REP-TAT-P-1353-02 Installing the high-pressure rail at the cylinders 1 to 3

WARNING: This page is about a different car, the 2018 BMW 340i, 2017 BMW 340i, and 2016 BMW 340i. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Non-observance of these requirements may result in leaks and damage.

Prepare the injectors for installation

NOTE: RISK OF DAMAGE
Damage to the injector tips and Teflon ring.
Improper handling of the injector tips and Teflon ring can lead to malfunctioning of the injector.

Avoid mechanical contact with injector tip.
When exchanging Teflon ring, hands and work surface must be clean and free of oil. Do not use any lubricating agents.
Do not use fingernails to slide Teflon ring on.

NOTE: TECHNICAL INFORMATION
Before re-exchanging the injector, the Teflon ring must be replaced. Once a Teflon ring has been installed, it may not be re-used. New injectors are supplied with a new Teflon ring.
After installation of a new Teflon ring on the injectors, the injector must be installed in the cylinder head within 10 minutes or protected with protective caps; otherwise, the Teflon ring will swell.

Before installing the injectors: Replace the Teflon rings (1).
Parts : Teflon rings
Avoid mechanical contact with injector tip (2).

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Dismount the Teflon ring (2) with the special tool 0 495 757 (13 0 191) (3) from the set of special tools 0 495 756 (13 0 190) from the injector (1).
If necessary, use a lint-free cloth to clean the cylindrical part of the injector tip. Do not use ultrasonic sound or other auxiliary materials.
Do not clean injector tip.

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Slide the new Teflon ring (1) onto the installation cone 0 496 771 (13 0 283) (2) from the set of special tools 0 496 668 (13 0 280).

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Mount the Teflon ring (1) with the installation cone 0 496 771 (13 0 283) (2) from the set of special tools 0 496 668 (13 0 280) on the injector tip (3).

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Use the sliding sleeve (1) of the special tool 0 496 769 (13 0 281) from the set of special tools 0 496 668 (13 0 280) to push the Teflon ring (2) into the groove (3) on the injector.

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Adjust the expanded Teflon ring with the special tool 0 496 770 (13 0 282) (1) from the set of special tools 0 496 668 (13 0 280) to the installation dimension.
Slide special tool 0 496 770 (13 0 282) (1) onto the injector (2) up to the stop.

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Push the sliding sleeve (1) of the special tool 0 496 770 (13 0 282) towards the rear and loosen the installation cone 0 496 771 (13 0 283) (2).

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Mount the holder (1) above the bayonet closure (2) on the injector.
If the holder (1) has a cast lug: Make sure that the holder is installed in the correct position.

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If applicable, note the position of the cast lug:
The holder is mounted correctly when the cast lug is located at the rear.

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If applicable, note the position of the cast lug:
The holder is mounted incorrectly when the cast lug (1) is in front.

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NOTE: RISK OF DAMAGE
Damage to injectors.
Weld seams on the injector may tear due to incorrect distances between the rail and injector so that the injector must be replaced.

Insertion of the distance gauge is compulsory.
Replace distance gauge, if a thickness of 8.5 mm is no longer given in the distance gauge.

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Use the special tool (distance gauge) 2 358 022 (1).
Replace (M5x30) screws.
Parts : Screws (M5x30)
Mount the injectors with the holders and the bolts (M5x30) (1) on the rail.
Place the high-pressure rail on a clean table so that the openings on the high-pressure rail for the injectors point up.
The electrical injector connections must point to the fuel pressure sensor.

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Slide the special tool (distance gauge) 2 358 022 (2) between the holders and the rail onto the injector head.
Make sure that the special tool (distance gauge) 2 358 022 (2) rests flat on the retaining bridge.
Evenly tighten both screws (M5x30) (1) hand-tight until special tool (distance gauge) 2 358 022 (2) lies flat on rail and bracket.
Remove special tool 2 358 022 (1).
Repeat this operation for all injectors.

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Check the injectors for a loose fit at the rail.
Align the position of the electrical injector connections parallel to the high-pressure rail.
The injectors must shift freely.

