Fuel System - Repair (n54) BMW Z4 E89

00 Safety information for working on vehicles with automatic engine start-stop function (MSA)

Observe safety precautions when working on MSA vehicles.

Before carrying out practical work on the engine, always ensure that the MSA functionality is deactivated so as to prevent automatic engine starting while work is being carried out in the engine compartment.

MSA function is deactivated

by

Scheme 18

1. Deactivate MSA by means of button (1) in passenger compartment
2. Open seat belt buckle and driver's door
3. Open engine bonnet/hood and ensure that engine hood/bonnet contact is not in workshop mode Workshop mode A = 10 mm Basic setting (engine hood/bonnet open) B = 7 mm To make sure that the engine hood/bonnet contact is at the basic setting, if necessary press the hood/bonnet contact up to the limit position before starting work and slowly release.

When working with diagnosis tools

1. Observe instructions in diagnosis tool

13 31 029 Checking fuel delivery pressure (N54, N54T)

Necessary preliminary work

1. Connect BMW diagnosis system.

Wear protective goggles and gloves.

Fuel can emerge spontaneously at high velocity when the fuel line is released!

Recycling

Catch and dispose of escaping fuel with auxiliary materials.

Observe country-specific waste disposal regulations.

Disconnect snap fastener (1) of fuel line.

Scheme 19

Insert special tool 13 5 270 into disconnected fuel line. Screw onto special tool 13 5 270, the special tool 11 4 310. Screw IMIB 100 bar pressure sensor (1) on the special tool 11 4 310.

Note. As an alternative to the 100 bar IMIB pressure sensor (1), the 25 bar pressure sensor can also be used. For this, screw on special tool 11 5 364 instead of special tool 11 4 310 into special tool 13 5 270. Or directly screw the pressure manometer from the set of special tools 13 3 060 onto the special tool 13 5 270.

Scheme 20

Establish fuel delivery pressure. Read off fuel delivery pressure on IMIB and compare with values in diagnosis system.

13 31 032 Check fuel pressure

Necessary preliminary work

1. Connect BMW diagnosis system.

Wear protective goggles and gloves.

Fuel can emerge spontaneously at high velocity when the fuel line is released!

Recycling

Catch and dispose of escaping fuel with auxiliary materials.

Observe country-specific waste disposal regulations.

Scheme 21

Check fuel delivery pressure

To check the fuel delivery pressure, special tool 13 0 290 must be assembled as follows.

Screw adapter 11 4 310 onto line 13 0 291.

Screw the IMIB 100 bar pressure sensor (1) onto adapter 11 4 310.

Alternatively, the pressure gauge from the set of special tools 13 3 060 can be screwed onto line 13 0 291.

Between lines 13 0 291 and 13 0 292, mount a shutoff tap (2) and a T-piece (3) from the set of special tools 13 3 060 .

Close up T-piece (3) from the set of special tools with the cap 13 0 293.

Note. The graphic shows F07 The procedure is identical for other vehicles.

Remove circlip (1).

Unlock and detach fuel line (2) to fuel tank from fuel line (2) to high pressure pump.

Scheme 22

Install special tool (1) 13 0 290 into detached fuel line with IMIB fuel pressure sensor (100 bar).

Connect IMIB with fuel pressure sensor.

Establish fuel delivery pressure. Read off fuel delivery pressure on IMIB and compare with values in diagnosis system.

Scheme 23

Scheme 24

Check fuel holding pressure

To check the fuel holding pressure, special tool 13 0 290 must be assembled as follows.

Screw adapter 11 4 310 onto line 13 0 291.

Screw the IMIB 100 bar pressure sensor (1) onto adapter 11 4 310.

Alternatively, the pressure gauge from the set of special tools 13 3 060 can be screwed onto line 13 0 291.

Between lines 13 0 291 and 13 0 292, mount a shutoff tap (2) and a T-piece (3) from the set of special tools 13 3 060 .

Mount pressure gauge (4) from special tool set 13 3 060 onto T-piece (3) from special tool set 13 3 060 .

Note. The graphic shows F07 The procedure is identical for other vehicles.

Remove circlip (1).

Unlock and detach fuel line (2) to fuel tank from fuel line (2) to high pressure pump.

Install special tool (1) 13 0 290 with pressure gauge (2) and IMIB 100 bar fuel pressure sensor (3) into the detached fuel line.

Establish fuel delivery pressure.

Close shutoff tap (4) and switch off the engine.

Scheme 25

Read off fuel holding pressure of high pressure pump from IMIB tester and compare with values in diagnosis system.

Read off fuel holding pressure to fuel tank on pressure gauge (2) and compare with values in diagnosis system.

Assemble engine.

Check fuel system for leak tightness.

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: 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.

