Precaution 1
Fuel Supply System
The 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.
• Release the pressure in the fuel rail.
• The fuel supply line is under pressure. Always wear protective eyewear and protective clothing to prevent injuries and fuel from coming in contact with your skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.
For safety reasons, interrupt 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 interrupt the current:
• Disconnect the battery.
or
• Remove the fuse for the fuel pump control module (J538) or for the fuel delivery unit.
or
• Disconnect the connector on the fuel delivery unit flange or for 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.
Always observe the following when removing and installing the fuel level sensor or the fuel pump from a full or partially filled fuel tank.
Remove the fuse for the fuel pump.
The fuel system is under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Wrap a cloth around the connection before disconnecting a fuel hose. Remove the hose connection carefully to release the pressure.
• Before starting work, switch the exhaust extraction system on and place an extraction hose close to the fuel tank opening to extract the 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!
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 ignition coils with power output stages when the engine is running or turning at starter 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 level sensor or the fuel pump from a full or partially filled fuel tank.
• Before starting work, switch the exhaust extraction system on and place an extraction hose close to the fuel tank opening to extract the 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!