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

Special tools required:

2 358 417
11 8 720
13 0 190
13 0 280
2 358 022

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.

IMPORTANT: Wear full face guard and hand protection.
Gas can emerge spontaneously at high speed when the high pressure line is released!

IMPORTANT: Wear safety goggles.
Oil and dirt particles may get into your loops!

Before removing the rail and injectors, clean or vacuum off injector shafts.

Recycling:

Fuel leakages when fuel lines are detached.

Catch and dispose of leakage fuel.

Observe country-specific waste disposal regulations.

IMPORTANT: Adhere to conditions of absolute cleanliness when carrying out repairs 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.

IMPORTANT: 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!

IMPORTANT: When removing or replacing the rail, the injectors need to be removed as well.
Injectors may be pulled out with a maximum tensile force of 2000 N and twisted only to 6 Nm (torsion movement). If these values are exceeded, the injectors must be replaced!
When assembling, it is essential to adhere to Fig 1!
Not adhering to the disassembly and installation instructions can lead to cracked weld seams and can thus cause an engine fire!!!

Preliminary work needed:

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 (2) from the rail.

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NOTE: To disconnect the connectors at the injectors, the lock (1) needs to be pulled out in arrow direction first. Then press the lock (1) together and detach the connector housing at the same time.

Release connector (1) and remove from the injectors.

Lay wiring harness to one side.

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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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NOTE: To disconnect the connector at the high pressure pump, the lock (1) needs to be pulled out in arrow direction first. Then compress the lock (1) in direction of the connector housing, detaching the connector at the same time.

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Unlock connector (1) and detach.

Release union nuts (2) and (3).

Detach pressure line between high pressure pump and rail.

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

Unlock connector (2) 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.

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If fitted:

Remove gaskets (1).

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

NOTE: The gaskets (1) are helium detecting gaskets.
These gaskets are only required during first assembly inside the works.

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Injectors may be pulled out with a maximum tensile force of 2000 N and twisted only to 6 Nm (torsion movement). If these values are exceeded, the injectors must be replaced!

The special tool 2 358 417 is required in order to remove the injectors.

Using the special tool 2 358 417 ensures that the tensile force of 2000 N will not be exceeded.

Special tool 2 358 417 consists of:

(1) Threaded sleeves
(2) Pull-out thread (left-hand thread)
(3) Stand for injector

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Unscrew stand 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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Install all stands (1) for the injectors.

NOTE: Locking (2) is not yet done, if the lever is up.

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Rotate the mounting (1) at 90° and latch 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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Insert threaded sleeves (3) again and screw threaded sleeves completely onto the stands for injectors.

Then tighten the screws (4) with 5 Nm.

IMPORTANT: Do not support on the panel of the extraction tool. Impermissible lateral forces can occur from this on the injectors.

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Set torque wrench to 7 Nm clockwise rotation.

Together with special tool 11 8 720 this corresponds to a tensile force of max. 2000 N.

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

This process is obligatorily to be carried out for every single injector.

IMPORTANT: If the torque wrench cracks noise at the time of pulling out the injectors, the tensile force of 2000 N was exceeded (can occasionally happen in case of strongly coked injectors). The injector must be then 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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Loosen the screws and remove the extraction tool 2 358 417 with injectors (1) carefully vertically upwards from the cylinder head.

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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Rotate the unlocked stand (1) at 90°. Release and remove the injector downwards.

Mark injectors according to the cylinders.

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Preparation for installation:

Before the rail is installed, the Teflon rings at the injectors must be replaced.

Replace Teflon ring:

Before the injectors are installed, the Teflon rings (1) at 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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Fit Teflon ring (1) on injector tip (3) with 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 slid on.

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

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To bring 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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NOTE: Pull mounting tip (1) of special tool 13 0 282 towards rear to release installation cone (2) 13 0 283.

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Installation:

IMPORTANT: 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 the retaining bridge (1) is equipped with a cast lug, the correct installation position needs to be observed.

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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 millimeter. If the actual value undershoots this dimension, the distance gauge needs to be replaced.

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

Keep the rail on a clean table in such a way, that the holders on the Rail are visible upwards. The electrical injector connections must then lie to the left of the holders of the rail.

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

Make sure the distance gauge rests against the retaining bridge!

Equally tighten both injector screws (1) M5x30 hand force until the distance gauge rests plane against the rail and the retaining bridge.

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Then the distance gauge (1) 2 358 022 is to be 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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Position rail with injectors from the top on the cylinder head.
1. Make sure the injector tips catch the corresponding holes in the cylinder head.
2. Make sure the alignment lugs of the injector are properly inserted into the retaining holes on the cylinder head.
As soon as a resistance can be felt when pushing down, position the rail screws M6x70 (A) and (B) and tighten them hand-tight.
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.
Insert rail screws (C) and (D).
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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Fig 1: Fuel Rail/Injectors Screws Tightening Sequence - B48 and B46 Engines

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Now tighten injector screws M5x30 in pairs (1 with 2, 3 with 4, 5 with 6, 7 with 8) and in alternating order for 180° hand-tight, using the socket on the extension (without reversible ratchet or torque wrench!).
Screw the injector screws M5x30 according to the following plan:
Set 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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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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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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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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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°.

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Check whether all rail screws (A) to (D) were tightened by an angle of rotation of 90±15°.

All marks (dashes) must lie diagonally (see graphic above).

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

First, tighten union nuts (3) on the rail 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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Connect connector on the high pressure pump until the lock (1) engages audibly.

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

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Connect connector (1) to the injectors.

Connectors (1) must engage audibly.

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

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

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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 wiring harness on 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 the drip shield (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: