Removing and installing/replacing all injectors (B36, B38) (Cooper)

Special tools required: 

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

Attention! 

Wear full face guard and hand protection.

The fuel may leak spontaneously at full speed when the high pressure line is released!

Attention! 

Wear safety goggles.

Oil and dirt particles could come in contact with the eyes!

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

Recycling  :

Fuel leakages when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Attention! 

Adhere to conditions of absolute cleanliness when carrying out repairs on the high- pressure fuel system.

Introduced contaminants can cause malfunctions in the system!

• No dirt particles or foreign bodies must enter the system
• Remove all traces of dirt contamination before dismantling lines or separate components
• Use only lint-free cloths.
• Seal all fuel system openings with protective caps or plugs.

Attention! 

Ignition coils must not be contaminated by fuel.

The resistance of the silicone material reduces significantly if it comes in contact with the fuel, which could lead to failure of the ignition coil!

Note the REPAIR INSTRUCTIONS  on cleaning the cylinder head in the area of the injectors with sandy/dusty contamination

Attention  !

When assembling, it is essential to adhere to Fig 1!

Non-compliance with the disassembly/installation instructions may result in cracks on the weld seams of the injectors and hence engine fires! 

Preliminary work needed  :

• Remove INTAKE SILENCER HOUSING .
• Remove ACOUSTIC COVER .
• Remove IGNITION COILS

Removal  :

Unscrew the screws (1).

Release wiring harness from cylinder head cover

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Remove screw (1).

Slightly push clean air pipe (2) to the rear and remove the sound insulation (3) of the high pressure pump.

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Slacken nut (1).

Detach the wiring harness from the high pressure rail.

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Release connector (1) and remove from the injectors.

Keep the wiring harness aside.

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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 loosening the high pressure rail:  Use an air gun to blow out the injector shafts (1) with a little pressure.

At the same time vacuum the dirt particles with an explosion-proof vacuum cleaner (2).

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Unlock connector (1) and detach.

Release union nuts (2) and (3).

Remove pressure line between high pressure pump and rail.

Catch and dispose of escaping fuel.

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Attention! 

Non-compliance with the disassembly instructions may result in cracks on the weld seams of the injectors and hence engine fires! 

Unlock connector from rail pressure sensor and detach.

Release screws (1) M5x30.

Remove screws (1).

Do not disassemble the tightly screwed combination from the injectors with the high pressure rail from the cylinder head  !

Screws (1) must not be reused!

Parts:  Screws M5x30.

Catch and dispose of leakage fuel with suitable materials.

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Release screws (1) M6x70.

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

Parts:  Screws M6x70.

Remove rail in upward direction.

Injectors remain in the cylinder head.

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If fitted  :

Remove gaskets (1).

Gaskets (1) are not  required and will not  be installed anymore!

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

Special tool 2 358 417 is required to remove the injectors.

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) Mount for the injector

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Unscrew the mount 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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Attach all mounts (1) for the injectors.

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Turn mounts (1) by 90° and lock the lock (2) downwards.

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Attach special tool 2 358 417 to cylinder head

Screw in screws (1) with few threads.

Screw in pull-out thread (2) completely.

The pull-out thread (2) is a left-hand thread  .

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Slide in threaded sleeves (3) again and screw them fully to the mounts for the injectors.

Then tighten screws (4) at 5 Nm.

Attention! 

Do not support on the special tool panel! Impermissible lateral forces can occur from this on the injectors.

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Set torque wrench to 13 Nm clockwise rotation.

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

This process must be carried out for each individual injector!

Attention! 

If the torque wrench makes a crack when the injector is pulled out, the injector must be replaced.

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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 recognized on the completely visible threads of the pull-out thread.

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Loosen the screws and carefully remove special tool 2 358 417 including injectors (1) horizontally upwards from the cylinder head.

Take off the combination of the special tool with injectors flatly on a clean table.

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Unlock the stand lock (1) from the top.

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Turn the unlocked mount (1) by 90°. Release and remove the injector downwards.

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Preparation for the installation  :

Replace Teflon ring: 

Before installing the injectors, Teflon rings (1) on 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 injector (1) using special tool (3) 13 0 191 from special tool set 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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Install Teflon ring (1) on injector tip (3) using installation cone (2) 13 0 283 from set of special tools 13 0 280.

• Do not use fingernails to slide Teflon ring on.
• Do not use any lubricating agents.
• The sealing ring is expanded when it is slid

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

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To size 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 stop on injector (2).

Do not use any lubricating agents.

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Attention! 

Injection quantity compensation!

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

The injection quantity compensation is carried out with the help of a so-called adjustment value.

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

Installation: 

Attention! 

Non-compliance with the installation instructions may result in cracks on the weld seams of the injectors and hence engine fires! 

Mount the holder (1) to the injector using the bayonet closure (2).

If fitted: 

If holder (1) has a cast lug, it must be fitted in the correct installation position.

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Holder mounted correctly  , cast lug located at the rear.

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Holder mounted incorrectly  , cast lug (1) located at the front.

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Distance gauge (1) 2 358 022.

Not using the gauge could pose a risk of a crack in the weld seam on the injector! 

