Removing and installing/replacing all fuel injectors (B46/B48 4-Cyl. Engine) (4' Series Coupe/Convertible, 4' Series Gran Coupe Sedan)

Special tools required: 

• 2 358 417 
• 13 0 190 
• 13 0 280 
• 13 0 282 
• 13 0 283 
• 2 358 022 

Before removing the rail and the injectors, clean or draw off the injector shafts.

Recycling: 

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Necessary preliminary work: 

• Remove IGNITION COILS .
• Release PRESSURE LINE  between rail and high pressure pump.

Removal: 

Slacken nut (1).

Thread out ground cable (2) and place to side.

Pull out the cable channel (3) and put it aside.

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Unlock and release connectors (1) for injectors.

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Unscrew the sealing cap (1) of the oil filler neck.

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Dismount the drip shield (1) from the cylinder head cover.

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Screw on the sealing cap (1) to the oil filler neck.

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Before releasing the high-pressure rail: Blow out the injector shafts with an air gun (1) with less pressure.

Simultaneously, draw off the dirt particles with an explosion proof vacuum cleaner (2).

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Release screws (1) M5x30.

Remove screws (1). Screws (1) must not  be reused!

Parts:  Screws M5x30.

Catch and dispose of escaping fuel with suitable materials.

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Unlock and disconnect plugs (1).

Release bolts M6x70  along the arrows.

Bolts may not  be reused!

Replace screws.

Parts:  Screws M6x70.

Remove rail upwards.

Injectors remain in the cylinder head.

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If fitted: 

Remove seals (1).

Seals (1) are not  required and will not  be installed any more!

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Injectors may be twisted to a maximum of 13 Nm with a torsional movement.

The special tool 2 358 417  is required in order to remove the injectors.

Using the special tool 2 358 417  ensures that the tensile force is not exceeded.

Special tool 2 358 417  consists of:

1. Threaded sleeves
2. Pull-out thread (left-hand thread)
3. Fixture for injector

Unscrew fixture for injectors (1) from special tool 2 358 417  .

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Press in lock (1) and remove threaded sleeve (2) from special tool 2 358 417  .

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Install all fixtures (1) for the injectors.

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Rotate the mounting (1) at 90° and latch the lock (2) downwards.

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Attach special tool 2 358 417  to cylinder head.

Tighten bolts finger tight along the arrows.

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Screw in pull-out thread (1) completely.

Pull-out thread (1) is a left-hand thread  .

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Insert threaded sleeves (1) again and screw threaded sleeves completely onto the fixtures for injectors.

Then tighten the bolts along the arrows to 5 Nm  .

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Adjust torque wrench to 13 Nm  in a clockwise rotation.

Turn torque wrench in clockwise direction until the injector is pulled out.

Disassemble all injectors individually.

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Before removing the special tool with the injectors check, whether all injectors were completely removed from the cylinder head. This can be seen on the fully visible threads (1) of the brass sleeves.

Release screws and carefully remove puller 2 358 417  with injectors vertically upwards from the cylinder head.

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Place the combination of special tool 2 358 417  and injectors (1) flatly on a clean table.

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Unlatch the lock (1) of the fixture upwards.

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Rotate the unlocked fixture (1) at 90°. Release and remove the injector downwards.

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Preparation for installation: 

Replace Teflon ring: 

Before the injectors are installed, the Teflon rings (1) at the injectors must be replaced.

Part:  Teflon rings.

Before replacing the Teflon ring (1), make sure your hands and the work surface are clean and free of oil.

Avoid mechanical contact with injector tip (2).

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Remove Teflon ring (2) from the injector (1) using special tool (3) 13 0 191 from the set of special tools 13 0 190  .

Use a fluff-free cloth only to remove combustion residues from cylindrical part of injector tip. (do not use ultrasound or other tools/agents)

Do not clean injector tip!

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Push new Teflon ring (1) onto installation cone (2) 13 0 283 from the set of special tools 13 0 280  .

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Fit Teflon ring (1) on injector tip (3) with installation cone (2) 13 0 283 from set of special tools 13 0 280  .

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Use special tool (1) 13 0 281 from set of special tools 13 0 280  to slide Teflon ring into groove (3) on injector.

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To adjust the widened Teflon ring to the installation dimension, special tool (1) 13 0 282 from set of special tools 13 0 280  must be slid up to limit position on injector (2).

Do not use any lubricating agents.

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An injection quantity compensation must be carried out if an injector is replaced or changed on the cylinder side.

Injection quantity compensation is carried out with the aid of a so-called adjustment value.

Additional information regarding the injection quantity compensation can be found at the end of the repair instructions.

Installation: 

Mount retaining bridge (1) via bayonet fitting (2) to injector.

If fitted: 

If the retaining bridge (1) is equipped with a cast lug, the correct installation position needs to be observed.

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Retaining bridge mounted properly  , cast lug is at rear.

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Retaining bridge mounted improperly  , cast lug (1) is at front.

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Distance gauge (1) 2 358 022  .

Not using the gauge may present the risk of cracking weld seams at the injector! 

The thickness of the distance gauge is 8.5 millimeter. If the actual value drops below this dimension, the distance gauge needs to be replaced.

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Mount injectors with retaining bridges and new  screws (M5x30) to the rail.

Keep the rail on a clean table in such a way, that the holders on the Rail are visible upwards. The electrical injector connections must then lie to the left of the holders of the rail.

Slide the distance gauge (2) 2 358 022  between retaining bridge and rail on top of the injector head.

Make sure the distance gauge rests against the retaining bridge!

Equally tighten both injector screws (1) M5x30 by hand until the distance gauge rests plane against the rail and the retaining bridge.