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 53 192 Removing and installing/replacing a pressure line (N54)

Necessary preliminary tasks

1. Remove «IGNITION COIL»(/bmw/z4/e89-2009-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-n54__12-13-511-replacing-ignition-coils) of corresponding cylinder

Note. Ignition coils must not be fouled by fuel! The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots! Before installing ignition coils, clean spark plug slots with compressed air. Make sure the spark plug slot is absolutely clean.

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Note. The following description applies to all pressure lines.

First release rail pressure lines to reduce existing fuel pressure if necessary. Fuel must not get into the spark plug slot. Then release pressure line on injector.

Scheme 26

Release nuts (1), gripping the injector with a wrench (2) in so doing.

Disconnect pressure line (3).

Close off injector with protective cap (1).

Protective caps are available from BMW Parts Service.

Seal rail with a matching plug from special tool kit 32-1270 PLUG .

Scheme 27

Seal pressure line (1) with a matching plug from special tool kit 32-1270 PLUG .

Scheme 28

Installing pressure line

Installation of pressure rail is described separately from removal.

Same procedure for all pressure lines.

Copper seals that may be fitted (1) are no longer needed and must be removed.

If using the pressure line, apply a light coating of gear oil to the thread. New pressure lines are already coated.

Scheme 29

To ensure distortion-free installation of the pressure line and to avoid damaging the thread, it must be possible for both nuts to be screwed on easily by hand!

Scheme 30

If the nuts cannot be easily screwed on by hand, the injector must be turned into the installation position!

Note. Description of "Turning injector into installation position" in the following two work steps.

Only if injector has to be turned into installation position

1. Release bolt a few turns until holding-down element (1) is slackened.
2. Turn injector (2) in direction of arrow until nuts on pressure line can be easily screwed on by hand.
3. To do so, engage wrench on hexagon head of injector if necessary.
4. Tighten nuts on pressure line hand-tight.

Tighten down screw for holding-down element (1).

Tightening torque 13 53 5AZ .

Scheme 31

Adhere to tightening sequence

1. First tighten down nut (1) on injector.
2. Then tighten down nut (2) on rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151.

Tightening torque 13 53 8AZ .

Scheme 32

Assemble engine.

Check fuel system for leaks.

Check function of DME.

13 53 332 Removing and installing/replacing feed line (N54)

Wear protective goggles.

Cover ignition coil with suitable means.

Necessary preliminary tasks

1. Remove «INTAKE AIR MANIFOLD»(/bmw/z4/e89-2009-2013/remont/mechanical/#engine-repair-n54__11-61-050-removing-and-installing)

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Unlock and detach fuel line (1).

Catch and dispose of escaping fuel.

Scheme 33

Seal fuel lines with special tools (1) 13 5 161 and (2) 13 5 162.

Scheme 34

Slacken nut (2).

Release screw (3).

Remove feed line.

Close off feed line and high-pressure pump with a matching plug from special tool kit 32-1270 PLUG .

Installation

Follow sequence of screw connections

1. Tighten down nut (2) with special tool «13 5 020»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-special-tools-n54) .
2. Replace aluminum screw (3).
3. Connect fuel line (3).

Assemble engine.

Check fuel system for leaks.

Check function of DME.

13 51 017 Removing and installing/replacing high-pressure fuel pump (N54)

Necessary preliminary work

1. Remove «THROTTLE BODY»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-54-030-removing-and-installingsealing)

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Apply silicone-free multifunction spray (part number 83 23 0 418 567) on to supports (1) of base well bracket (2).

Unplug connector (3) and (4) from base well.

Slide base well (2) in direction of arrow.

Scheme 35

Scheme 36

Insert special tool 00 7 300 in mounting points (1) on base well.

Note. Place tips of special tool 00 7 300 between retainers (2) and then center (arrow).

Detach base well (1) from bracket (2) with special tool 00 7 300 .

Scheme 37

Unlock connector (1) and remove.

Unlock and detach fuel line (2).

Catch and dispose of escaping fuel.

Scheme 38

Seal fuel lines with special tools 13 5 281 and 13 5 282.

Scheme 39

Slacken nut (1).

Release screw (2).

Installation note

1. Replace aluminum screw (2).

Remove feed line (3).

Scheme 40

Seal feed line with matching plug from set of special tools 32-1270 PLUG .

Scheme 41

Slacken nut (1).

Scheme 42

Undo screws (1) and raise acoustic cover (2) in front area.

Scheme 43

Slacken nut (1).

Scheme 44

Seal fuel line connections of high pressure pump (1) with matching plugs from set of special tools 32-1270 PLUG .

Scheme 45

Release bolts with special tool 11 8 610 .

Detach high pressure pump (1) and remove.

