Removing and installing/replacing high pressure fuel injection pump (B46/B48 4-Cyl. Engine) (4' Series Coupe/Convertible, 4' Series Gran Coupe Sedan)

WARNING: Observe warning on cylinder head cover.
Disconnect NEGATIVE BATTERY TERMINAL (risk of fire due to short-circuiting 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.

IMPORTANT: Wear full face guard and protective gloves.
Fuel can emerge spontaneously at high speed when the high pressure line is released!

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

IMPORTANT: Adhere to conditions of absolute cleanliness when carrying out repair work 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 contamination before removing lines or separate components.
Use only lint-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!

Necessary preliminary work:

Release FEED LINE (do not remove) .
Remove PRESSURE LINE between rail and high pressure pump.

Removal:

NOTE: To disconnect the connector (2) from the high pressure pump, the lock (1) must be pulled out in direction of arrow first, then the lock (1) pushed together and then the connector (2) detached.

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Unlock and disconnect plugs (1).

Release screws (2) alternately.

IMPORTANT: Remove high pressure pump (3).

When the high pressure pump (3) is pulled off, engine oil can leak out, have cleaning cloths at hand.

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Preparation for installation:

Before the high pressure pump is installed, the cam of the high pressure pump drive must be turned to bottom dead center . To do this, twist the engine if necessary in the direction of engine rotation to the central bolt of the crankshaft.

Lay depth gauge (1) flat on fuel 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 .

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Installation:

Check thread (1) on high pressure pump flange for residues of sealing compound.

Clean thread with a M6 thread cutter.

Make sure that no contamination enters the engine. Cover opening at the high pressure pump flange with suitable materials.

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Replace gasket (1).

Part: Gasket.

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Install high pressure pump (3).

Replace screws (2).

Part: Bolts (bolts are coated with sealing compound)

Provisionally fasten screws (2) of the high pressure pump (3) and tighten alternately in 90° increments until final torque, piston can otherwise break due to tilting!

Tightening torque 13 51 1AZ .

Attach and lock connector (1).

Connector (1) must engage audibly.

Installation note:

Fit connector (2) onto high pressure pump until connector latches audibly into place.

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Then lock the lock (1) in the direction of the arrow.

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Required follow-up work:

Install PRESSURE LINE between rail and high-pressure pump
Re-fasten FEED LINE .