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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 12-13-2013, 10:41 AM
Dragan Dragan is offline
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Fuel Injector Leak on 530i when freezing cold

It's been below -20 degrees Celsius pretty consistently here in Thunder Bay, Ontario for a while now and I've been smelling fuel in the cabin as of late. Turns out the fuel injectors themselves are leaking and not the upper nor lower o-rings.



Here's a video of my girlfriend turning the ignition on but not cranking the car when cold. As soon as the fuel pump builds pressure, the injectors leak. All six (even though I don't show it in the video). They are instantly saturated.

The temperature was -27 degrees C when this video was taken and the car sat overnight. No block heater (but I ordered one from one of the western Canadian BMW dealerships).

I guess I'm out about $700 thanks to Siemens.

I used doru's thread as a reference and I also cited his thread in my YouTube video in the description.

Hope this helps others.
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Last edited by Dragan; 12-13-2013 at 10:44 AM.
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  #2  
Old 12-13-2013, 11:07 AM
cn90 cn90 is offline
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So it leaks from the ? cracked plastic casing rather than the O-ring, correct?

There is a used set for $80, taken from an E60:
(same PN 13537546245)
http://www.ebay.com/itm/M54-Fuel-Inj...-/200994004862
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  #3  
Old 12-13-2013, 11:19 AM
Dragan Dragan is offline
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Correct. I guess the metal housing shrinks a bit quicker than the plastic housing and when temperatures are extreme enough, they cause a leak form the body.

And those injectors (from the E60) will likely suffer from the same problem. Apparently Siemens VDO found and fixed the problem and has been making "good" ones since then. Not sure exactly when that was.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #4  
Old 12-13-2013, 11:47 AM
cn90 cn90 is offline
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I wonder if this qualifies as "safety recall" and they should fix it for free.
The problem you have seems unique to PN 13537546245 for 530i series.
I don't have any issues with my injectors.
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  #5  
Old 12-13-2013, 11:53 AM
Dragan Dragan is offline
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I always thought that a fuel leak, especially in the engine bay, qualifies for a safety recall.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap

Last edited by Dragan; 12-13-2013 at 12:30 PM.
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  #6  
Old 12-13-2013, 02:32 PM
poolman poolman is offline
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As these cars age, it seems like this is coming up more often. Wonder if the problem is the same for the 525 engines? They had different injectors,,but were made by the same company.
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  #7  
Old 12-13-2013, 02:52 PM
CitizenOfDreams CitizenOfDreams is offline
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I have had good luck with rebuilt injectors (eBay seller "fuelinjectorconnection"). I paid $120 for the set of 8.
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  #8  
Old 12-13-2013, 04:00 PM
Dragan Dragan is offline
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poolman: As far as I know, I've only heard about this defect with the injectors for the 3.0L engines.

Citizen of Dreams: Apparently rebuilt injectors don't remedy this problem. And my injectors were fine until my car was exposed to these kind of temperatures.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #9  
Old 12-14-2013, 06:59 AM
CitizenOfDreams CitizenOfDreams is offline
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Quote:
Originally Posted by Dragan View Post
Citizen of Dreams: Apparently rebuilt injectors don't remedy this problem.
How about rebuilt injectors of a different model? I can't imagine that all injectors that fit your engine have the cold leaking problem.
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  #10  
Old 12-14-2013, 08:02 AM
Dragan Dragan is offline
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Quote:
Originally Posted by CitizenOfDreams View Post
How about rebuilt injectors of a different model? I can't imagine that all injectors that fit your engine have the cold leaking problem.
You're right. Once Siemens VDO became aware of this issue, they've found the problem and fixed the issue. They have been making good injectors since.

I've contacted BMW Canada regarding this issue and they will be looking into it.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #11  
Old 12-14-2013, 08:30 AM
EconoBox EconoBox is offline
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At $85 a pop, that's a nice hit to the wallet.
At least your car didn't light on fire.
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  #12  
Old 12-14-2013, 12:13 PM
poolman poolman is offline
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With this going on and starting to be known by owners--hope that BMW will stand up and help with the fix for you on this.. I have for years lookd into using the Bosh injectors with the 4 holes at the bottom,,they are supposed to help fuel atomozation and that would help with fuel mileage and power also. Thing is,,there's something special about our intakes on these carsw that won't allow the use of anything else but what came in the car. Now Bosh does make an injector for the 525,,but that are about 200 buck a peice....There aren't generic injectors that will work. Some may be modifies to work--but that's not for sure either.
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  #13  
Old 12-14-2013, 05:08 PM
CitizenOfDreams CitizenOfDreams is offline
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Bosch doesn't even claim to make injectors for your engine. At least I couldn't find one on Bosch Auto Parts website.

