13 51 070 Removing and installing/replacing right high pressure pump (N63)

Special tools required:

WARNING: Observe warning on cylinder head cover.
Disconnect NEGATIVE BATTERY 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 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.

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 tasks:

Remove intake silencer housing . See 13 71 030 REMOVING AND INSTALLING/REPLACING BOTH INTAKE FILTER HOUSINGS (N63) .
Remove fan cowl . See 17 11 035 REMOVING AND INSTALLING/RENEWING FAN COWL WITH ELECTRIC FAN (N63) .

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Release clamp (1).

Disconnect charge air line (2) to exhaust turbocharger.

Fig 1: Identifying Charge Air Line And Clamp

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

Pull off hose (1) from clean air pipe (3).

Release screw (2).

Tightening torque: 13 71 1AZ .

Pull off clean air pipe in direction of travel from exhaust turbocharger. Check seal on clean air pipe and renew if necessary.

Fig 2: Identifying Clean-Air Pipe And Screw

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Unlock plug catch (1) on ignition coil (2) and unplug connector.

Slowly pull out the ignition coil (2) in an upwards direction with no jerky actions.

NOTE: There is a possibility that the silicone tube will tear and therefore be destroyed. This procedure is applicable to all ignition coils.

Fig 3: Pulling Plug Catch On Ignition Coil

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Installation note:

Position the ignition coil (1) and gently push it to the limit position, if necessary by twisting it back and forth slightly. Then check anti-twist lock.

The rubber cap must completely surround the sealing collar of the cylinder head cover.

NOTE: If rubber parts are squashed, the ignition coil can slip out again during engine operation.

Fig 4: Locating Ignition Coil

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Installation note:

Push connector (1) with connector catch (2) open onto ignition coil. Carefully close connector catch (2) in direction of arrow.

The connector catch must snap into place without great effort.

The connector must be positioned on the counter piece with hardly any gaps when the locking lever is being closed. In the process, the cheeks of the lever are positioned inside the counter piece.

Fig 5: Closing Connector Catch

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NOTE: The locking lever can become deformed if it is not installed correctly. This means that there is no longer a safety lock on the plug connection. As a result, the connector can slip out during engine operation (loose contact, misfiring).

Release screw (1).

Fig 6: Identifying Screw

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Release pressure line at the injectors (1).

Fig 7: Identifying Injectors And Pressure Line

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Installation note:

Tighten pressure line onto the injector using torque wrench (2) and special tool (1) 13 0 161 (from the set of special tools 13 0 160 ).

In so doing, grip hexagon head of injector with spanner (3).

Tightening torque: 13 53 3AZ

Fig 8: Tightening Pressure Line On Injector With Torque Wrench And Special Tool

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Release the union nuts of the fuel delivery line (1) and pressure line (2) at the high pressure pump (3).

Fig 9: Identifying Union Nuts Of Fuel Delivery Line And Pressure Line

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Installation note:

Tighten fuel delivery line (1) and pressure line (2) hand-tight at high pressure pump.

Then tighten pressure line onto high pressure pump using torque wrench (2) and special tool (3) 00 1 440 .

Tightening torque: 13 53 3AZ

Fig 10: Tightening High-Pressure Line On High-Pressure Pump Using Torque Wrench

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Disconnect fuel delivery line. Close fuel lines using special tool (1) 13 5 161 and (2) 13 5 162 (from set of special tools 13 5 160 ).

Catch and dispose of escaping fuel.

Fig 11: Identifying Seal Fuel Lines With Special Tools (13 5 160 And 13 5 162)

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

Fig 12: Identifying Connector With Holder

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Pull off connector (1) from high pressure pump (2).

Fig 13: Identifying High Pressure Pump Connector

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IMPORTANT: High-pressure pump can be pretensioned by camshaft cams!
Slightly slacken screws (1) of high pressure pump (2). If the high pressure pump is forced out, the engine will have to be turned to bring the camshafts to a different position.
Otherwise it will not be possible to install the high-pressure pump! Release screws (1).

Fig 14: Identifying High Pressure Pump And Screws

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Replace screws. Screws are coated with a screw locking agent.
The pump plunger can fall out when the high-pressure pump (2) is pulled out! Detach high-pressure pump (2) and remove.
Engine oil can emerge when pulling off the pump; have cloths ready.
Installation note:
Before installing the high pressure pump, the cam of the high pressure pump drive must be turned to BDC. To do this, twist the engine if necessary in the direction of engine rotation to the central bolt of the crankshaft.
Adhere to tightening/torque sequence.

Lay depth gauge (1) flat on high pressure pump flange.

Turn engine at central bolt in direction of engine rotation until the depth gauge shows that the camshaft has reached the BDC position .

Fig 15: Checking Depth Gauge Flat On High Pressure Pump Flange

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Installation note:

Replace sealing ring (1).

Clean contact surfaces.

Fig 16: Identifying Sealing Ring

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Install high pressure pump (2).

Replace screws (1). Screws (1) are coated with sealing compound.

Installation note:

Provisionally fasten screws (1) on high pressure pump (2) and tighten alternately in 90° increments until final tightening, otherwise the piston may break as a result of tilting!

Tightening torque: 13 51 1AZ

Fig 17: Identifying High Pressure Pump And Screws

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Assemble engine.

Check fuel system for tightness.

Check function of DME.