E30 318i M40: Bosch injectors and tips - checking condition

Next on the agenda to find the culprit of the rough running and stalling idle was to examine the injector condition and the plastic tips. The injector bodies are quite rusty and corroded so they could well be the original set, but on closer inspection the tips are fine and they look to be in pretty good condition, so onwards.

To inspect the injectors the lower inlet manifold will need to be removed, which involves de-plumbing the fuel lines and some of the water hoses. 

E60: Engine Swap Week - Day 6

• Replace snapped T-piece on injector leak-off pipes.
• Torque up crank-pulley and HP-pump.
• Refit drive-belts.
• Refit radiators / coolers.
• Refit headlights and crash bar.
• Refit slam-panel and grilles / ducts.
• Plumb cooling, A/C and PAS back in at the front.
• Loosely refit exhaust and heat-shield.
• Fill with oil and coolant.
• Refit ECU and plug loom in.
• Plug in all wire connectors to engine.
• Refit fuel-rail and pipes.
• Refit turbo and exhaust-manifold.
• Refit rocker-cover and injectors.
• Refit inlet-manifold.
• Attempt start!

NOTE: Fasten engine-mount top nuts! Neaten up fuel-rail return pipe!

Well, sadly, it didn't fire right up in the first few tried like last time, but the battery has been sitting for a month and died quickly, so I will charge it overnight and have another crack tomorrow.

• Check for missing wire-connectors. Crank-sensor?
• Bleed injectors and check for rail pressure.
• Flywheel position sensor - is it a different flywheel? Swap to original.
• Check injector-leads for pulses with multimeter.
• High-pressure pump - does it need bleeding? Is it working?
• Is 'Service Due' warning affecting immobiliser?

If all these check out and it still won't go then I will have to get a computer on it and get some fault-codes. I'm back in work next week, without a break, so I should be able to bring the Launch home.

It's been a hella lot of work the last 6 days so it would have been nice to have the engine fire up on the third go like it did when I fitted the new cylinder head, but ah well, I'm full of optimism at the close of today.

Plastic T-piece nozzle snapped off in the injector leak-off hose. Luckily I got fuel pipes with the new engine [even though the pump itself was missing] and didn't have to buy a new one.

From an '03, to an '09 and now back to an '04 - this is the third head in the E60.

E39 530d: Fuel Boost Pump Problems

Symptoms:

The car refuses to start.

There is a loss of power when driving, particularly common while going uphill.

The engine is losing revs and stalling.

BMW Parts-Diagram: [From RealOEM.com - http://realoem.com/bmw/showparts.do?model=DL72&mospid=47545&btnr=16_0432&hg=16&fg=15]

No.	Description	Supplement	Qty	From	Up To	Part Number	Price	Notes
01	Rear fuel pipe		1		05/2001	16121184768
02	Rear fuel pipe		1		05/2001	16121184768
03	FRONT FUEL RETURN LINE	I	1		05/2001	16121184777
04	FRONT FUEL FEED LINE		1		05/2001	16121184774
05	FRONT FUEL RETURN LINE	II	1		05/2001	16121184780
06	DISTRIBUTION PIECE		1		05/2001	16121184632
07	Fuel hose	8X13MM	?		05/2001	13537563456	$44.77
	Rape methyl ester capability (RME)
08	Hose clamp	L12-15	?		05/2001	07129952104	$1.18
09	Diesel pump		1		05/2001	16126756157	$363.20
	For vehicles with Rape methyl ester version (RME)	S201A=Yes
09	Diesel pump		1		05/2001	16126756157	$363.20
10	BRACKET FUEL STRAINER	D=55MM	1		05/2001	13321702583	$16.33
11	Fillister head with washer	M6X25-Z1	1		05/2001	07119920161	$0.38
12	Vent pipe		1		05/2001	16111183301	$20.23
13	Fuel pipe		1		05/2001	16111183297	$19.50
14	Universal socket housing uncoded	2 POL.	1			61138373332	$2.70
	only in conjunction with
--	Socket contact ELO-Power 2,8x0,63	0,5-1,0 MM²	2			61138364832	$0.35

Items pictured but not listed are not installed on your vehicle.Notes

• Items pictured without a number are listed on another diagram.