Removing and installing/replacing pressure line between rail and high pressure pump (Cooper)

WARNING: Observe warning on cylinder head cover.
Disconnect BATTERY GROUND LEAD. (risk of fire due to short-circuiting 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 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 in a suitable container.

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!
Cover ignition coil with suitable means.

Preliminary work needed:

Removal:

Unscrew the screws (1).

Release wiring harness from cylinder head cover.

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Remove screw (1).

Slightly push clean air pipe (2) to the rear and remove the sound insulation (3) of the high pressure pump.

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NOTE: To disconnect the connector at the high pressure pump, the locking mechanism (1) first needs to be pulled out in the arrow direction. Then compress the locking mechanism (1) in the arrow direction and detach the connector (2) at the same time.

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Unlock connector (1) and detach.

Release union nuts (2) and (3).

Release and remove pressure line between high- pressure pump and rail.

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Installation:

Mount high pressure line at the rail first, then mount high pressure line at the high pressure pump.

First, tighten union nuts (3) on the rail hand-tight.

Then, tighten union nut (2) on the high pressure pump hand-tight.

First, tighten union nuts (3) on the rail to tightening torque.

Tightening torque 13 53 6AZ .

Then tighten union nut (2) on the high pressure pump to tightening torque.

Tightening torque 13 53 6AZ .

Attach connector (1) to high-pressure pump.

Connector (1) must engage audibly.

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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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Install sound insulation (3).

Fit clean air pipe (2).

Tighten screw (1).

Tightening torque 13 71 6AZ .

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Install wiring harness on cylinder head cover.

Tighten down screws (1).

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Required follow-up work:

Install IGNITION COILS .
Install INTAKE SILENCER HOUSING .
Install ACOUSTIC COVER .