Removing and installing/replacing the high-pressure pump (Cooper)

WARNING: Observe warning on cylinder head cover.
Disconnect BATTERY GROUND LEAD. (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 hand protection.
Gas can emerge spontaneously at high speed when the high pressure line is released!

Recycling:

Fuel leakages when fuel lines are detached.

Catch and dispose of leakage fuel.

Observe country-specific waste disposal regulations.

IMPORTANT: Adhere to conditions of absolute cleanliness when carrying out repairs 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!

Preliminary work needed:

Remove PRESSURE LINE between rail and high pressure pump.
Remove front WHEEL ARCH COVER .

Removal:

NOTE: To disconnect the connector at the high pressure pump, the lock (1) needs to be pulled out in arrow direction first. Then compress the lock (1) in direction of the connector housing, detaching the connector at the same time.

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Courtesy of BMW OF NORTH AMERICA, INC.

Unlock connector (2) and remove.

Release union nut (1) on feed line.

Lay feed line to one side.

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Courtesy of BMW OF NORTH AMERICA, INC.

Release screws (1) alternately.

Remove high pressure pump.

Motor oil can leak when pump is detached; have a cleaning cloth ready.

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Courtesy of BMW OF NORTH AMERICA, INC.

Preparation for installation:

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.

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

Twist 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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Courtesy of BMW OF NORTH AMERICA, INC.

Replace seal (1).

Part: Gasket.

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Courtesy of BMW OF NORTH AMERICA, INC.

Install high-pressure pump.

Use new screws.

Attach screws (1) of the high-pressure pump and tighten alternately in 90° steps, otherwise the piston can break due to canting.

Tightening torque 13 51 1AZ .

G11645639

Courtesy of BMW OF NORTH AMERICA, INC.

Screw union nut (1) of feed line to high-pressure pump hand-tight.

Then tighten union nut (1).

Tightening torque 13 53 4AZ .

Attach connector (2) to high-pressure pump.

Connector (2) must snap audibly into place.

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Courtesy of BMW OF NORTH AMERICA, INC.

Connect connector on the high pressure pump until the lock (1) engages audibly.

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

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Courtesy of BMW OF NORTH AMERICA, INC.

Required follow-up work:

Install PRESSURE LINE between rail and high pressure pump.
Install front WHEEL ARCH COVER .
Connect BATTERY GROUND LEAD.