Engine oil can escape when pump is detached; have a cleaning cloth ready.

Scheme 46

Installing high pressure pump

Installation of high pressure pump is described separately from removal.

Replace sealing ring (1).

Clean contact surfaces.

Scheme 47

When installing, turn high pressure pump (1) if necessary in direction of arrow until bore holes for screws are flush.

Scheme 48

Scheme 49

Only hand-tighten nut (1).

Only hand-tighten nut (1).

Note. Feed lines with a soldered bracket must be replaced by the new version with elastomer clamp holder. Observe installation position of fuel low-pressure sensor. Lines for solenoid switches are laid behind fuel line.

Install feed line (3).

Only hand-tighten nut (1).

Tighten screw (2). Replace aluminum screw.

Tightening torque 13 53 9AZ.

Tighten down screws with special tool 11 8 610 .

Tightening torque 13 51 1AZ.

Tighten nut (1).

Tightening torque 13 53 7AZ.

Tighten down nut (1) with special tool 13 5 020 .

Tightening torque 13 53 7AZ.

Tighten down nut (1) with special tool 13 5 020 .

Tightening torque 13 53 6AZ.

Scheme 50

Install and lock connector (1).

Scheme 51

Slide base well (2) on to bracket (1) as far as it will go.

Install and lock connector (3) and (4).

Assemble engine.

Check fuel system for leak tightness.

Check function of DME.

13 53 158 Removing and installing/replacing high-pressure rail (N54)

Necessary preliminary tasks

1. Remove «PRESSURE LINES»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-53-192-removing-and-installingreplacing)
2. Remove «INTAKE FILTER HOUSING»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-71-000-removing-and-installingreplacing)

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Unlock plug (1) and remove.

Pull connector holder off high-pressure rail.

Remove all holders for wiring harness from high-pressure rail.

Scheme 52

Slacken nut (1).

Unlock and disconnect plug (2) on high-pressure sensor.

Release screws (3) and remove high-pressure rail (4).

Scheme 53

Installing high-pressure rail

Installation of high-pressure rail is described separately from removal.

Install high-pressure rail (4); in so doing, tighten screws (3) and nut (1) hand-tight only.

Note. It must still be possible for the high-pressure rail to slide on the cylinder head. Nut (2) must be able to be screwed on easily by hand.

Push on plug for high-pressure sensor (2).

Fitting pressure lines

(Same procedure for all pressure lines)

Connect pressure line (1). Tightening nuts hand-tight only.

Note. Description of "Turning injector into installation location" in the following work step.

Only if one injector has to be turned into installation position

1. Release bolt a few turns until holding-down element (1) is slackened.
2. Turn injector (2) in direction of arrow until nuts on pressure line can be easily screwed on by hand.
3. To do so, engage wrench on hexagon head of injector (2) if necessary.
4. Tighten nuts on pressure line hand-tight.

Tighten down screws (1).

Tightening torque

13 53 1AZ .

Tighten nut (2).

Tightening torque

13 53 7AZ .

Scheme 54

Tighten down screw for holding-down element (1).

Tightening torque 13 53 5AZ .

Note. This work step is only necessary if one of the holding-down elements has been slackened beforehand.

Adhere to tightening sequence

1. First tighten down nut (1) on injector.
2. Then tighten down nut (2) on high-pressure rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151.

Tightening torque 13 53 8AZ .

Assemble engine.

Check fuel system for leaks.

Check function of DME.

13 53 596 Replacing high-pressure fuel sensor (N54)

Necessary preliminary tasks

1. Remove «ACOUSTIC COVER»(/bmw/z4/e89-2009-2013/remont/oem-general-information/#maintenance-and-general-information-repair-n54__11-removing-and-installingreplacing-acoustic-cover) .

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Unlock plug (1) and remove.

Release high-pressure sensor (2) and remove.

Tightening torque 13 53 3AZ with special tool 32 2 100.

Seal rail (3) if necessary with a matching plug from special tool kit 32-1270 PLUG .

Scheme 55

Assemble engine.

Check fuel system for leaks.

Check function of DME.

Necessary preliminary tasks

1. Remove «IGNITION COIL»(/bmw/z4/e89-2009-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-n54__12-13-511-replacing-ignition-coils) of corresponding cylinder

Note. Ignition coils must not be fouled by fuel! The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots! Before installing ignition coils, clean spark plug slots with compressed air. Make sure the spark plug slot is absolutely clean.

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Note. The following description applies to all pressure lines. First release rail pressure lines to reduce existing fuel pressure if necessary. Fuel must not get into the spark plug slot. Then release pressure line on injector.

Release nuts (1), gripping the injector with a wrench (2) in so doing.

Disconnect pressure line (3).

Mark pressure lines.