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Then the distance gauge (1) 2 358 022  is to be removed again.

Repeat this operation for all injectors.

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Check injectors (1) for loose fit on the rail.

Align connectors of the injectors (1) roughly parallel to the rail, injectors (1) need to be freely movable!

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1. Mount rail (1) with injectors from above onto cylinder head.

   Attach and lock connector (2).

   Connector (2) must engage audibly.

   1. Make sure the injector tips catch the corresponding holes in the cylinder head.
   2. Make sure the alignment lugs of the injector are properly inserted into the retaining holes on the cylinder head.
2. As soon as resistance is felt on pressing downwards, fit the rail screws M6 x 70 (A), (B), (C) and (D) and hand-tighten.
3. Tighten bolts (A), (D), (B) and (C) alternately with 90° with the torque wrench until the high-pressure rail rests on the cylinder head (see illustration below.
4. Tighten rail screws in the following order by 5 Nm: 
   1. Tighten screw (A) by 5 Nm.
   2. Tighten screw (D) by 5 Nm.
   3. Tighten screw (B) by 5 Nm.
   4. Tighten screw (C) by 5 Nm.

   Rail bases (1) are open on cylinder head.

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   Fig 1: Rail, Fuel Injector Screws Tightening Sequence

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1. Now tighten injector screws M5x30 in pairs (1 with 2, 3 with 4, 5 with 6, 7 with 8) and in alternating order through 90° until they are hand-tight using the socket on the extension (without reversible ratchet or torque wrench!).)  .
2. Screw the injector screws M5x30 according to the following plan:

   Set torque wrench to 5 Nm  .

   Compliance with the sequence is absolutely mandatory!

   • Fuel injector 1: 
     1. Tighten injector screw (1) by 90° with torque wrench.
     2. Tighten injector screw (2) by 90° with torque wrench.
     3. Repeat steps  a and  b until both screws have reached 5 Nm  .
   • Fuel injector 2: 
     1. Tighten injector screw (3) by 90° with torque wrench.
     2. Tighten injector screw (4) by 90° with torque wrench.
     3. Repeat steps  a and  b until both screws have reached 5 Nm  .
   • Fuel injector 3: 
     1. Tighten injector screw (5) by 90° with torque wrench.
     2. Tighten injector screw (6) by 90° with torque wrench.
     3. Repeat steps  a and  b until both screws have reached 5 Nm  .
   • Fuel injector 4: 
     1. Tighten injector screw (7) by 90° with torque wrench.
     2. Tighten injector screw (8) by 90° with torque wrench.
     3. Repeat steps  a and  b until both screws have reached 5 Nm  .
   Fig 2: Rail, Fuel Injector Screws Tightening Sequence

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3. All injector screws (1) to (8) must be marked by a line (see illustration).

   Tighten injector screws with an angle of rotation! 

   1. Tighten injector screw (1) with an angle of rotation of 90°.
   2. Tighten injector screw (2) with an angle of rotation of 90°.
   3. Tighten injector screw (3) with an angle of rotation of 90°.
   4. Tighten injector screw (4) with an angle of rotation of 90°.
   5. Tighten injector screw (5) with an angle of rotation of 90°.
   6. Tighten injector screw (6) with an angle of rotation of 90°.
   7. Tighten injector screw (7) with an angle of rotation of 90°.
   8. Tighten injector screw (8) with an angle of rotation of 90°.
      Fig 3: Rail, Fuel Injector Screws Tightening Sequence

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4. Check whether all injector screws (1) to (8) have been tightened with an angle of rotation of 90°.

   All marks (dashes) must lie diagonally (see illustration).

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5. Release rail screws M6x70 (A), (B), (C), (D) (releasing procedure is mandatory!)  .

   After that, tighten rail screws again in the following order by 5 Nm: 

   1. Tighten screw (A) by 5 Nm.
   2. Tighten screw (D) by 5 Nm.
   3. Tighten screw (B) by 5 Nm.
   4. Tighten screw (C) by 5 Nm.

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6. All rail screws (A) to (D) must be marked by a dash (see illustration).

   Tighten rail screws M6x70 (A), (B), (C), (D) with an angle of rotation of 90°.

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7. Check whether all rail screws (A) to (D) were tightened by an angle of rotation of 90°.

   All marks (dashes) must lie diagonally (see illustration).

   Connect and lock connectors (1) to injectors.

   Connectors (1) must engage audibly.

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   Connect connector on the injectors until the lock (1) engages audibly.

   Then lock the lock (1) in the direction of the arrow.

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   Feed in cable channel (3) to rail and install.

   Feed in ground cable (2) and install.

   Tighten nut (1).

   Tightening torque 12 52 5AZ .

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   Unscrew the sealing cap (1) of the oil filler neck.

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   Mount the drip shield (1) on the cylinder head cover.

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   Screw on the sealing cap (1) to the oil filler neck.

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   Required follow-up work: 

   • Install IGNITION COILS .
   • Install PRESSURE LINE  between rail and high pressure pump.
   • Connect NEGATIVE BATTERY CABLE .
   • Check fuel system for leak tightness.
   CAUTION: If a solenoid injector was replaced or replaced on the cylinder side, the ultra small quantity adaptation must be reset.

   Reset ultra-small quantity adaptation: 

   • Connect diagnosis system and follow the diagnosis instructions.
   • Read out vehicle data
   • Identification without vehicle test
   • Start vehicle test
   • Vehicle handling
   • Service functions
   • Power train
   • Engine electronics
   • Reset adaptation values
   • Adaptation values of fuel system
   • Continue service function