13 53 158 Removing and installing/replacing rail (N20 hybrid drive)

WARNING: High-voltage system - danger to life
Compliance with the following points is mandatory before beginning work:

Observe SAFETY INFORMATION for working with electric vehicles.

WARNING: Observe warning on cylinder head cover.
Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short circuit on 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.

Attention!

Wear full face guard and protective gloves.

Fuel can emerge spontaneously at high speed when the high pressure line is released!

Attention!

Adhere to conditions of absolute cleanliness when carrying out repair work 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 contamination before removing lines or separate components.
Use only lint-free cloths.
Seal all fuel system openings with protective caps or plugs.

Attention!

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.

Attention!

Ignition coils must not be contaminated by fuel.

The resistance of the silicone material is reduced significantly by contact with fuel, which may cause the ignition coil to fail!

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Necessary preliminary tasks:

Disconnect NEGATIVE BATTERY TERMINAL .
Remove IGNITION COILS .
Remove PRESSURE LINE .

Removal:

Unlock and disconnect plugs (1).

Unlock and release clamp (2).

Thread out wiring harness (3) and place to side.

Fig 1: Identifying Injector Wiring Harness, Connector And Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock connector (1) and pull off.

Unscrew nuts (2).

Loosen screws (3).

Remove rail (4).

Fig 2: Identifying Rail, Screws, Connector And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Slacken nut (1).

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

Fig 3: Identifying Ground Cable And Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Installation:

NOTE: Reconnecting:
When reconnecting the fuel line, lubricate the outer thread. Penetration of lubricant into the fuel-conducting area should be avoided.

NOTE: To relax the fuel system the hold-down devices must be slackened at the injectors before the rail is installed.
Release screws (1) and (2) and slacken hold-down device (3).

Fig 4: Identifying Hold-Down Device And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Install (4) rail, manually tightening nuts (3) and bolts (2) only.

NOTE:

Rail must still be displaceable on cylinder head.
Nuts (2) must be able to be screwed on easily by hand.
Connect and lock connector (1) for rail pressure sensor.

Fig 5: Identifying Rail, Screws, Connector And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Observe screwing sequence.

First tighten screw (1).
Tightening torque 13 53 5AZ .
Then tighten screw (2).
Tightening torque 13 53 5AZ .

Fig 6: Identifying Screws
Courtesy of BMW OF NORTH AMERICA, INC.

Observe screwing sequence.
First tighten screws (3).
Tightening torque 13 53 4AZ .
Then tighten nuts (2) at the injectors.
Tightening torque 13 53 6AZ .

Fig 7: Identifying Rail, Screws, Connector And Nuts

Courtesy of BMW OF NORTH AMERICA, INC.

Thread in and install ground cable (1), and tighten nut (2).

Tightening torque 12 52 2AZ .

Fig 8: Identifying Ground Cable And Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Feed in and install wiring harness (3).

Attach and lock connector (1).

Connector (1) must engage audibly.

Connect clamp (2) and lock.

Fig 9: Identifying Injector Wiring Harness, Connector And Clamp

Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work:

Install PRESSURE LINE .
Install IGNITION COILS .
Connect the NEGATIVE BATTERY TERMINAL .
Check fuel system for leak tightness.