BMW 525 tds Turbocharger Replacement

My brother and I are planning to replace the injectors (injector bodies only) in his BMW 525tds, E39, manufactured in 1999.
I have experience with the TDI injectors from my AHU engine, and I have a device to test the opening pressure. Bosch specifies a value of 150 bar.

I'd like to know in advance if there's anything specific to consider when working on a BMW. Ideally, the process should be comparable to that of a regular VW TD. I have the instructions for the Golf 3 1.9 TD, but they specify a setting of 158 bar.

Has anyone replaced the injectors on this 2.5 TDI engine or the 2.5 TD Opel (which uses the same injectors)?
Are these single-spring nozzle holders or double-spring nozzle holders?
Is the thread size the same as for VW TDI engines?

I would be very grateful for any comments, instructions, and tips.

Best regards, Georg.

Now I've found a little time to comment on the nozzle replacement.

These were the older types of nozzle holders with spigot nozzles.
The thread: standard M12.

To replace the nozzles, you need a 27mm long socket with a side opening for the NBF tool.
If you do not want to mix the nozzle with NBF, the nozzle can still be replaced without removing the intake manifold.

We removed the exhaust manifold and checked all the injectors.
Nozzles replaced, bled, and reinstalled.
Although the nozzles were thoroughly cleaned before assembly and the new folding seals were installed,
Three out of six nozzles were leaking after the engine started.
A large amount of diesel fuel leaked out of the threaded rod.
Okay, the nozzles are out again, cleaned, new sealing rings installed, and that's it.
We had to repeat the procedure several times on the nozzle until it was absolutely leak-proof.
Therefore, it is highly recommended to acquire several sets of copper sealing rings and corrugated gaskets.
We used new sealing rings for the intake manifold, but it wasn't actually necessary.

In summary, the replacement process was considerably more complicated than it was with my TDI.

The result:
Better start, more powerful engine, reduced soot emissions, and slightly lower fuel consumption.
There's nothing standing in the way of achieving another 200,000 kilometers.

Best regards, Georg.

Hello everyone,


Short question: Where did you source these copper rings from? Dimensions: 21.6 x 17.6 x 1.5 mm.

So far, I haven't had any success with the local BMW dealerships (not through the electronic parts catalog), our local engine rebuilder, or our Bosch service center.

"Therefore, it is highly recommended to acquire several sets of copper sealing rings and corrugated gaskets."


AND - how did you verschandeln the injector threads and sealing surfaces on the cylinder head before reinstalling the injectors?


Thank you in advance for your replies!



Best regards,


Ralph.

You can find the correct seals where you buy the fuel injectors - perhaps not necessarily from sellers on platforms like eBay who don't know what they're selling.

Tip: You can find many "standard parts" like CU sealing rings, etc. in an agricultural machinery workshop. They still do a lot of repairs there, and therefore, they usually have materials in stock.