor and throttle body) (M62)

Switch off ignition.

Turn fasteners on acoustic cover 90° counterclockwise.

Remove acoustic cover.

Scheme 39

Release hose clamp (2).

Detach intake hose from air-mass flow sensor.

Installation

Check sealing ring for damage and correct seating, replace if necessary.

Do not use any antiseize agent to install sealing ring/intake hose.

Scheme 40

Release hose clamp (1).

Detach vacuum hose (2) from intake hose.

Press lock (4) and detach vacuum line (3) from intake hose.

Push vacuum line (3) onto intake hose until locking ring can clearly be heard snapping into place.

Detach intake hose from throttle assembly.

Scheme 41

Installation

Check sealing ring (1) for damage and correct seating, replace if necessary.

Do not use any antiseize agent to install sealing ring/intake hose.

Scheme 42

13 62 531 Replacing coolant-temperature sensor (M62)

Note. Interrogate fault memory of DME control unit. Switch off ignition.

Turn fasteners on acoustic cover 90° counterclockwise.

Remove acoustic cover.

Scheme 43

Coolant temperature sensor is mounted on water pipe at front.

Remove vacuum lines (1).

Detach plug (2) from temperature sensor.

Scheme 44

Catch and dispose of escaping coolant.

Observe country-specific waste-disposal regulations.

Twist out temperature sensor (1).

Tightening torque, refer to 12 62 4AZ in FUEL SYSTEM - TIGHTENING TORQUES .

Replace sealing ring.

Scheme 45

Vent cooling system and check for leaks

refer to 17 00 039 in COOLING SYSTEM - TIGHTENING TORQUES .

Coolant

refer to OPERATING FLUIDS - MAINTENANCE & GENERAL INFORMATION .

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

13 62 560 Removing and installing/replacing mass air flow sensor (M60, M62, M73)

Interrogate fault memory of DME control unit.

Switch off ignition.

Disconnect plug connection (1) from air-mass flow sensor.

Release hose clip (2).

Detach intake hose from air-mass flow sensor.

Scheme 46

Open clips (1).

Detach air-mass flow sensor from air cleaner upper section.

Scheme 47

Check seal (1) between air-mass flow sensor and air cleaner upper section for damage, replace if necessary.

To facilitate assembly, coat seal with acid-free grease.

Read out fault memory of control unit of Digital Motor Electronics (DME).

Check stored fault messages.

Rectify faults.

Now clear the fault memory.

Scheme 48

13 63 590 Replacing fuel pump relay

Interrogate fault memory of DME control unit.

Switch off ignition.

Remove right glovebox.

Release screws (1).

Remove fuse box (2) towards bottom (do not disconnect electrical connections).

Scheme 49

Detach fuel pump relay (1).

After removal of fuel pump relay and during engine starting sequence

Scheme 50

1. the fuel pump no longer starts up
2. the engine does not start.

Note. Interrogate fault memory of DME control module.

Check stored fault messages.

Rectify faults.

Then clear fault memory.

13 64 541 Replacing all fuel injectors

Necessary preliminary tasks

1. Switch off ignition.
2. Remove complete injection pipe.

Unclip retainers (1).

Withdraw fuel injectors (2) from injection pipe.

Replace fuel injectors.

Scheme 51

Installation

Coat sealing rings with anti-friction rubber coating (e.g. petroleum jelly).

Scheme 52

Necessary preliminary tasks

1. Switch off ignition
2. Remove complete injection pipe

Detach retainer (1).

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.

Scheme 53

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 (M62)

Turn off ignition.

Remove and install air-mass flow sensor

refer to 13 62 560 REMOVING AND INSTALLING/REPLACING MASS AIR FLOW SENSOR (M60, M62, M73) .

Release screw (1).

Press together locking ring (2) and detach hose (3).

Push on hose (3) as far as it will go. Locking ring (2) must clearly be heard snapping into place.

Scheme 54

Press together locking lugs and pull intake filter housing (1) out of intake pipe (2).

Remove intake filter housing (1).

Scheme 55

13 72 001 Replacing air cleaner insert (M62)

Open retainers (1).

Press together locking ring (2) and detach hose (3).

Push on hose (3) as far as it will go. Locking ring (2) must clearly be heard snapping into place.

Raise upper section of intake filter housing a little.

Scheme 56

Remove air cleaner insert.

Clean upper and lower sections of intake filter housing from inside.

Install new air cleaner insert.

Scheme 57

13 90 500 Replacing tank vent valve (M62)

Interrogate fault memory of DME control unit.

Switch off ignition.

Location

Tank venting valve is fitted between cylinder head on left and fan cowl.

Disconnect plug (1).

Remove tank venting valve (2) from holder.

Scheme 58

Detach fuel hose (1) from tank venting valve.

Press locking ring (2) and detach hose (3) from tank venting valve.

Push hose (3) onto tank venting valve until locking ring (2) can clearly be heard snapping into place.

Scheme 59

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

See also:
• FUEL SYSTEM - TIGHTENING TORQUES
• COOLING SYSTEM - TIGHTENING TORQUES
• OPERATING FLUIDS - MAINTENANCE & GENERAL INFORMATION
• 13 63 590 REPLACING FUEL PUMP RELAY
• 13 31 ... FUEL PRESSURE CHECK
• 13 54 250 REPLACING INLET HOSE (BETWEEN MASS AIR FLOW SENSOR AND THROTTLE BODY) (M62)
• 13 62 560 REMOVING AND INSTALLING/REPLACING MASS AIR FLOW SENSOR (M60, M62, M73)