Close off injector with protective cap (1).

Protective caps are available from BMW Parts Service.

Seal rail with a matching plug from special tool kit 32-1270 PLUG .

Seal pressure line (1) with a matching plug from special tool kit 32-1270 PLUG .

Installing pressure line

Installation of pressure rail is described separately from removal.

Same procedure for all pressure lines.

Copper seals that may be fitted (1) are no longer needed and must be removed.

If using the pressure line, apply a light coating of gear oil to the thread. New pressure lines are already coated.

Scheme 56

Note. Description of "Turning injector into installation position" in the following two work steps.

Only if injector has to be turned into installation position

1. Release bolt a few turns until holding-down element (1) is slackened.
2. Turn injector (2) in direction of arrow until nuts on pressure line can be easily screwed on by hand.
3. To do so, engage wrench on hexagon head of injector if necessary.
4. Tighten nuts on pressure line hand-tight.

Tighten down screw for holding-down element (1).

Tightening torque 13 53 5AZ .

Adhere to tightening sequence

1. First tighten down nut (1) on injector.
2. Then tighten down nut (2) on rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151.

Tightening torque 13 53 8AZ .

Assemble engine.

Check fuel system for leaks.

Check function of DME.

13 53 310 Removing and installing/replacing an injector (N54)

Necessary preliminary tasks

1. Remove «IGNITION COIL»(/bmw/z4/e89-2009-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-n54__12-13-511-replacing-ignition-coils) of corresponding cylinder

Note. Ignition coils must not be fouled by fuel! The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots! Before installing ignition coils, clean spark plug slots with compressed air. Make sure the spark plug slot is absolutely clean. Remove PRESSURE LINE of corresponding cylinder

Note. The following description applies to all injectors.

Unlock plug (1) and remove.

Scheme 57

Release screw and remove hold-down device (2).

Remove injector (3).

Note. If several injectors are removed, ensure that each injector is reinstalled in its original location (cylinder).

Mark injectors.

Procedure in event of stuck injector

Mount special tool 13 0 180 on injector (1).

Scheme 58

Mount special tool 13 5 250 .

Carefully knock out injector (1) with special tools 13 0 180 and 13 5 250 .

Scheme 59

After removing, fit protective caps (1 and 3) to injector tip and fuel line connection.

Protective caps are available from BMW Parts Department.

Scheme 60

Installation

When installing a new injector

1. Replace uncoupling element (2).
2. Remove protective cap (1) from injector tip max. 10 min. before installation (PTFE sealing ring swells up).

Installation

When reusing fuel injector

1. Replace uncoupling element (2).
2. Replace PTFE sealing ring (1).

A PTFE seal which has been heated once by engine operation must be replaced before the fuel injector is reinstalled.

Scheme 61

Replacing PTFE sealing ring

Before replacing PTFE sealing ring (1), make sure hands and work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

Scheme 62

Remove PTFE sealing ring (1) with special tool 13 0 191 from injector (2).

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other tools/agents).

Do not clean injector tip.

Scheme 63

Slide new PTFE sealing ring (1) onto mounting taper 13 0 195.

Scheme 64

User fingers and mounting taper 13 0 195 to slide PTFE sealing ring (1) onto injector (2).

Note. Do not use fingernails to slide PTFE sealing ring on. Do not use any lubricating agents. The sealing ring is expanded when slid on.

Scheme 65

To bring the expanded PTFE sealing ring to its installation dimension, slide three assembly sleeves with decreasing diameters onto the injector.

Slide assembly sleeve (1) with large opening first onto injector (1).

Do not use any lubricating agents.

Scheme 66

First slide assembly sleeve 13 0 192 (large diameter) onto injector (1).

Then slide assembly sleeve 13 0 193 (medium diameter) onto injector (1).

Scheme 67

Finally, press injector (1) into assembly sleeve 13 0 194 (small diameter).

Installation

Install injector within 10 minutes or slide on protective cap see scheme 117 (PTFE sealing ring swells up).

Scheme 68

Installing injector

Installation of injector is described separately from removal.

Before installing injector in engines that have been run

1. Check injector bore for dirt.
2. Clean injector bore: To do so, preferably slide injector without uncoupling element (2) but with new PTFE sealing ring (1) in and out of injector bores several times.
3. Clean contact surfaces of uncoupling elements (2) in cylinder head.
4. Replace uncoupling element (2).

An injector adjustment must be carried out if an injector is replaced or changed on the cylinder side.

Scheme 69

Injector adjustment is carried out with the aid of a so-called adjustment value.

The adjustment value is printed in two blocks of three digits on the injector.

The adjustment value must be read off before installation!

Enter the adjustment value according to the installation position (cylinder) of the injector.

