13 51 065 Remove/install/replace left high pressure pump (N63 B40/B44 O 1, S63 B44 T 2)

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 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!
Cover ignition coil with suitable means.

Necessary preliminary tasks:

Remove ACOUSTIC COVER .
Remove CHARGE AIR HOSE at left (only N63 B40/B44 O 1).
Remove CLEAN AIR PIPE on left.
Remove IGNITION COILS , cylinders 5-8.
Release WATER VALVE for heating and air-conditioning unit and place to one side, do not disconnect coolant hose.
Remove FAN COWL .

Recycling:

Fuel escapes when fuel lines are detached.

Catch and dispose of escaping fuel.

Observe country-specific waste disposal regulations.

Release screws (1) and (2).

Fig 1: Identifying Screws

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Release pressure line at the injectors (1).

Tighten pressure line on injector with torque wrench and special tool 13 0 161 .

Tightening torque 13 53 2AZ .

Fig 2: Identifying Injectors

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

Fig 3: Identifying Pressure Pump Holder And Connector

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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 4: 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 5: Tightening High-Pressure Line

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

Tightening torque: 12 51 2AZ

IMPORTANT: Screw back on all screw points of cable channels without fail. Some screw points are also ground points .

Fig 6: Identifying Cable Channel And Screws

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Release screws (1) a few rotations and slacken rail.

Tightening torque: 13 53 1AZ

Fig 7: Identifying High Pressure Pump Rail 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 8: Sealing Off Fuel Lines Using Special Tools (13 5 160 And 13 5 162)

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

Fig 9: 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.
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.

Fig 10: Identifying High Pressure Pump And Screws

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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 11: Checking High Pressure Pump Flange Depth

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Installation note:

Replace sealing ring (1).

Clean contact surfaces.

Fig 12: 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 13: Identifying High Pressure Pump And Screws

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Assemble engine.

Check fuel system for tightness.

Check function of DME.