13 53 318 Removing and installing/replacing all injectors (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 the injectors, clean or draw off the 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!

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 work:

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

Courtesy of BMW OF NORTH AMERICA, INC.

Slacken nut (1).

Detach the wiring harness from the rail.

Fig 3: Rail Wiring Harness And Nut

Courtesy of BMW OF NORTH AMERICA, INC.

NOTE: To disconnect the connectors at the injectors, the lock (1) needs to be pulled out in direction of arrow first. Then compress the lock (1) and pull off the connector (2) at the same time.

Fig 4: Disconnecting Connectors At Injectors

Courtesy of BMW OF NORTH AMERICA, INC.

Release connector (1) and remove from the injectors.

Lay wiring harness to one side.

Fig 5: Injector Connectors

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 6: Sealing Cap Of Oil Filler Neck

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 7: Cylinder Head Cover Drip Shield

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 8: Sealing Cap On Oil Filler Neck

Courtesy of BMW OF NORTH AMERICA, INC.

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 arrow and pull off the connector at the same time.

Fig 9: Disconnecting Connector At High Pressure Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock connector (1) and pull off.

Release union nuts (2) and (3).

Remove pressure line between high pressure pump and rail.

Catch and dispose of escaping fuel.

Fig 10: Union Nuts And Connector

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT: 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 pull off.

Release screws (1) M5x30.

Remove screws (1).

IMPORTANT: 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) M6x70.

Remove screws (1). Screws (1) must not be reused! Replace screws M6x70.

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.

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)

Courtesy of BMW OF NORTH AMERICA, INC.

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

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 18: Rotating Mounting At 90°

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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 .

Fig 19: Thread And Screws

Courtesy of BMW OF NORTH AMERICA, INC.

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 special tool panel! Impermissible lateral forces can occur from this on the injectors.

Fig 20: 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 21: Turning Torque Wrench Clockwise

Courtesy of BMW OF NORTH AMERICA, INC.

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 pull-out thread.

Fig 22: Removing Injectors From Cylinder Head

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 23: Injectors

Courtesy of BMW OF NORTH AMERICA, INC.

Unlock the fixture lock (1) from the top.

Fig 24: Unlatching Lock Of Fixture Upwards

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

Fig 25: Rotating Unlocked Fixture At 90°

Courtesy of BMW OF NORTH AMERICA, INC.

Preparation for installation:

Replace Teflon ring:

Before the injectors are installed, the Teflon rings (1) at the injectors must be replaced.

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 26: Teflon Ring And Injector Tip

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.

Fig 27: Removing Teflon Ring From Injector Using Special Tool

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 28: Teflon Ring And Installation Cone

Courtesy of BMW OF NORTH AMERICA, INC.

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 29: Teflon Ring, Injector Tip And Installation Cone

Courtesy of BMW OF NORTH AMERICA, INC.

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 30: Sliding Teflon Ring Into Groove On Injector

Courtesy of BMW OF NORTH AMERICA, INC.

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 31: Sliding Special Tool To Limit Position On Injector

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NOTE: Pull mounting tip (1) of special tool 13 0 281 towards rear to release installation cone (2) 13 0 283.

Fig 32: Pulling Mounting Tip Of Special Tool

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IMPORTANT:

Injection quantity compensation:

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

Injection quantity compensation is carried out with the aid of a so-called adjustment value.

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

Installation:

IMPORTANT: 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 fitting (2).

If fitted:

Ensure the installation position is correct if the holder (1) features a cast lug

Fig 33: Bayonet Fitting And Retaining Bridge

Courtesy of BMW OF NORTH AMERICA, INC.

Holder mounted correctly, cast lug located at the rear.

Fig 34: Checking Retaining Bridge Mounted Properly

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

Fig 35: Checking Retaining Bridge Mounted Improperly

Courtesy of BMW OF NORTH AMERICA, INC.

Distance gauge (1) 2 358 022 .