If injector adjustment is not carried out, the engine may run roughly or fail to start.

Description of injector adjustment at end of instruction.

Scheme 70

Installing injector

Installation

Install hold-down device (1) with curvature facing upwards.

Scheme 71

Install injector (3).

Install hold-down device (2).

Connect contact plug (1).

Note. Make sure hold-down device (1) is correctly seated.

Scheme 72

Copper seals (1) that may be fitted on the pressure lines are no longer needed and must be removed.

If using the pressure line, apply a light coating of gear oil to the thread. New lines are already pretreated.

Connect pressure line (1), tightening nuts hand-tight only in the process.

Turn injector (2) if necessary in direction of arrow until nuts on pressure line can be easily screwed on by hand.

Tighten nuts on pressure line hand-tight.

Then tighten down bolt for hold-down device (1).

Tightening torque 13 53 5AZ .

Scheme 73

Adhere to tightening sequence

1. First tighten down nut (1) on injector.
2. Then tighten down nut (2) on rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151.

Tightening torque 13 53 8AZ .

Carrying out injector adjustment

1. Connect DIS Tester
2. Identify car
3. Select "Function selection"
4. Select "Service functions"
5. Select "Engine electronics"
6. Select "Adjustment programs"
7. Select "Adjust injectors"
8. Change "Test schedule"
9. For each replaced injector, the adjustment value must be entered according to the installation position (cylinder).

Clean spark plug slot.

Assemble engine.

Check fuel system for leaks.

Check function of DME.

Wear protective goggles.

Cover ignition coil with suitable means.

Necessary preliminary tasks

1. Remove «INTAKE AIR MANIFOLD»(/bmw/z4/e89-2009-2013/remont/mechanical/#engine-repair-n54__11-61-050-removing-and-installing)

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Unlock and detach fuel line (1).

Catch and dispose of escaping fuel.

Seal fuel lines with special tools (1) 13 5 161 and (2) 13 5 162.

Slacken nut (2).

Release screw (3).

Remove feed line.

Close off feed line and high-pressure pump with a matching plug from special tool kit 32-1270 PLUG .

Installation

Follow sequence of screw connections

1. Tighten down nut (2) with special tool «13 5 020»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-special-tools-n54) .
2. Replace aluminum screw (3).
3. Connect fuel line (3).

Assemble engine.

Check fuel system for leaks.

Check function of DME.

Necessary preliminary tasks

1. Remove «PRESSURE LINES»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-53-192-removing-and-installingreplacing)
2. Remove «INTAKE FILTER HOUSING»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-71-000-removing-and-installingreplacing)

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste-disposal regulations.

Unlock plug (1) and remove.

Pull connector holder off high-pressure rail.

Remove all holders for wiring harness from high-pressure rail.

Slacken nut (1).

Unlock and disconnect plug (2) on high-pressure sensor.

Release screws (3) and remove high-pressure rail (4).

Installing high-pressure rail

Installation of high-pressure rail is described separately from removal.

Install high-pressure rail (4); in so doing, tighten screws (3) and nut (1) hand-tight only.

Note. It must still be possible for the high-pressure rail to slide on the cylinder head. Nut (2) must be able to be screwed on easily by hand.

Push on plug for high-pressure sensor (2).

Fitting pressure lines

(Same procedure for all pressure lines)

Connect pressure line (1). Tightening nuts hand-tight only.

Note. Description of "Turning injector into installation location" in the following work step.

Only if one injector has to be turned into installation position

1. Release bolt a few turns until holding-down element (1) is slackened.
2. Turn injector (2) in direction of arrow until nuts on pressure line can be easily screwed on by hand.
3. To do so, engage wrench on hexagon head of injector (2) if necessary.
4. Tighten nuts on pressure line hand-tight.

Tighten down screws (1).

Tightening torque

13 53 1AZ .

Tighten nut (2).

Tightening torque

13 53 7AZ .

Tighten down screw for holding-down element (1).

Tightening torque 13 53 5AZ .

Note. This work step is only necessary if one of the holding-down elements has been slackened beforehand.

Adhere to tightening sequence

1. First tighten down nut (1) on injector.
2. Then tighten down nut (2) on high-pressure rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151.

Tightening torque 13 53 8AZ , see 13 53 FUEL INJECTION NOZZLES AND PIPES .

Assemble engine.

Check fuel system for leaks.

Check function of DME.

Necessary preliminary tasks

1. Remove «ACOUSTIC COVER»(/bmw/z4/e89-2009-2013/remont/oem-general-information/#maintenance-and-general-information-repair-n54__11-removing-and-installingreplacing-acoustic-cover) .

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste-disposal regulations.

Unlock plug (1) and remove.

Release high-pressure sensor (2) and remove.

