Mine was also a manual, soon after buying I had my Indy change the g/box & diff oils - as it happened the stuff in there was OK but I'm a great believer in 'preventative maintenance' because oil's cheap for what it does.
Has it really been 18 months since I last posted on this thread? I still have my trusty E39, but unfortunately after noticing a strong smell of diesel through the ventilation system when driving it, I discovered there is a fuel leak from or near the injectors. While I know that the phrase "M57 injectors" is one that can strike fear in even the bravest of us, I decided that I didn't want to pay a garage for work that could very easily hit four figures, and decided to investigate it myself. After removing the engine cover, look what I found! At least two of the clamps that hold the injectors in place are cracked, and the ones that aren't are damaged. I think a previous owner replaced the injectors, didn't have the right tools, and levered them out with a screwdriver or something. So I decided to pull all six, replace the clamps, copper washers and O rings, and leak-off pipe. I borrowed an injector puller from a mechanic neighbour and got one out fairly easily: I was unable to get the other five out because the tool of the correct size in the generic kit I borrowed doesn't fit over the plastic injector cap. I was lucky with the first one because there was room to rotate the entire cap around to remove the top. To pull them, you have to unscrew the cap of the injector, exposing the innards , then screwing on the tool which is basically a slide hammer, in the cap's place. I've ordered the correct tool, which should hopefully arrive this week, then if all goes the plan I'll get the other five out, get them checked by a diesel place nearby who can do them for £15 each, then reinstall everything, which should be the reverse of removing them. I'll just be swearing in different places. Wish me luck!
Just want to say great thread!! and keep it coming! My first foray into BMW ownership was an E39 523i manual. It was a fantastic car, really solid and very DIYable in terms or work and maintenance. I documented a fair bit of the work I did on it on the old site. The engine bay was relatively "roomy" even with the 2.5 litre lump in there. I can't remember having to give it to a garage to do any maintenance in all the years I owned it. In hindsight I regretted selling it as it was so nice but such is life... glad to see you keeping this one up and running! ~S.
Well, this is not going well. I can't get the other five injectors out. Not because they are stuck (I don't know if they are yet) but because I can't find a way to attach the slide hammer to them. It seems there are two ways to pull the injector from these engines: Pull them from the fuel connector (the things in between the holes stuffed with paper towels in my earlier post) Unscrew the cap of the injector and screw on an adapter in the place of the cap. I'd prefer to do 1, which I am told will work if they are not too stuck, but the puller set I have has no adapter that will screw on to this. I can't do 2 because I can't get the caps off, despite trying THREE different tools sold for the purpose, because none of them fit, all for different reasons, the last one I tried not having enough clearance to fit! I'm not sure what to do now, other than scrapping the car.
Looks like you are not alone : Real eye opener when he said the front of the car was lifting! Looks like number 2 is the winner... This one illustrates just how stuck they can be!! Pretty sure that's an officeial BMW trebuchet injector removal tool ~S.
Yes, I'd already watched both those videos as well as a few others. The first one did come out reasonably easily, so hopefully the other five aren't too stuck. I've ordered yet another tool that I am assured will attach correctly, I'm just waiting for it to arrive. Autodoc isn't the fastest!
So, it's proven to be a no go trying to pull the injectors using the fuel connector. The angle is just too off to be able to get enough force to free them. That means I will have to remove the tops, so I can screw on the slide hammer on to there. As I mentioned earlier I am having great difficulty getting them off. The problem, in more detail is as follows: The window socket on the right would fit the nut on the injector, but because it gets narrower about 15mm in, it won't fit over the cap. So I ordered the one on the left, which does fit over the cap, but won't go on because the walls are significantly thicker and there isn't enough clearance due to other parts of the engine. So I am at a bit of a loss as to what to do. I'm wondering if it's possible for someone with a metalwork lathe to shave off a couple of mm from the circumference. The one on the left is 3.5mm wider than the one on the left.
I eventually got the tops off after having the socket modified by a machine shop, but ended up breaking the slide hammer attachment, so I took a deep breath and forked out £100 for an injector puller specifically designed for M57 engines. I literally cannot move the spanner any further and the injector still won't budge. The bleeding thing must be welded in!
Thats crazy! I think it says a lot that someone actually went to the trouble of building a tool specifically for this engine! Have you tried Impact gun/Breaker bar? You would be able to get more torque on it with a bigger lever. Shocks from impact wrench might help too. ~Shaun
I've got 5 of the 6 out. Two came out easily, two with a slide hammer and a lot of effort, and one with this tool. it's the last one that's a real pig. I'm scared of snapping off the part arrowed. The really annoying thing is new injectors are going to cost me more than I paid for the car. But I've gone this far now...
Yes it's crazy. Yep I need a bigger lever. But I'm worried about snapping off part of the cylinder head. I don't have an impact wrench. EDIT: Just tried a longer spanner, and it ripped the thread out of the inside of the injector.
Depending on much meat there is left on the injector I'd suggest drilling, tapping and helicoiling the injector body to resume pulling. I'd be soaking the injector day and night with penetrating oil. If you can hammer the injector I'd be doing that too, not too hard, but lots of times. With seized bolts and screws a good hammer first often fractures the corrosion,
Thanks for the advice. My mechanic neighbour suggested using a professional guy he uses when he can't get them out, so I think I am going to do that, as I don't feel comfortable going any further and risking breaking something. I'd previously soaked the thing in carb cleaner, although a couple of people have recommended cola, they say the phosphoric acid in that will eat away at the corrosion.
This popped up on my facebook reels.... instantly thought of this thread.... https://www.facebook.com/reel/1207185440483418 Interesting tool... Any further update? ~S.
Hi yes I've seen that pneumatic tool before, they look awesome. The injector guy came round last week, had a look and told me he'd have to drill out the inside, tap it, and then pull it that way. The car's outside so he says he'll come and do it when it eventually stops raining. He says it's £150 if it comes out that way, £450 if he has to machine the entire thing out. As I'm already going to have to spend at least £1000 on five new injectors, this is proving to be an expensive little project!
