13 53 332 Remove and install/replace the feed line (N63 B40/B44 O 1)

Special tools required:

13 5 160

WARNING: Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short circuit 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 safety goggles.

Wear protective gloves!

IMPORTANT: Adhere to conditions of absolute cleanliness when working 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 dirt before removing lines or separate components.
Use only fluff-free cloths.
Seal all fuel system openings with protective caps or plugs.

Necessary preliminary tasks:

Remove alternator DRIVE BELT .
Remove charge air cooler EXPANSION TANK .

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel in a suitable container.

Observe country-specific waste disposal regulations.

Release clamps (1).

Tightening torque 13 71 8AZ .

Release clamps (2).

Replace clamps (2).

Detach both charge-air ducts (3) and remove.

Check the gaskets on the exhaust turbocharger. replacing if necessary.

Fig 1: Identifying Charge-Air Ducts And Clamps

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Picture shows the left side, the procedure for the right side is identical.

Detach hoses (1) from clean air pipe.

Release screw (2).

Tightening torque 13 71 1AZ .

Detach clean-air pipe (3) in direction of travel from exhaust turbocharger.

Check the gaskets on the clean air pipe. replacing if necessary.

Fig 2: Identifying Clean-Air Pipe, Hoses And Screw

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Disengage all the lines and connectors (1) from the holder and put them to the side.

Fig 3: Identifying Feed Lines And Connectors

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Unlock and pull off connector (1) from alternator.

Release nut at bottom of cover (2).

Tightening torque 12 41 1AZ .

Remove positive battery cable from alternator and place to one side.

Installation note:

Reinstall cover (2) without fail risk of short circuiting!

Fig 4: Identifying Alternator Connector

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Release the screws (1) from the coolant pump for the exhaust turbocharger (2).

Place the turbocharger coolant pump to the side. Do not remove the turbocharger coolant pump!

Fig 5: Identifying Exhaust Turbocharger Coolant Pump And Screws

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Release screws (1).

Tightening torque 12 31 1AZ .

Feed out and remove the holder for the expansion tank in the direction of travel.

Fig 6: Identifying Fuel Feed Line Screws

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Pull off connector (2) with holder (1) in an upwards direction.

Fig 7: Identifying Connector Holder

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Release connector holder (1) from bracket and place to one side.

Fig 8: Identifying Connector Holder

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Unlock and disconnect the fuel delivery line.

Seal fuel lines with special tools (1) and (2) 13 5 160 .

Fig 9: Identifying Seal Fuel Lines With Special Tools (13 5 160 And 13 5 162)

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Release the fuel feed line (1) on the high-pressure pumps.

Unfasten screws (2).

Release nuts (3) on retaining clips.

Catch and dispose of escaping fuel.

Feed out and remove fuel feed line (2).

Fig 10: Identifying Fuel Feed Line, Nuts And Screws

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Installation note:

Observe tightening sequence .

1. Fit fuel feed line.
In so doing, apply only hand-tight force to tighten screw connections!
2. Apply tightening force to fuel delivery line at high pressure pumps.
Tightening torque 13 53 4AZ .
3. Apply tightening force to the fuel delivery line at cylinder head cover and engine block.
Tightening torque 13 53 6AZ .
4. Tighten down retaining clips.
Tightening torque 13 53 7AZ .

Assemble engine.

Check fuel system for tightness.

Check function of DME.