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Attach the rail (1) with the injectors to the cylinder head from the top.
Make sure the injector tips catch the corresponding holes in the cylinder head.
Make sure the guides on the injector are properly inserted into the guide bores in the cylinder head.
Press down until resistance can be felt; position and hand-tighten the screws (M6x30) (A) and (B).
Alternatingly tighten screws (A) and (B) hand-tight by 180° with torque wrench until rail lies on cylinder head.

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The illustration shows the rail resting flat against the cylinder head.
Insert bolts (C) and (D).

NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Non-observance of these requirements may result in leaks and damage.

Tighten bolt (A) to 5 Nm.
Tighten bolt (D) to 5 Nm.
Tighten bolt (B) to 5 Nm.
Tighten bolt (C) to 5 Nm.
Connect and lock the connector (2).
The connector (2) must engage audibly.
Make sure that the rail (1) rests flat against the cylinder head.

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Attach a socket to an extension.
Do not use a reversible ratchet or torque wrench.
Tighten the bolts (M5x30) in pairs ((1) with (2), (3) with (4), (5) with (6)) in alternating order hand-tight to 90° .
Set the torque wrench to 5 Nm.

Fig 1: Fuel Injector Bolts Tightening Sequence

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NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Non-observance of these requirements may result in leaks and damage.

Screw the (M5x30) bolts according to the following plan:
- Fuel injector 1:
- Tighten screw (1) at an angle of rotation of 90° ±15° with the torque wrench.
- Tighten screw (2) at an angle of rotation of 90° ±15° with the torque wrench.
- Repeat the operations for bolts (1) and (2) until both bolts reach a torque of 5 Nm.
- Fuel injector 2:
- Tighten screw (3) at an angle of rotation of 90° ±15° with the torque wrench.
- Tighten screw (4) at an angle of rotation of 90° ±15° with the torque wrench.
- Repeat the operations for bolts (3) and (4) until both bolts reach a torque of 5 Nm.
- Fuel injector 3:
- Tighten screw (5) at an angle of rotation of 90° ±15° with the torque wrench.
- Tighten screw (6) at an angle of rotation of 90° ±15° with the torque wrench.
- Repeat the operations for bolts (5) and (6) until both bolts reach a torque of 5 Nm.
Mark all bolts (1) to (6) with a vertical line (see illustration).
Tighten screws using an angle of rotation.
- Tighten the screw (1) with an angle of rotation of 90° ±15°.
- Tighten the screw (2) with an angle of rotation of 90° ±15°.
- Tighten the screw (3) with an angle of rotation of 90° ±15°.
- Tighten the screw (4) with an angle of rotation of 90° ±15°.
- Tighten the screw (5) with an angle of rotation of 90° ±15°.
  
  Fig 2: Fuel Injector Bolts Tightening Sequence
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- Tighten the screw (6) with an angle of rotation of 90° ±15°.
Check if all bolts (1) to (6) have been tightened with a 90° ±15° angle of rotation.
All marks (lines) must be horizontal (see illustration).

Fig 3: Fuel Injector Bolts Tightening Sequence
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Unscrew the bolts (M6x30) (A) to (D).
It is imperative that the bolts are unscrewed.

NOTE: TECHNICAL INFORMATION
When assembling, it is essential to observe screwing sequences and tightening torques.
Non-observance of these requirements may result in leaks and damage.

Fig 4: Fuel Injector Bolts Loosening Sequence

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Tighten bolt (A) to 5 Nm.
Tighten bolt (D) to 5 Nm.
Tighten bolt (B) to 5 Nm.
Tighten bolt (C) to 5 Nm.
Mark all bolts (A) to (D) with a vertical line (see illustration).
Tighten bolts (M6x30) (A) to (D) to a 90° angle of rotation.

Fig 5: Fuel Injector Bolts Tightening Sequence
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Check if all bolts (A) to (D) have been tightened with a 90° angle of rotation.
All marks (lines) must be horizontal (see illustration).

Fig 6: Fuel Injector Bolts Tightening Sequence
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Connect and lock all connectors (1) to the injectors.
All connectors (1) must engage audibly.

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Thread in cable duct (3) and install.
Thread in ground cable (2) and install.
Tighten the screws (1).

TIGHTENING TORQUES SPECIFICATION

Ground cable to rail
M6	tightening torque	5 Nm

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