Fuel Tank and Lines

Fuel Tank and Lines Inspection and Verification

WARNING: Do NOT carry out any work on the fuel system with the engine running. The fuel pressure within the system can be as high as 1600 bar (23,206 lb/in2). Failure to follow this instruction may result in personal injury.

WARNING: Eye protection must be worn at all times when working on or near any fuel related components. Failure to follow this instruction may result in personal injury.

WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions. Failure to follow this instruction may result in personal injury.

WARNING: After carrying out repairs, the fuel system must be checked visually for leaks. This should be done after the engine has been run, but with the engine switched OFF. Failure to follow this instruction may result in personal injury.

WARNING: If taken internally, DO NOT induce vomiting. Seek immediate medical attention. Failure to follow this instruction may result in personal injury.

WARNING: If fuel contacts the eyes, flush the eyes with cold water or eyewash solution and seek medical attention. Failure to follow this instruction may result in personal injury.

WARNING: Wash hands thoroughly after handling, as prolonged contact may cause irritation. Should irritation develop, seek medical attention. Failure to follow this instruction may result in personal injury.

CAUTION: Before disconnecting any part of the system, it is imperative that all dust, dirt and debris is removed from around components to prevent ingress of foreign matter into the fuel system. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: The fuel pipes between the injectors and the rail must be discarded after each use, and new pipes installed. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: It is essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or lines. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that the workshop area in which the vehicle is being worked on is as clean and dust-free as possible. Areas in which work on clutches, brakes or where welding or machining are carried out are not suitable in view of the risk of contamination to the fuel system. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that any protective clothing worn is clean and made from lint-free non-flocking material. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that any protective gloves worn are new and are of the non-powdered latex type. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Make sure that clean, non-plated tools are used. Clean tools using a new brush that will not lose it's bristles and fresh cleaning fluid prior to starting work on the vehicle. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Use a steel-topped work bench and cover it with clean, lint-free, non-flocking material. Failure to follow this instruction may result in damage to the vehicle.

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.

NOTE:
Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.
1 Verify the customer concern.
2 Visually inspect for obvious signs of mechanical or electrical damage.





3 If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4 If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for Diagnostic Trouble Codes (DTCs) and refer to the DTC Index.

DTC Index
For a complete list of all Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to A L L Diagnostic Trouble Codes ( DTC ).For additional information, refer to Diagnostic Trouble Code (DTC) Index - V8 5.0L Petrol/V8 S/C 5.0L Petrol, DTC: Engine Control Module Testing and Inspection