13 51 070 Removing and installing/replacing right high pressure pump (N63O1)

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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 REMOVE INTAKE SILENCER HOUSING
Remove FAN COWL WITH ELECTRIC FAN

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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Version 1:

Unlock the retainer.
Pull off the retainer together with the line.

Fig 2: Unlocking And Pulling-Off Retainer
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Version 2:

Pull the line (1) gently in the direction indicated by the arrow.

At the same time, use a screwdriver (3) to unlock the latch mechanisms (2) one after the other.

Pull the connecting line off the clean air pipe and engine crankcase ventilation line.

Fig 3: Unlocking Latch Mechanisms

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Release screw (1).

Tightening torque 13 71 1AZ .

Pull clean air pipe (2) from exhaust turbocharger.

Fig 4: 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 5: Unlocking 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 6: Positioning Ignition Coil

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Installation note:

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

The connector latch mechanism must engage 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 crank webs of the lever are positioned inside the counter piece.

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).

Fig 7: Pushing Connector Onto Ignition Coil

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Release screw (1).

Fig 8: Identifying Screw

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Release pressure line at the injectors (1).

Fig 9: Identifying Injectors

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Installation note:

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

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

Tightening torque: 13 53 3AZ

Fig 10: Tightening Pressure Line On Injector Using 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 11: Identifying Union Nuts Of Fuel Delivery Line And Pressure Line At High Pressure Pump

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Installation note:

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

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

Tightening torque: 13 53 3AZ

Fig 12: Tightening Fuel Delivery Line And Pressure Line

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

Tightening torque: 12 51 2AZ

Fig 13: Identifying Cable Channel Screws

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Loosen the screw (1) and clip (2) and place the filler pipe for the window washer system (3).

Fig 14: Identifying Washer Fluid Filler Pipe, Clip, And Screw

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Unclip hose pipe (1) from holder (2).

Fig 15: Identifying Hose Pipe And Holder

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Release screws (1).

Tightening torque: 13 53 1AZ

Fig 16: Identifying Screws

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

Catch and dispose of escaping fuel.

Fig 17: Sealing Fuel Lines With Special Tools

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

Fig 18: Identifying Holder And Connector

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

Fig 19: 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.

Fig 20: Identifying High-Pressure Pump Screws

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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 bottom dead center. 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 21: Placing Depth Gauge Flat On High Pressure Pump Flange

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Installation note:

Replace gasket (1).

Clean contact surfaces.

Fig 22: 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 23: Identifying High-Pressure Pump Screws

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Assemble engine.

Check fuel system for tightness.

Check function of DME.