Safety Precautions

Safety Precautions


• Fuel pressure in the high pressure pipe can be up to 120 bar! Follow the safety precautions when releasing the pressure in the high pressure side. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

• The fuel system is under pressure! Always wear protective eye-wear and protective clothing to prevent injuries and fuel from coming in contact with your skin.

• Before loosening line connections, place a cloth around the connection point. Then release pressure by carefully pulling off the line.

For safety reasons, turn off the current to the fuel pump before opening the fuel system. Otherwise the fuel pump will activate when the drivers door is opened. Use one of the following ways to turn off the current:

• Battery, disconnecting

or

• Remove the fuse for the fuel pump control module (J538)

or

• Disconnect the connector from the fuel delivery unit flange or from the fuel pump control module


When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following:

• Do not touch or disconnect the ignition coils with power output stages when the engine is running or turning at starting speed.

• The ignition must be turned off before connecting or disconnecting injection and ignition system wiring or tester cables.

Always observe the following when removing and installing the fuel delivery unit or the fuel pump from a full or partially filled fuel tank.

• Before starting work, turn the exhaust extraction system on and place an extraction hose close to the fuel tank opening to extract fuel fumes. If no exhaust extraction system is available, a radial fan (as long as motor is not in air flow) with a displacement greater than 15 m3/h can be used.

• Prevent fuel from contacting skin! Wear fuel resistant gloves!

If special testing equipment is required during a road test, note the following:

• Test and measuring instruments must be secured to the rear seat and operated by a second person from this location.

• If the vehicle is involved in a collision while testing and measuring equipment is operated from the front passenger seat, the person sitting in that seat could be seriously injured when the airbag deploys.