13 51 017 Removing and installing or replacing high-pressure fuel pump

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2010 BMW 535xi, 2010 BMW 535i, 2009 BMW 535xi, 2009 BMW 535i, and 2008 BMW 535xi. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Observe warning on cylinder head cover.
Disconnect BATTERY NEGATIVE TERMINAL (risk of fire due to short-circuiting on removal).
Electric fuel pump starts up automatically each time door is opened!
Carry out installation work on fuel system only with coolant temperature below 40 °C.

WARNING: Observe warning on cylinder head cover.

Disconnect BATTERY NEGATIVE TERMINAL (risk of fire due to short circuit on removal).

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 protective gloves.

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

IMPORTANT: Adhere to conditions of absolute cleanliness when working on the high-pressure fuel system.

Introduced dirt contamination can cause malfunctions in the system!

Do not allow any dirt particles or foreign bodies to get into the system.
Remove all traces of dirt contamination before removing lines or separate components.
Use only fluff-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!

Cover ignition coil with suitable means.

Necessary preliminary work

Remove THROTTLE BODY

Recycling

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Apply silicone-free multifunction spray (part number 83 23 0 418 567) on to supports (1) of base well bracket (2).

Unplug connector (3) and (4) from base well.

Slide base well (2) in direction of arrow.

Fig 1: Applying Silicone-Free Multifunction Spray On Base Well Bracket Supports

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Fig 2: Inserting Special Tools (00 7 300) In Base Well Mounting Points

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Insert special tool 00 7 300 in mounting points (1) on base well.

NOTE: Place tips of special tool 00 7 300 between retainers (2) and then center (arrow).

Detach base well (1) from bracket (2) with special tool 00 7 300.

Fig 3: Removing Base Well From Bracket Using Special Tool (00 7 300)

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Unlock connector (1) and remove.

Unlock and detach fuel line (2).

Catch and dispose of escaping fuel.

Fig 4: Identifying Connector And Fuel Line

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Seal fuel lines with special tools 13 5 281 and 13 5 282.

Fig 5: Identifying Seal Fuel Lines With Special Tools (13 5 281) And (13 5 282)

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Slacken nut (1).

Release screw (2).

Installation note:

Replace aluminum screw (2).

Remove feed line (3).

Fig 6: Identifying Nut, Screw And Feed Line

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Seal feed line with matching plug from set of special tools 32 1 270.

Fig 7: Identifying Seal Feed Line With Matching Plug From Special Tool Kit (32 1 270)

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Slacken nut (1).

Fig 8: Identifying Slacken Nut

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Undo screws (1) and raise acoustic cover (2) in front area.

Fig 9: Raising Acoustic Cover In Front Area

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Slacken nut (1).

Fig 10: Identifying Slacken Nut

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Seal fuel line connections of high pressure pump (1) with matching plugs from set of special tools 32 1 270.

Fig 11: Identifying Seal Fuel Line Connections Of High-Pressure Pump With Matching Plugs From Special Tool Kit (32 1 270)

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Release bolts with special tool 11 8 610 (socket wrench).

Detach high pressure pump (1) and remove.

Engine oil can escape when pump is detached; have a cleaning cloth ready.

Fig 12: Removing High-Pressure Pump Using Special Tool (11 8 610)

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Installing high pressure pump

Installation of high pressure pump is described separately from removal.

Replace sealing ring (1).

Clean contact surfaces.

Fig 13: Identifying Sealing Ring

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When installing, turn high pressure pump (1) if necessary in direction of arrow until bore holes for screws are flush.

Fig 14: Identifying High-Pressure Pump

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IMPORTANT: Only hand-tighten screws (1) of high pressure pump (2) with special tool 11 8 610 (socket wrench).

This helps ensure that no strain is produced when the high pressure line is tightened.

Fig 15: Identifying High Pressure Pump With Screws

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Copper seals that may be fitted on the high pressure line are no longer needed and must be removed.

If reusing pressure line, lightly grease threads of pressure connections.

Threads of new pressure lines are already coated.

Only hand-tighten nut (1).

Fig 16: Identifying Hand-Tightened Nut

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Only hand-tighten nut (1).

Fig 17: Identifying Hand-Tightened Nut

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NOTE: Feed lines with a soldered bracket must be replaced by the new version with elastomer clamp holder. Observe installation position of fuel low-pressure sensor. Lines for solenoid switches are laid behind fuel line.

Install feed line (3).

Only hand-tighten nut (1).

Tighten screw (2). Replace aluminum screw.

Tightening torque: see 9AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .

Fig 18: Identifying Nut, Screw And Feed Line

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Tighten down screws with special tool 11 8 610 (socket wrench).

Tightening torque: see 1AZ in 13 51 INJECTION PUMP, CONTROL

Fig 19: Installing High-Pressure Pump Using Special Tool (11 8 610)

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Tighten nut (1).

Tightening torque: see 7AZ in 13 53 FUEL INJECTION NOZZLES AND PIPES .