The thickness of the distance gauge is 8.5 mm. If it is less than this dimension, the distance gauge must be replaced.

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Mount the injectors with holders and the new  bolts (M5x30) to the rail.

To do this, place the rail on a clean table so that the openings on the rail for the injectors point upwards. The electrical injector connections must then be on the left of the openings on the rail for the injectors.

Push the gauge (2) 2 358 022 onto the injector between the holder and the high pressure rail.

Ensure that the distance gauge rests on the holder!

Tighten the two M5x30 screws (1) evenly by hand until the distance gauge rests flat on the rail and the holder.

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

Repeat this operation for all injectors.

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Check injectors for loose fit at the rail.

Roughly align the position of the electrical injector connections parallel to the high pressure rail; the injectors must move freely!

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1. Position high pressure rail with injectors from the top on the cylinder head.
   1. Ensure that the injector tips hit the holes provided in the cylinder head for this.
   2. Ensure that the guides on the injector are slid correctly into the guide bore holes in the cylinder head.
2. As soon as there is resistance when pressing down, position the M6x70 rail screws (A), (B), (C), and (D) and turn them until hand-tight.
3. Tighten the screws (A), (D), (B) and (C) alternately by 90° each using the torque wrench until the rail rests on the cylinder head (see image below).
4. Tighten the screws to 5 Nm  in the following sequence:
   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.

High pressure rail (1) is fully in contact with the cylinder head.

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1. Now alternately tighten the M5x30 screws in pairs (1 and 2, 3 and 4, 5 and 6) in increments of 90° hand force and use the adapter on the extension (without reversible ratchet or torque wrench!  ).).
2. Screw the M5x30 screws according to the following pattern: 

   Set the torque wrench to 5 Nm  .

   Compliance with the sequence is absolutely mandatory!

   • Fuel injector 1  :
     1. Tighten screw (1) by 90° ±15° using a torque wrench.
     2. Tighten screw (2) by 90° ±15° using a torque wrench.
     3. Repeat steps a and b until both screws have arrived at 5 Nm.
   • Fuel injector 2: 
     1. Tighten screw (3) by 90° ±15° using a torque wrench.
     2. Tighten screw (4) by 90° ±15° using a torque wrench.
     3. Repeat steps a and b until both screws have arrived at 5 Nm.
   • Fuel injector 3: 
     1. Tighten screw (5) by 90° ±15° using a torque wrench.
     2. Tighten screw (6) by 90° ±15° using a torque wrench.
     3. Repeat steps a and b until both screws have arrived at 5 Nm.

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3. All screws (1) to (6) must be highlighted with a line (see graphic).
   • Tighten screws using an angle of rotation  !
     1. Tighten the screw (1) with an angle of rotation of 90° ±15°.
     2. Tighten the screw (2) with an angle of rotation of 90° ±15°.
     3. Tighten the screw (3) with an angle of rotation of 90° ±15°.
     4. Tighten the screw (4) with an angle of rotation of 90° ±15°.
     5. Tighten the screw (5) with an angle of rotation of 90° ±15°.
     6. Tighten the screw (6) with an angle of rotation of 90° ±15°.

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4. Check whether all screws (1) to (6) have been tightened to an angle of rotation of 90° ±15°.

   All marks (dashes) must lie horizontal (see graphic).

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5. Loosen the M6x70 screws (A), (B), (C), (D) (loosening process is mandatory  !).).

   Then retighten the screws to 5 Nm  in the following sequence:

   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 screws (A) to (D) must be marked with a line (see graphic).

   Tighten the M6x70 screws (A), (B), (C), (D) to an angle of rotation of 90° ±15°.

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

   All marks (dashes) must lie horizontal (see graphic).

Mount high pressure line at the high pressure rail first, then mount high pressure line at the high pressure pump.

First turn union nuts (3) on the rail until hand-tight.

Then, tighten union nut (2) on the high pressure pump hand-tight.

Tighten the union nuts (3) and (2) to the tightening torque.

Tightening torque 33±2 Nm.

Attach connector (1) to high-pressure pump.

Connector (1) must engage audibly.

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Plug the connector to the high pressure pump until lock (1) engages audibly.

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

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Connect connector (1) to the injectors.

Connectors (1) must engage audibly.

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

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

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Mount wiring harness (1) on high pressure rail.

Tighten nut (1).

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Install sound insulation (3).

Fit clean air pipe (2).

Tighten screw (1).

Tightening torque 13 71 6AZ .

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Install the wiring harness on the cylinder head cover.

Tighten down screws (1).

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

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Mount drip protection (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 INTAKE SILENCER HOUSING .
• Install the ACOUSTIC COVER .
• Install IGNITION COILS .
• Connect BATTERY GROUND LEAD.

Attention! 

If an injector is replaced or replaced on the cylinder side, the minimum quantity adaptation must be reset. 

Reset minimum quantity adaptation: 

• Connect diagnostic system and follow the diagnosis instructions using the appropriate scan tool. 
• Read out vehicle data
• Identification with vehicle test
• Start vehicle test
• Vehicle handling
• Service functions
• Power train
• Engine electronics
• Reset adaptation values
• Fuel system adaptation values
• Continue service function