13 51 065 Removing and installing/replacing the left high pressure pump (N63 B40/B44 O 1)

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:

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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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, Hoses 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: Identifying 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 screws (1) and (2).

Fig 6: Identifying High Pressure Pump Screws

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Release pressure line at the injectors (1).

Fig 7: Identifying Injectors

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Installation note:

Tighten pressure line on injector with torque wrench (2) and special tool (1) 13 0 161 .

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 Fuel Delivery Line, Pressure Line And High Pressure Pump

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Installation note:

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

Then tighten the pressure line on the high pressure pump with the torque wrench (2) and special tool (3) 00 1 440 .

Tightening torque: 13 53 3AZ

Fig 10: Tightening High-Pressure Line Using Torque Wrench

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Release the screws (1) and attach the cable channel (2).

Tightening torque: 12 51 2AZ

Fig 11: Identifying Cable Channel And Screws

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Pull off the holder (1) for the water valve (2) towards the top.

Fig 12: Identifying Water Valve And Holder

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Release screws (1).

Tightening torque: 13 53 1AZ

Fig 13: Identifying High Pressure Pump Screws

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Disconnect fuel delivery line. Close the fuel line with special tool (1) 13 5 160 and special tool (2) 13 5 162 .

Catch and dispose of escaping fuel.

Fig 14: 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 15: Identifying Connector Holder

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

Fig 16: 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).
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.

Fig 17: Identifying High Pressure Pump And Screws

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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 18: Checking High Pressure Pump Flange Depth

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Installation note:

Replace sealing ring (1).

Clean contact surfaces.

Fig 19: Identifying O-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 20: Identifying High Pressure Pump And Screws

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Assemble engine.

Check fuel system for tightness.

Check function of DME.