13 53 156 Removing and installing/replacing rail (B48, B46)

Special tools required: 

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

Electric fuel pump starts up automatically when door is opened!

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

Attention  !

Wear full face guard and protective gloves.

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

Attention  !

Wear safety goggles.

Oil and dirt particles may get into your eyes!

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

Recycling: 

Fuel escapes 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!

• 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.

Attention  !

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!

Attention  !

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 screwing sequences and tightening torques!

Necessary preliminary tasks: 

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

Removal: 

Release screws (1).

Release wiring harness from cylinder head cover.

Release screw (1).

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

Slacken nut (1).

Detach the wiring harness (2) from the rail.

Release connector (1) and remove from the injectors.

Lay wiring harness to one side.

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

Dismount the drip shield (1) from the cylinder head cover.

Screw on the sealing cap (1) to the oil filler neck.

Unlock connector (1) and pull off.

Release union nuts (2) and (3).

Detach pressure line between high pressure pump and rail.

Unlock connector (2) from rail pressure sensor and pull off.

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 escaping fuel with suitable materials.

Release screws (1) M6x70.

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

Parts:  Screws M6x70.

Remove rail upwards.

If fitted: 

Remove gaskets (1).

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

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) Fixture for injector
Fig 14: Threaded Sleeves, Pull-Out Thread And Fixture For Injector
Courtesy of BMW OF NORTH AMERICA, INC.

Unscrew fixture for injectors (1) from special tool 2 358 417 .

Press in lock (1) and remove threaded sleeve (2) from special tool 2 358 417 .

Install all fixtures (1) for the injectors.

Rotate the mounting (1) at 90° and latch the lock (2) downwards.

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.

Insert threaded sleeves (3) again and screw threaded sleeves completely onto the fixtures for injectors.

Then tighten the screws (4) with 5 Nm.

Attention  !

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

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.

Attention  !

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.

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.

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.

Unlatch the lock (1) of the fixture upwards.

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

Mark injectors according to the cylinders  .

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).

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.

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

Fit Teflon ring (1) on injector tip (3) with installation cone (2) 13 0 283 from set of special tools 13 0 280 .

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

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 limit position on injector (2).

Do not use any lubricating agents.

Installation: 

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

If fitted: 

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

Retaining bridge mounted properly, cast lug is at rear.

Retaining bridge mounted improperly, cast lug (1) is at front.

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 drops below this dimension, the distance gauge needs to be renewed.

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 by hand until the distance gauge rests plane against the rail and the retaining bridge.

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

Repeat this operation for all injectors.

Check injectors for loose fit at the rail.

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

1. 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.
2. As soon as a resistance can be felt when pushing down, position the rail screws M6x70 (A) and (B) and tighten them hand-tight.
3. Tighten rail screws (A) and (B) alternating in every 180° steps, until the rail rests against the cylinder head (see illustration).
4. Insert rail screws (C) and (D).
5. 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.

Fig 40: Rail Screws
Courtesy of BMW OF NORTH AMERICA, INC.

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 180° hand-tight, using the socket on the extension (without reversible ratchet or torque wrench!).
2. 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.
   Fig 42: Fuel Injector Screws Tightening Sequence
   Courtesy of BMW OF NORTH AMERICA, INC.
3. All injector screws (1) to (8) must be marked by a line (see illustration).
   Fig 43: Fuel Injector Screws

   Courtesy of BMW OF NORTH AMERICA, INC.
   • 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°.
   Fig 44: Marked Injector Screws

   Courtesy of BMW OF NORTH AMERICA, INC.
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 illustration).

   Fig 45: Rail Screws

   Courtesy of BMW OF NORTH AMERICA, INC.
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.
   Fig 46: Fuel Rail Screws Tightening Sequence

   Courtesy of BMW OF NORTH AMERICA, INC.
6. All rail screws (A) to (D) must be marked by a dash (see illustration).

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

   Fig 47: Marked Rail Screws

   Courtesy of BMW OF NORTH AMERICA, INC.
7. 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 illustration).

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.

Connect connector on the high pressure pump until the lock (1) engages audibly.

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

Connect connector (1) to the injectors.

Connectors (1) must engage audibly.

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

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

Mount wiring harness (1) on rail.

Tighten nut (1).

Install sound insulation (3).

Fit clean air pipe (2).

Tighten screw (1).

Tightening torque: 13 71 6AZ .

Install wiring harness on cylinder head cover.

Tighten down screws (1).

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

Mount the drip shield (1) on the cylinder head cover.

Screw on the sealing cap (1) to the oil filler neck.