Safety Precautions

Safety Precautions


• Follow the safety measures for releasing the high side pressure. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

• The fuel system is under pressure! Always wear protective eyewear 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, Interrupt the current supply to the fuel pump before opening the fuel system. Otherwise the fuel pump will activate when the drivers door is opened. Interrupt the current supply in one of the following ways:

• 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 test cables.

• The battery must only be disconnected and connected with the ignition turned off, otherwise the Engine Control Module (ECM) can be damaged. Obtain the radio code for radios with a anti-theft code before disconnecting the battery.

• Follow required safety precautions after connecting the battery.

Always observe the following when removing and installing the fuel level sensor or fuel delivery unit from a full or partially filled fuel tank:

• Before starting work, turn on the exhaust extraction system and place an extraction hose close to the fuel tank opening to extract escaping 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 test and measuring instruments are operated from the front passenger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.