Tightening torque 13 53 3AZ with special tool 32 2 100.

Seal rail (3) if necessary with a matching plug from special tool kit 32-1270 PLUG .

Assemble engine.

Check fuel system for leaks.

Check function of DME.

11 61 365 Removing and installing/replacing left charge air duct (N54, N54T)

Necessary preliminary tasks

1. Remove «FAN COWL»(/bmw/z4/e89-2009-2013/remont/cooling-system-mechanical/#cooling-system-repair-n54__17-11-035-removing-and-installingreplacing)
2. Remove front «UNDERBODY PROTECTION»(ref-381258-S36346312162010122800000)
3. Remove «INTAKE SILENCER HOUSING»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-71-000-removing-and-installingreplacing)

Unlock quick-connect coupling.

Detach charge air duct (1) from charge air cooler (2).

Installation note

1. Coat sealing rings of snap fasteners with lubricant.
2. Pressure pipes must audibly snap into place.

Scheme 74

Release quick-connect couplings (1) by turning lock through 90°.

Detach recirculated-air hoses (2) and lay to one side.

Disconnect plug connection (3).

Unlock quick-connect coupling (5) and detach charge air duct (6) from throttle valve actuator.

Pull charge air duct (6) out of rubber grommet (4) and remove towards top.

Scheme 75

Installation note

Bring lock (1) back 90° into installation position.

Pay attention to markings.

Recirculated-air hoses must snap audibly into place.

Scheme 76

Scheme 77

Attach charge air duct (1) with special tool 11 8 670 to charge air cooler (2).

Installation note

Texts refer to and illustrations show the right side.

The procedure is identical for the left side.

11 61 362 Removing and installing/replacing right charge air duct (N54, N54T)

Necessary preliminary tasks

1. Remove «COOLANT EXPANSION TANK»(/bmw/z4/e89-2009-2013/remont/cooling-system-mechanical/#cooling-system-repair-n54__17-11-100-removing-and-installingreplacing)
2. Remove «UNDERBODY PROTECTION»(ref-381258-S36346312162010122800000)
3. Remove right «TENSION STRUT»(ref-381258-S30910208292010122800000)

Mark vacuum hoses (1) and detach.

Mark vacuum hose (2) and detach.

Unscrew nuts (3).

Release screw (4).

Tightening torque, screw 11 65 6AZ .

Raise bracket slightly.

Mark vacuum hose (5) on underside of pressure accumulator.

Remove vacuum accumulator with bracket.

Scheme 78

Release nuts (1) and screws (2), remove heat shield (3).

Scheme 79

Release clamps (1, 2), detach charge air duct (3).

Scheme 80

Installation note

Faulty O-rings must be replaced.

Prior to fitting, coat O-ring with suitable antiseize agent.

Scheme 81

Unlock and detach coolant hose (1).

Unlock quick-connect coupling.

Detach charge air duct (2) from charge air cooler (3) and remove towards top.

Scheme 82

Attach charge air duct (1) with special tool 11 8 670 to charge air cooler.

Installation note

1. Coat sealing rings of quick-connect couplings with antiseize agent.
2. Pressure pipes must audibly snap into place

Assemble engine.

Check DME (turbocharger) for correct operation.

13 54 030 Removing and installing/sealing throttle valve assembly (N54)

Necessary preliminary tasks

1. Switch off ignition
2. Remove left «CHARGE-AIR DUCT»(/bmw/z4/e89-2009-2013/remont/mechanical/#engine-repair-n54__11-61-365-removing-and-installingreplacing)

Unlock and disconnect line (1).

Unlock connector (2) and remove.

Release screws.

Tightening torque 13 54 1AZ .

Remove throttle assembly (3).

Scheme 83

Installation

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

Scheme 84

Installation

Check stored fault messages.

Now clear the fault memory.

13 62 531 Replacing coolant temperature sensor (N54)

Recycling

Catch and dispose of escaping coolant.

Observe country-specific waste-disposal regulations.

Necessary preliminary tasks

1. Read out fault memory of DME control unit
2. Switch off ignition
3. Remove «ACOUSTIC COVER»(/bmw/z4/e89-2009-2013/remont/oem-general-information/#maintenance-and-general-information-repair-n54__11-removing-and-installingreplacing-acoustic-cover)

Note. Coolant temperature sensor is mounted on cylinder head at front.

Unlock plug (1) and remove.

Release temperature sensor (2).

Installation

Tightening torque 13 62 1AZ .

Check COOLING SYSTEM for leaks.

Scheme 85

Note. Check stored fault messages. Now clear the fault memory.

