M57 330d Big Turbo | Bosch CP3 R90 rebuild

This is not a comprehensive guide by any means. It is just a primer to show you the inside, to make the task seem less daunting.
Most of the media from the rebuild process is on my laptop, this is all i could find saved on my phone still. I hope it gives you a good idea. It's quite a simple process, and with some common sense you can figure out the bits not shown step by step. If you can't, then with greatest of respect, don't attempt (may do more harm than good).
I am not convinced a typical refurbed r90 pump selling for £400-600 from some sellers is anything more than a basic inspection, reseal (as shown), clean up with paint, then tested on flow bench to confirm pumping capacity is within spec - seriously. New pump body core's are not available, and unless someone is machining the bore and supplying new oversized matching piston/plunger/cups to suit, then this is also not the done thing for a refurbed pump (hint, those that do sell for eye watering prices as a "stroker" pump, typically in American truck community market). Sooooo.... why are you paying someone an extra few hundred pounds for a few hours diy?
The seal kit used here is about £25-30 on Ebay, genuine Bosch kit's are similar priced if you have a service centre near you, and it takes a few hours to DIY rebuild.
Only special tool used was the bearing puller but even that isn't needed, I pulled one open by (carefully) prying with screwdriver and by hand. The shaft seal needs careful finessing as shown, then driving in carefully with mallet and suitable sized socket. There are some check valves with ball bearings, the kits come with new ones to replace so don't worry if some go AWOL on removal.
It's good practice to test the FCA - it's a simple solenoid and now would be a good idea to carry out the "Relentless Diesel FCA mod" (Google it) if you want. Additionally, the delivery valve in the back of the pump (connects to the rail) can be modified too - I will detail this separately at a later date (basically helps hold rail pressure for longer).
As long as you aren't a total ape with feet for hands, it's unlikely you'll pull out the input shaft out or over torque anything. Thus its not very likely you'll screw the rebuild up AS LONG AS YOU KEEP IT CLEAN INSIDE (you'll ruin your injectors otherwise!). I wasn't convinced if it was worth the risk to rebuild as the pump was immaculate inside and the seals looked healthy.. but in hindsight it was worth it, and i recommend it if you feel confident in your ability.
The pump is working well for 7000miles so far. The tolerances are so fine within that any slight deterioration/internal leak will see noticeable decline in pumping efficiency, so it's worthwhile if you are due to fit the pump. I wouldn't remove one just to rebuild unless it's totally FUBAR.
At the very least, you should open the pump cover of any used pump to inspect (could be full of rust), or ideally send to a shop to have inspected and tested either way. I didn't send mine off for testing YOLO, it has proved itself via logs...
If there's any sign of rust inside, the pump is no good. Fit only if you want to remove it again.

[@mariusfridlund55]

Nice👍 love the m57. Torqe beasts

[@Waldek77]

Thanks.

[@ronanjuries7091]

Great video so how do they swap out internals to R110. Or how do you get better flow. I now see 50ppm fuel needs 2 stroke to lube and cool that pump. Quite similar to cp1 but cp1 has heads.

[@OdedraPerformance]

R110 internals would require precisionnnn machining of the body which is like 60 Rockwell hardness (VERY tough, same as bearing race which is why is sh*ts on cp4). It's definitely possible though, and some companies offer this, but expensive and you risk cracking the pump body with sustained high rail pressure use (r90 already has tendency to crack above 2400bar, and you're taking material away for r110 elements). I'd prefer using the r110 pump itself... Cp1 is different beast. I've not opened one yet, but you can DIY swap elements for larger pumping capacity. I believe mercedes elements of some sort fit straight in either, r85 or 90 equivalent - that sort of ball park. Definitely enough for most m57.

[@insideridin1376]

Stupid question but is the fuel pump «timed» to the crank/camshafts? Does the engine need to be at a specific time/tdc when removing or installing the high pressure fuel pump?

[@OdedraPerformance]

Thankfully no, pump is not timed to the engine.

[@insideridin1376]

@@OdedraPerformance thank you for answering! Now i can safely buy a m57 car with broken hpfp😄

[@OdedraPerformance]

@@insideridin1376 just to check, when you say broken what do you mean exactly? Low rail pressure codes?

[@insideridin1376]

@@OdedraPerformance good question. Honestly i dont know. The seller says hpfp and fuel rail needs to be replaced. Doubt he has diagnostic tools. Will run inpa when i come to see the car.

[@OdedraPerformance]

@@insideridin1376 we are talking about m57 aren't we? Which variant? The later cp3 is very robust. And rarely fail totally unless something like mis-fuelled. If n-series, that is cp4. They are weaker and fail more readily (you will need to check if they are not timed like m57, original answer was assuming m57). Just keep in back of mind if the pump actually has failed, there's a decent chance it's taken out injector(s) too in the worst case.

[@gytiskundrotas1939]

What mods did you do for this R90 for better flow?

[@OdedraPerformance]

Internally? Nothing, just fitted new seals. There are a few basic mods you can do to help eliminate bottlenecks in the other components, namely FCA and delivery valve (widely documented under "relentless diesel mod" title on Google, it does help). Other weak points are in-tank fuel pump, upgraded to walbro 450 and then optimising by closing up the DRV and some tweaks to FCA maps in software. That's it. You'll max out a good r90 with healthy injectors this way.

[@andreas6446]

where you bought the seals for the pump link please?

[@OdedraPerformance]

Bosch service centre would be the best place

[@fanattyzm8137]

U didn't think about dual-pump R90 ?

[@OdedraPerformance]

Dual pump plan is in progess ;)

[@fanattyzm8137]

@@OdedraPerformance I think the same... but first methanol ;P

[@OdedraPerformance]

@@fanattyzm8137 once dual pumps installed and injectors maxed out, I would like to try methanol as additional fuel source, should help get close to maxing turbo out! 2 stage setup can add up to 40bhp but it's risky business, I've seen methanol responsible for a lot of cooked pistons if not setup or used responsibly 😂

[@fanattyzm8137]

@@OdedraPerformance ou know how it is with alcohol - use it responsible ;)

[@OdedraPerformance]

@@fanattyzm8137 hahahahaha right! "Here for a good, not a long time"