Not using the gauge may result in cracks on the weld seam of 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 36: Distance Gauge

Courtesy of BMW OF NORTH AMERICA, INC.

Mount the injectors to the rail including holders and new screws (M5x30).

Keep the rail on a clean table in such a way, that the openings on the rail for the injectors point up. The electrical injector connections must then be located to the left of the openings for injectors on the rail.

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

Make sure the gauge is in contact with the holder!

Evenly tighten both M5x30 screws (1) by hand until the gauge is fully in contact with the rail and the holder.

Fig 37: Sliding Distance Gauge Between Retaining Bridge And Rail On Top Of Injector Head

Courtesy of BMW OF NORTH AMERICA, INC.

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

Repeat this operation for all injectors.

Fig 38: Distance Gauge Position

Courtesy of BMW OF NORTH AMERICA, INC.

Check injectors for loose fit at the rail.

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

Fig 39: Checking Injectors For Loose Fit At Rail

Courtesy of BMW OF NORTH AMERICA, INC.

Fig 40: Rail Screws

Courtesy of BMW OF NORTH AMERICA, INC.

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 guides on the injector are properly inserted into the guide bores in the cylinder head.
As soon as you feel a resistance when you press down the component, position the M6x70 screws (A) and (B) and tighten them by hand.
Alternately tighten the screws (A) and (B) in 180° steps until the rail is in contact with the cylinder head.
Insert the screws (C) and (D).
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.

Rail (1) is fully in contact with the cylinder head.

Fig 41: Fuel Rail

Courtesy of BMW OF NORTH AMERICA, INC.

Now alternately tighten the M5x30 screws in pairs (1 and 2, 3 and 4, 5 and 6) in increments of 90° by hand and use the adapter on the extension (without reversible ratchet or torque wrench! ).
Screw the M5x30 screws according to the following plan:
Set 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.
All screws (1) to (6) must be highlighted with a line (see illustration).
- 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°.
  Fig 45: Injector Screws
  Courtesy of BMW OF NORTH AMERICA, INC.
Check whether all screws (1) to (6) have been tightened to an angle of rotation of 90° ±15°.
All marks (dashes) must lie diagonally (see illustration).

Fig 46: Checking Injector Marks
Courtesy of BMW OF NORTH AMERICA, INC.
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.
All screws (A) to (D) must be marked with a line (see illustration).
Tighten the M6x70 screws (A), (B), (C), (D) to an angle of rotation of 90° ±15°.

Fig 48: Marking Rail Screws
Courtesy of BMW OF NORTH AMERICA, INC.
Check whether all rail screws (A) to (D) have been tightened to an angle of rotation of 90°.
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.

Fig 49: Checking Rail Screws

Courtesy of BMW OF NORTH AMERICA, INC.

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.

Fig 50: 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 51: Locking Connector On High Pressure Pump

Courtesy of BMW OF NORTH AMERICA, INC.

Connect connector (1) to the injectors.

Connectors (1) must engage audibly.

Fig 52: Injector Connectors

Courtesy of BMW OF NORTH AMERICA, INC.

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

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

Fig 53: Locking Injector Connector

Courtesy of BMW OF NORTH AMERICA, INC.

Mount wiring harness (1) on rail.

Tighten nut (1).

Fig 54: 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 55: 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 56: 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 57: Sealing Cap On Oil Filler Neck

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 58: Cylinder Head Cover Drip Shield

Courtesy of BMW OF NORTH AMERICA, INC.

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

Fig 59: Sealing Cap Of Oil Filler Neck

Courtesy of BMW OF NORTH AMERICA, INC.

IMPORTANT:

If a solenoid injector was replaced or replaced on the cylinder side, the ultra small quantity adaptation must be reset .

Reset minimum quantity adaptation:

Connect diagnosis system and follow the diagnosis instructions
Read out vehicle data
Identification without vehicle test
Start vehicle test
Vehicle handling
Service functions
Power train
Engine electronics
Adjustment functions
Injection quantity compensation