Necessary preliminary tasks

1. Remove «IGNITION COIL»(/bmw/z4/e89-2009-2013/remont/gauges-instrument-panels/#engine-electrical-system-repair-n54__12-13-511-replacing-ignition-coils) of corresponding cylinder

Note. Ignition coils must not be fouled by fuel! The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail! Cloths/rags must therefore be used to prevent fuel from getting into the spark plug slots! Before installing ignition coils, clean spark plug slots with compressed air. Make sure the spark plug slot is absolutely clean. Remove PRESSURE LINE of corresponding cylinder

Note. The following description applies to all injectors.

Unlock plug (1) and remove.

Release screw and remove hold-down device (2).

Remove injector (3).

Note. If several injectors are removed, ensure that each injector is reinstalled in its original location (cylinder).

Mark injectors.

Procedure in event of stuck injector

Mount special tool 13 0 180 on injector (1).

Mount special tool 13 5 250 .

Carefully knock out injector (1) with special tools 13 0 180 and 13 5 250 .

After removing, fit protective caps (1 and 3) to injector tip and fuel line connection.

Protective caps are available from BMW Parts Department.

Installation

When installing a new injector

1. Replace uncoupling element (2).
2. Remove protective cap (1) from injector tip max. 10 min. before installation (PTFE sealing ring swells up).

Installation

When reusing fuel injector

1. Replace uncoupling element (2).
2. Replace PTFE sealing ring (1).

A PTFE seal which has been heated once by engine operation must be replaced before the fuel injector is reinstalled.

Replacing PTFE sealing ring

Before replacing PTFE sealing ring (1), make sure hands and work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

Remove PTFE sealing ring (1) with special tool 13 0 191 from injector (2).

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip (do not use ultrasound or other tools/agents).

Do not clean injector tip.

Slide new PTFE sealing ring (1) onto mounting taper 13 0 195.

User fingers and mounting taper 13 0 195 to slide PTFE sealing ring (1) onto injector (2).

Note. Do not use fingernails to slide PTFE sealing ring on. Do not use any lubricating agents. The sealing ring is expanded when slid on.

To bring the expanded PTFE sealing ring to its installation dimension, slide three assembly sleeves with decreasing diameters onto the injector.

Slide assembly sleeve (1) with large opening first onto injector (1).

Do not use any lubricating agents.

First slide assembly sleeve 13 0 192 (large diameter) onto injector (1).

Then slide assembly sleeve 13 0 193 (medium diameter) onto injector (1).

Finally, press injector (1) into assembly sleeve 13 0 194 (small diameter).

Installation

Install injector within 10 minutes or slide on protective cap see scheme 118 (PTFE sealing ring swells up).

Installing injector

Installation of injector is described separately from removal.

Before installing injector in engines that have been run

1. Check injector bore for dirt.
2. Clean injector bore: To do so, preferably slide injector without uncoupling element (2) but with new PTFE sealing ring (1) in and out of injector bores several times.
3. Clean contact surfaces of uncoupling elements (2) in cylinder head.
4. Replace uncoupling element (2).

An injector adjustment must be carried out if an injector is replaced or changed on the cylinder side.

Injector adjustment is carried out with the aid of a so-called adjustment value.

The adjustment value is printed in two blocks of three digits on the injector.

The adjustment value must be read off before installation!

Enter the adjustment value according to the installation position (cylinder) of the injector.

If injector adjustment is not carried out, the engine may run roughly or fail to start.

Description of injector adjustment at end of instruction.

Installing injector

Installation

Install hold-down device (1) with curvature facing upwards.

Install injector (3).

Install hold-down device (2).

Connect contact plug (1).

Note. Make sure hold-down device (1) is correctly seated.

Copper seals (1) that may be fitted on the pressure lines are no longer needed and must be removed.

If using the pressure line, apply a light coating of gear oil to the thread. New lines are already pretreated.

Connect pressure line (1), tightening nuts hand-tight only in the process.

Turn injector (2) if necessary in direction of arrow until nuts on pressure line can be easily screwed on by hand.

Tighten nuts on pressure line hand-tight.

Then tighten down bolt for hold-down device (1).

Tightening torque 13 53 5AZ .

Adhere to tightening sequence

1. First tighten down nut (1) on injector.
2. Then tighten down nut (2) on rail.

When tightening nut (1) on injector, grip hexagon head of injector with wrench (3).

Tighten down nuts with special tool 37 1 151.

Tightening torque 13 53 8AZ .

Carrying out injector adjustment

1. Connect DIS Tester
2. Identify car
3. Select "Function selection"
4. Select "Service functions"
5. Select "Engine electronics"
6. Select "Adjustment programs"
7. Select "Adjust injectors"
8. Change "Test schedule"
9. For each replaced injector, the adjustment value must be entered according to the installation position (cylinder).

Clean spark plug slot.

Assemble engine.

