13 53 156 Removing and installing/replacing rail (B36, B38)

WARNING: This page is about a different car, the 2017 MINI Cooper, 2016 MINI Cooper, 2015 MINI Cooper, and 2014 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

WARNING:

Observe warning on cylinder head cover.

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

Wear full face guard and protective gloves.

Fuel 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 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.

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!

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!

IMPORTANT:

When assembling, it is essential to adhere to screwing sequences and tightening torques!

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

Necessary preliminary tasks:

Removal:

Release screws (1).

Release wiring harness from cylinder head cover.

Fig 1: Wiring Harness Screws Of Cylinder Head Cover

Courtesy of BMW OF NORTH AMERICA, INC.

Release screw (1).

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

Fig 2: Sound Insulation, Air Pipe And Screw

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Slacken nut (1).

Detach the wiring harness (2) from the rail.

Fig 3: Rail Wiring Harness And Nut

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

Fig 4: Disconnecting Connectors At Injectors

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Release connector (1) and remove from the injectors.

Lay wiring harness to one side.

Fig 5: Injector Connectors

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

Fig 6: Sealing Cap Of Oil Filler Neck

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

Fig 7: Cylinder Head Cover Drip Shield

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

Fig 8: Sealing Cap On 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 direction of arrow first. Then compress the lock (1) in direction of the connector housing, pulling off the connector at the same time.

Fig 9: Disconnecting Connector At High Pressure Pump

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Unlock connector (1) and pull off.

Release union nuts (2) and (3).

Detach pressure line between high pressure pump and rail.

Fig 10: Union Nuts And Connector

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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 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! Replace screws M5x30.

Catch and dispose of escaping fuel with suitable materials.

Fig 11: Injectors And Rail Screws

Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) M6x30.

Remove screws (1). Screws (1) must not be reused! Replace screws M6x30.

Remove rail upwards.

Injectors remain in the cylinder head.

Fig 12: Rail Screws

Courtesy of BMW OF NORTH AMERICA, INC.

If fitted:

Remove gaskets (1).

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

Fig 13: Injector Gaskets

Courtesy of BMW OF NORTH AMERICA, INC.

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

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:

Fig 14: Threaded Sleeves, Pull-Out Thread And Fixture For Injector

Courtesy of BMW OF NORTH AMERICA, INC.

Threaded sleeves
Pull-out thread (left-hand thread)
Fixture for injector

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

Fig 15: Unscrewing Fixture For Injectors 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 .

Fig 16: Removing Threaded Sleeve From Special Tool (2 358 417)

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Install all fixtures (1) for the injectors.

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

Fig 17: Installing Fixtures For Injectors

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

Fig 18: Rotating Mounting At 90°

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Install all fixtures (1) for the injectors.

Therefore, position the fixtures and turn them for 90°.

Make sure the lock (2) engages.

Fig 19: Installing Fixtures For Injectors

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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.

Fig 20: Thread And Screws

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

Fig 21: Threaded Sleeves And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 22: Turning Torque Wrench Clockwise

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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.

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.

Fig 23: Removing Injectors From Cylinder Head

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 24: Injectors

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Unlatch the lock (1) of the fixture upwards.

Fig 25: Unlatching Lock Of Fixture Upwards

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

Mark injectors according to the cylinders.

Fig 26: Rotating Unlocked Fixture At 90°

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 27: Teflon Ring And Injector Tip

Courtesy of BMW OF NORTH AMERICA, INC.

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).

Fig 28: Removing Teflon Ring From Injector Using Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

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 .

Fig 29: Teflon Ring And Installation Cone

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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 .

NOTE:

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

Fig 30: Teflon Ring, Injector Tip And Installation Cone

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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.

Fig 31: Sliding Teflon Ring Into Groove 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 limit position on injector (2).

Do not use any lubricating agents.

Fig 32: Sliding Special Tool To Limit Position On Injector

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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.

Fig 33: Pulling Mounting Tip Of Special Tool

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Installation:

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

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.

Fig 34: Bayonet Fitting And Retaining Bridge

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Retaining bridge mounted properly , cast lug is at rear.

Fig 35: Checking Retaining Bridge Mounted Properly

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

Fig 36: Checking Retaining Bridge Mounted Improperly

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

Fig 37: Distance Gauge

Courtesy of BMW OF NORTH AMERICA, INC.

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 at the left hand side 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.

Fig 38: Sliding Distance Gauge Between Retaining Bridge And Rail On Top Of Injector Head

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 39: Distance Gauge Position

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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!

Fig 40: Checking Injectors For Loose Fit At Rail

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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 M6x30 (A) and (B) and tighten them hand-tight.
Tighten rail screws (A) and (B) alternating in every 180° steps, until the rail rests against the cylinder head.
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.

Fig 42: Fuel Rail

Courtesy of BMW OF NORTH AMERICA, INC.

Now tighten injector screws M5x30 in pairs (1 with 2, 3 with 4, 5 with 6) 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!

Fig 43: Injector Screws Tightening Sequence
Courtesy of BMW OF NORTH AMERICA, INC.
- 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 bb until both screws have arrived at 5 Nm.
All injector screws (1) to (6), must be marked by a dash (see illustration).
- 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°.
Check whether all injector screws (1) to (6) have been tightened with an angle of rotation of 90±15°.
All marks (dashes) must lie diagonally (see illustration).

Fig 48: Checking Injector Marks
Courtesy of BMW OF NORTH AMERICA, INC.
Release rail screws M6x30 (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.
All rail screws (A) to (D) must be marked by a dash (see illustration).
Tighten rail screws M6x30 (A), (B), (C), (D) with an angle of rotation of 90±15°.

Fig 50: Marking Rail Screws
Courtesy of BMW OF NORTH AMERICA, INC.
Check whether all rail screws (A) to (D) were tightened by an angle of rotation of 90°.
All marks (dashes) must lie diagonally (see illustration).

Fig 51: Checking Rail Screws
Courtesy of BMW OF NORTH AMERICA, INC.

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) to final torque.

Tightening torque 33±2 Nm.

Attach connector (1) to high-pressure pump.

Connector (1) must engage audibly.

Fig 52: Union Nuts And Connector

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Fig 53: Locking Connector On High Pressure Pump

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Connect connector (1) to the injectors.

Connectors (1) must engage audibly.

Fig 54: Injector Connectors

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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.

Fig 55: Locking Injector Connector

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Mount wiring harness (1) on rail.

Tighten nut (1).

Fig 56: Rail Wiring Harness And Nut

Courtesy of BMW OF NORTH AMERICA, INC.

Install sound insulation (3).

Fit clean air pipe (2).

Tighten screw (1).

Tightening torque: 13 71 6AZ .

Fig 57: Sound Insulation, Air Pipe And Screw

Courtesy of BMW OF NORTH AMERICA, INC.

Install wiring harness on cylinder head cover.

Tighten down screws (1).

Fig 58: Wiring Harness Screws Of Cylinder Head Cover

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 59: Sealing Cap On Oil Filler Neck

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 60: Cylinder Head Cover Drip Shield

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 61: Sealing Cap Of Oil Filler Neck

Courtesy of BMW OF NORTH AMERICA, INC.