Removing and installing/replacing all injectors (B48 and B46 engines) (Cooper Clubman S and JCW)

Special tools required: 

• 2 358 417
• 1 30 190
• 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 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 contamination before removing 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!

Attention! 

When assembling, it is essential to adhere to Figure!

Not adhering to the disassembly and installation instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

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 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! 

Not adhering to the disassembly instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

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 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 upwards.

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 with a maximum torsional movement of 13 Nm.

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

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.

Tighten screws (1) hand-tight.

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.

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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 brass tubes.

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Release screws and remove extraction tool 2 358 417 with injectors (1) vertically towards the top from the cylinder head with care.

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

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Unlatch the lock (1) of the stand upwards.

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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.

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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. Follow the diagnosis instructions.

Installation: 

Attention! 

Not adhering to the installation instructions can lead to cracked weld seams and can thus cause an engine fire!!! 

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

If fitted: 

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

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

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

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

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

Ensure that the distance gauge rests on the retaining bridge!

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

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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.

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

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1. Position 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 aligning lugs on the injector are slid correctly into the retaining 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 rail screws (A) and (B) alternating in every 90° seach using the torque wrench until the rail rests on the cylinder head (see figure 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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1. Now tighten injector screws M5x30 in pairs (1 with 2, 3 with 4, 5 with 6, 7 with 8) and in alternating order for 90° hand-tight, using the socket on the extension (without reversible ratchet or torque wrench!).). 
2. Screw the M5x30 injector 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 injector screw (1) by 90±15° with torque wrench.
     2. Tighten injector screw (2) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 Nm.
   • Fuel injector 2: 
     1. Tighten injector screw (3) by 90±15° with torque wrench.
     2. Tighten injector screw (4) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 Nm.
   • Fuel injector 3: 
     1. Tighten injector screw (5) by 90±15° with torque wrench.
     2. Tighten injector screw (6) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 Nm.
   • Fuel injector 4: 
     1. Tighten injector screw (7) by 90±15° with torque wrench.
     2. Tighten injector screw (8) by 90±15° with torque wrench.
     3. Repeat steps  a and  b until both screws have arrived at 5 Nm.

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3. All injector screws (1) to (8) must be marked by a line (see graphic).
   • Tighten injector screws with an angle of rotation! 
     1. Tighten injector screw (1) with an angle of rotation of 90±15°.
     2. Tighten injector screw (2) with an angle of rotation of 90±15°.
     3. Tighten injector screw (3) with an angle of rotation of 90±15°.
     4. Tighten injector screw (4) with an angle of rotation of 90±15°.
     5. Tighten injector screw (5) with an angle of rotation of 90±15°.
     6. Tighten injector screw (6) with an angle of rotation of 90±15°.
     7. Tighten injector screw (7) with an angle of rotation of 90±15°.
     8. Tighten injector screw (8) with an angle of rotation of 90±15°.

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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 graphic).

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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 graphic).

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

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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 graphic).

Mount high pressure line at the 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 union nuts (3) and (2).

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

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Mount wiring harness (1) on 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 IGNITION COILS. .
• Install the ACOUSTIC COVER .
• 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 appropriate diagnostic system and follow the diagnosis instructions using the applicable scan tool. 
• Read out vehicle data
• Identification without vehicle test
• Start vehicle test
• Vehicle handling
• Service functions
• Power train
• Engine electronics
• Reset adaptation values
• Fuel system adaptation values
• Continue service function