Mini Cooper Parts Catalog Mini Cooper Accessories Catalog Mini Cooper Technical Articles Mini Cooper Tech Forums
 
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
Turbocharged Engine Fuel Injectors Replacement
 
Bookmark and Share

Pelican Technical Article:

Turbocharged Engine Fuel Injectors Replacement

Nick Czerula

Time:

4 hours4 hrs

Tab:

$600

Talent:

*****

Tools:

Set of sockets hex and Torx flathead screwdriver, clean rags

Applicable Models:

R56 MINI Cooper S Hatchback (2007-11)

Parts Required:

Fuel Injectors, fuel injector Teflon seals, steel fuel lines

Hot Tip:

Work with a cool engine and relieve fuel system pressure

Performance Gain:

Clean and even flowing fuel injectors

Complementary Modification:

Replace with performance injectors

MINI R56 turbocharged utilize one fuel injector per cylinder. Each fuel injector is an electrically controlled solenoid which, when triggered by a pulse from the engine control module, sprays a precisely metered amount of atomized fuel directly into the combustion chamber. This is referred to as direct injection. The ECM supplies constant power to the injectors; the injector opening is controlled by the ground side of the circuit. Since fuel pressure at the injectors is (relatively) constant, the length of time (in milliseconds) of the grounding pulse from the ECM determines the amount of fuel injected.

Over time fuel injectors can become restricted or fail electrically. If you have an injector giving you a problem, I suggest replacing them in sets of four. This way you maintain an even flow from all the injectors. If you are removing fuel injectors to replace the intake manifold and you plan to reuse the fuel injectors, replace all the fuel injector Teflon sealing rings and metal supports.

Direct injection style injectors require a few steps and special tools to replace that you may not be familiar with. Be sure to read through the entire procedure before beginning.

In this tech article, I will describe how to replace each style of fuel injector.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches.

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you're working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability.

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.

Disconnect the negative (-) battery cable. See our tech article on Battery Connection Notes.

Before removing the injectors, fuel rail pressure has to be relieved. You can unplug the in-tank fuel pump. Then run the engine until the vehicle stalls. This will remove the majority of fuel rail pressure. See our tech article on fuel pump replacing for connector access.

Pelican sells a kit for this project, CLICK HERE for kit info.

The fuel injectors are mounted below the intake manifold and mount into the combustion chamber, held in place by a fuel rail (red arrows).
Figure 1

The fuel injectors are mounted below the intake manifold and mount into the combustion chamber, held in place by a fuel rail (red arrows).

The negative battery cable should already be removed, when removing the intake.
Figure 2

The negative battery cable should already be removed, when removing the intake. If it isn't, remove it now (red arrow).

The fuel line from the high pressure fuel pump to the fuel rail is shown here (red arrows).
Figure 3

The fuel line from the high pressure fuel pump to the fuel rail is shown here (red arrows). When this fuel line is loosened it has to be replaced. There are two nuts at each end. Loosen these while covering the nut with a rag to bleed off the remaining fuel rail pressure.

This photo shows the upper nut on the line being bled-off (red arrow) with a rag in place to catch any escaping fuel (inset).
Figure 4

This photo shows the upper nut on the line being bled-off (red arrow) with a rag in place to catch any escaping fuel (inset). Loosen the nut all the way. Use a 12mm line wrench.

Next, loosen the fuel line nut at the fuel rail (red arrow).
Figure 5

Next, loosen the fuel line nut at the fuel rail (red arrow). Use a 12mm line wrench.

Remove the fuel line (red arrow) and throw it away.
Figure 6

Remove the fuel line (red arrow) and throw it away. It has to be replaced.

Working at the top of the fuel rail, cut the tie straps (red arrows) and remove the harness from the fuel rail.
Figure 7

Working at the top of the fuel rail, cut the tie straps (red arrows) and remove the harness from the fuel rail.

Working at the fuel rail pressure sensor, disconnect the electrical (red arrow) connector by lifting the tab and pulling it straight off.
Figure 8

Working at the fuel rail pressure sensor, disconnect the electrical (red arrow) connector by lifting the tab and pulling it straight off.

Working at each fuel injector, squeeze the release tab on the electrical connector (red arrows) and pull the connector straight off.
Figure 9

Working at each fuel injector, squeeze the release tab on the electrical connector (red arrows) and pull the connector straight off.

Then, remove the four T45 Torx fasteners (red arrows).
Figure 10

Then, remove the four T45 Torx fasteners (red arrows).

This photo shows a close up of the four T45 Torx fasteners (red arrows).
Figure 11

This photo shows a close up of the four T45 Torx fasteners (red arrows).

Then pull the fuel rail straight up and out of the cylinder head.
Figure 12

Then pull the fuel rail straight up and out of the cylinder head. Be careful not to damage a fuel injector when removing. If O-rings are stuck, you can remove the fuel rail and leave the injector stuck in the head. At that point you will need the special tool used to extract the injector, MINI tool number 13 0 220.

To remove individual fuel injectors, pull the fuel injector straight out of the fuel rail.
Figure 13

To remove individual fuel injectors, pull the fuel injector straight out of the fuel rail. The injector support (red arrow) will come off with the injector. Be sure to replace this when reinstalling. When replacing injectors on turbocharged engines, I like to use the old injector to clean the injector bore. I slide the injector in and out of the bore a bunch of times to clean the debris from the hole.



When installing a new injector, the Teflon seals will come preinstalled and covered with a protective metal cover.
Figure 14

When installing a new injector, the Teflon seals will come preinstalled and covered with a protective metal cover. Leave this cover on until you are ready to install the injector. Remove the cover and slide the injector into the cylinder head. Install the retainer and fuel rail. Then install the new fuel line to the fuel rail. When installing the new fuel line, slowly tighten each end until it's snug and then tighten. This will seat the fuel line. Reassemble the remaining items in the reverse order of the disassembly steps. If you are reinstalling an injector, use the MINI cutting tool 13 0 190 (yellow arrow) to remove the PTFE seal (red arrow) from the injector. Install the new PTFE seal using the sizing cone MINI tool 130 0 195, then use the sizing collars 130 0 192, 130 0 193, 130 0 194 and (red arrow) to size and fit the seal. Install the old injector as noted above.





Bookmark and Share
Comments and Suggestions:
juan Comments: hi, I got new injectors, do you guys have the tool sizing cone MINI tool for the ptfe seal? thanks
November 21, 2016
  Followup from the Pelican Staff: Pelican can get it for you. Give The Pelican Parts parts specialists a call at 1-888-280-7799.
- Nick at Pelican Parts
 
Rodneyr56 Comments: Can this be one without mini tool 130 0 195?
June 6, 2016
  Followup from the Pelican Staff: No. - Nick at Pelican Parts  

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Project/Wish List]
  [Privacy Statement]  [Contact Us] [About Us] [Shipping] [Careers]

Copyright © Pelican Parts Inc. -    DMCA Registered Agent Contact Page

Page last updated: Sat 12/3/2016 02:54:28 AM