Removing and installing/replacing both pressure lines (S55 engine)

Special tools required: 

• 11 8 610
• 13 5 020
• 32 1 270

Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short-circuiting on removal).

Electric fuel pump starts up automatically when door is opened!

Carry out installation work on fuel system only with coolant temperature below 40°C.

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

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.
• High pressure lines may be rescrewed a maximum of 10 times.

Recycling: 

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste disposal regulations.

Necessary preliminary tasks: 

• Remove INTAKE PLENUM .

Removal: 

Courtesy of BMW OF NORTH AMERICA, INC.

Release nuts (1 and 2).

Remove H.P line.

Seal connections of the high-pressure rail and high pressure pump with suitable plugs from set of special tools 32 1 270.

Installation: 

Courtesy of BMW OF NORTH AMERICA, INC.

Fit high pressure line.

When reinstalling lines, lubricate the thread and bearing face of the ball with a little transmission oil or grease! When they are installed for the first time the nuts have a coating of lubricant (only effective once). Penetration of lubricant into the fuel - conducting area should be avoided.

Lay the high pressure line with the ball bush to the high pressure pump. When doing so, the ball bush of the high pressure line must lie in the center of the cone on the high-pressure rail. If the ball bush does not lie in the center of the cone, the installation position of the high-pressure rail must be adjusted. To do this the following fuel system components must be released:

• Release pressure lines on injectors and on high-pressure rail.
• Release mounting bolts on high-pressure rail.

Follow sequence of screw connections: 

1. Mount high pressure line on high pressure pump and on high pressure rail hand-tight.
2. Mount high pressure lines between the injectors and the high pressure rail hand-tight.
3. Fit mounting bolts on the high pressure rail and cylinder head hand-tight.
4. Tighten mounting bolts on high pressure rail and cylinder head.

   Tightening torque 13 53 2AZ .

5. Tighten high pressure line on injectors. Tightening torque 13 53 9AZ .
6. Tighten high pressure line (high pressure line between high pressure rail and high pressure pump) at the high pressure rail.

   Tightening torque 13 53 8AZ .

7. Tighten high pressure line on high pressure pump.

   Tightening torque 13 53 8AZ .

Required follow-up work: 

• Install INTAKE PLENUM .