I guess you either have to go with other brands (Beck/Arnley, GB...), or find a Bosch injector that matches your original ones (same physical size, coil resistance and flow rate).
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  #14  
Old 12-16-2013, 12:28 PM
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doru doru is offline
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Dragan, I watched your vid. Your leak is very small compared to what I had... Mine were actually "spraying" around that distorted mating area, having affectively a "cloud" of fuel vapors coming out. I was really scared to drive that thing after I saw what was going on under hood. All that would take was a miniscule spark. Think: starter, alternator, any different electrical contacts & connectors....
That should have been a safety recall as far as I'm concerned. But at 600+ $ a pop, I don't think BMW was eager to acknowledge the issue. Car out of warranty - you're on your own: they call it wear & tear......
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  #15  
Old 12-16-2013, 03:53 PM
Dragan Dragan is offline
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I actually got a call back today from BMW Canada wanting to know more information regarding my situation. Unfortunately, I missed their call since I'm in the midst of finals at school so they left me a voicemail to call them back. By the time I was done, I called back and no one picked up. I guess I'll have to wait until tomorrow.

Doru, I hope my situation doesn't become as bad as yours. I'm already worried as it is.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #16  
Old 12-16-2013, 08:51 PM
cn90 cn90 is offline
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Actually, this is a serious hazard, many car makers if they see a pattern may respond with a safety recall.

Believe it or not, a friend has a 2000 Mercedes MLB 350 series, PS hose broke and sprayed fluid (a fire hazard). I searched and found out there was a recall, even 13 years later. She got her Mercedes fixed for free even 13 years later.

The bottom line:
- Be nice to BMW Canada!
- They will likely ask you to bring the E39 to local dealer, if you do so, drive slowly with a fire extinguisher in the trunk.
Or better yet, tow the baby to dealer.
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  #17  
Old 12-19-2013, 11:13 AM
Dragan Dragan is offline
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I spoke with BMW Canada. Explained my situation in detail to a guy named Stefan, and he will be forwarding the information and video to the engineers and other people further up the ladder for further investigation. I'm sure it will be quite a while before I hear from them again.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #18  
Old 01-22-2014, 05:33 PM
yoyomin yoyomin is offline
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I guess I replied to your YouTube video. BMW Canada told me to bring the car to a dealer for inspection. But the thing is once the car is warmed up there is no leak what so ever. The dealer has to wait for the car to cool down to minus 20c before they could see the leak. After being parked in a garage at about 0C I drove my car yesterday, no leak. It really has to be extremely cold before the leak.
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  #19  
Old 01-22-2014, 05:42 PM
Dragan Dragan is offline
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Yea. It has to be AT LEAST below -20 for the leak to appear. They told me to bring it in to a dealer for inspection but considering I live in Thunder Bay and the closest dealer is about 7.5 hours away (Winnipeg) it's not exactly feasible. If you were to do it, you'd probably have to leave it at a dealer overnight where the night is cold enough for it to leak. That way, once they look at it first thing in the morning, they'll see (and smell) it and there won't be the whole "cannot replicate customer complaint" business. Where abouts are you?
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #20  
Old 01-22-2014, 07:40 PM
yoyomin yoyomin is offline
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I'm in Ottawa so dealer is reasonably close. I asked if there would be costs associated to the inspection. Still waiting for reply from BMW Canada. Sucks that now I have to check the weather before driving...
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  #21  
Old 01-23-2014, 05:52 AM
Dragan Dragan is offline
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I feel the pain, man. Keep me posted on your situation.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #22  
Old 01-23-2014, 10:05 AM
yoyomin yoyomin is offline
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Just got reply saying that I would need to pay for inspection. I also gave my contacts for a formal complain. I doubt that they will have a recall for this issue tho, since it only affects very few people living in cold areas. I checked again for the leak, the fuel seems to be coming from the seam between the metal body and plastic part, also from inside the electrical connector. I'm wondering if there is a way to take the injectors apart to change internal o-rings?
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  #23  
Old 01-23-2014, 10:23 AM
Dragan Dragan is offline
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That sucks. I'm curious to see what happens. Thanks for the update. Not sure about the internal seals though.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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  #24  
Old 01-27-2014, 10:38 AM
Rick Hayes Rick Hayes is offline
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Cold as Ice

I am having the same issue with my car. Had it fixed a couple of weeks ago when I noticed the problem. However, it happened again today. Now that I see your post, it sounds like the injectors and not the O-rings. Great.
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  #25  
Old 01-27-2014, 11:06 AM
Dragan Dragan is offline
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Sorry to hear that. It's a shame you didn't come across this before you had it fixed. Nevertheless, I'm glad I could help.
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2002 530i Sport Package 5-speed
Style 42s for summer
Style 29s for winter
CDV delete
Skibag retrofit
G.A.S. DISA Valve Repair Kit
G.A.S. 1.2 Bar Expansion Tank Cap
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