Check fuel system for leaks.

Check function of DME.

13 71 170 Removing and installing/replacing rear air duct (N54)

Necessary preliminary tasks

1. Remove left «TENSION STRUT»(ref-381258-S30910208292010122800000)
2. Remove front «UNDERBODY PROTECTION»(ref-381258-S36346312162010122800000)

Note. For purposes of clarity, the pictures show the engine removed.

Release sheet metal nuts (1).

Unfasten screws (2).

Remove heat shield (3).

Unlock and disconnect line (1).

Unlock connector (2) and remove.

Unlock and disconnect quick-connect coupling (3).

Scheme 86

Installation

Turn lock (1) until arrow markings are flush.

Risk of damage!

Air duct may break!

Scheme 87

Release screw (1).

Tightening torque 13 71 8AZ .

Release screw (2) and remove bracket (3).

Tightening torque 13 71 12AZ .

Note. Illustration with engine removed.

Pull off air duct (1) from turbocharger, feed out and remove.

Note. Illustration with engine removed.

Scheme 88

Installation

Check sealing ring (1) for damage.

Replace damaged sealing ring.

Make sure sealing ring (1) is correctly seated in air duct (2).

Scheme 89

Assemble engine.

Check air duct for leaks.

13 71 160 Removing and installing/replacing front air duct (N54)

Necessary preliminary tasks

1. Remove «FAN COWL»(/bmw/z4/e89-2009-2013/remont/cooling-system-mechanical/#cooling-system-repair-n54__17-11-035-removing-and-installingreplacing)
2. Draining «COOLANT»(/bmw/z4/e89-2009-2013/remont/cooling-system-mechanical/#cooling-system-repair-n54__17-00-008-draining-and-adding)

Unlock and remove coolant hose (1).

Release quick-connect coupling (2) by turning lock and detach.

Release hose clamp and detach air duct (3).

Tightening torque 13 71 5AZ .

Scheme 90

Installation

Turn lock (1) back until arrow markings are flush.

Push air hose onto air duct.

Air hose must audibly snap into place.

Release bolts and detach coolant hose (1).

Tightening torque 11 53 6AZ .

Installation

Check sealing ring.

Replace damaged sealing ring.

Scheme 91

Unfasten screws (2).

Tightening torque 13 71 6AZ .

Unclip A/C line (1) from holder.

Unlock and detach coolant hose (2) from coolant thermostat and release from holder (4).

Release coolant hose (3) from holder (4) and lay downwards to one side.

Scheme 92

Scheme 93

Detach air duct (1) in direction of arrow.

Note. Illustration with engine removed.

Installation

Check sealing ring (1) for damage.

Replace damaged sealing ring.

Make sure sealing ring (1) is correctly seated in air duct (2).

13 71 000 Removing and installing/replacing intake filter housing (N54)

Necessary preliminary tasks

1. Remove intake duct

Scheme 94

Unlock and disconnect line (1).

Unclip line (1) from intake filter housing.

Release clamp and detach air intake hose.

Tightening torque 13 71 5AZ .

Scheme 95

Release clamp and detach air duct.

Tightening torque 13 71 5AZ .

Pull off wiring harness holders (1) in upward direction.

Detach intake filter housing (2) from bearing journal and remove.

Scheme 96

Installation

Make sure intake filter housing is correctly seated on bearing journal.

Note. Assemble engine.

13 90 500 Replacing tank vent valve (N54)

Necessary preliminary tasks

1. Check stored fault messages
2. Switch off ignition
3. Remove «INTAKE FILTER HOUSING»(/bmw/z4/e89-2009-2013/remont/fuel-system/#fuel-system-repair-n54__13-71-000-removing-and-installingreplacing)

Installation location

The tank vent valve is located at the rear below the intake air manifold.

Unlock plug (1) and remove.

Unlock hose (2) and detach.

Unlock hose (3) on throttle valve assembly and disconnect.

Detach tank vent valve (4) from holder and remove.

Scheme 97

Note. Read out fault memory of DME control unit.

Now clear the fault memory.

See also:
• 13 0 290
• BATTERY NEGATIVE LEAD
• IGNITION COIL
• 32-1270 PLUG
• 13 53 5AZ
• INTAKE AIR MANIFOLD
• 00 7 300
• ACOUSTIC COVER
• 13 53 FUEL INJECTION NOZZLES AND PIPES
• FAN COWL
• COOLANT EXPANSION TANK
• 11 65 6AZ
• ESD PROTECTION (ELECTRO STATIC DISCHARGE)
• CHARGE-AIR DUCT
• COOLING SYSTEM
• COOLANT
• 13 53 310
• THROTTLE BODY
• PRESSURE LINES
• INTAKE FILTER HOUSING