13 53 158 Removing and installing/replacing rail (Bosch) (N55 Hybrid)

Special tools required:

WARNING: High-voltage system - danger to life!
The following points must be strictly observed prior to starting work :

Observe SAFETY INFORMATION for handling hybrid cars.

WARNING: Observe warning on cylinder head cover.
Disconnect NEGATIVE BATTERY TERMINAL and NEGATIVE BATTERY TERMINAL OF AUXILIARY BATTERY (risk of fire caused by short circuit during dismantling).
Electric fuel pump starts up automatically when door is opened!
Carry out installation work on fuel system only with coolant temperature below 40 °C.

IMPORTANT: Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the high pressure line is released!

IMPORTANT: Adhere to conditions of absolute cleanliness when working on the high-pressure fuel system.
Introduced contaminants can cause malfunctions in the system!

Do not allow any dirt particles or foreign bodies to get into the system.
Remove all traces of dirt before removing lines or separate components.
Use only fluff-free cloths.
Seal all fuel system openings with protective caps or plugs.

IMPORTANT: When working on the oil, coolant or fuel circuit, you must protect the alternator against dirt contamination.
Cover alternator with suitable materials.
Failure to comply with this procedure may result in an alternator malfunction.

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Necessary preliminary work:

Disconnect PRESSURE LINES .
Remove INTAKE SILENCER HOUSING .

Release wiring harnesses (1) from rail and lay to one side.

Undo clamps (2) from rail.

Fig 1: Identifying Wiring Harnesses And Clamps

Courtesy of BMW OF NORTH AMERICA, INC.

Slacken nut (1).

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

Release screws (3).

Remove rail (4).

Fig 2: Identifying High-Pressure Sensor Plug, Rail And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Installing the rail:

Rail installation is described separately from removal.

Installation note:

Before installing the rail, renew the decoupling elements (1).

Fig 3: Identifying Decoupling Element And Sleeves

Courtesy of BMW OF NORTH AMERICA, INC.

Install (4) rail while manually tightening nuts (3) and bolts (1).

NOTE:

Rail must still be displaceable on cylinder head.
Nut (2) must be able to be screwed on easily by hand.

Fig 4: Identifying High-Pressure Sensor Plug, Rail And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

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

IMPORTANT: Connect pressure line (1) without tension only.

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!

Fitting pressure lines:

(Same procedure for all pressure lines)

Install pressure line (1). Tighten nuts (2) hand-tight only.

Reinstall line damper (3).

Fig 5: Identifying Pressure Line And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten down screws (1).

Tightening torque 13 53 2AZ .

Fig 6: Fuel Rail Mounting Screws And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: Reset special tool in early to avoid bending pressure lines.

Adhere to tightening sequence:

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

Tighten nuts with special tool (3) 13 0 161 from the set of special tools 13 0 160 .

Tightening torque 13 53 9AZ .

Fig 7: Identifying Injector And Rail Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Tighten nut (2).

Tightening torque 13 53 8AZ .

Fig 8: Fuel Rail Mounting Screws And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Assemble engine.

Check fuel system for tightness.

Check function of DME.