Fuel Gauge Sender: Service Precautions

Safety Precautions


Fuel pressure in the high pressure pipe can be up to 150 bar! Follow the safety precautions when releasing the high side fuel pressure.

• High side fuel pressure, releasing. Refer to => [ High Side Fuel Pressure, Releasing ] Service and Repair.

• 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 removing 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:

• Battery, disconnecting

or

• Remove the fuel pump control module fuse

or

• Disconnect the connector from the fuel delivery unit flange or 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 routing 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 ignition coils with power output stages when the engine is running or turning at starter speed.

• Only disconnect and reconnect wires for the injection and ignition system, including test leads, when the ignition is turned off.

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, place a extracting hose from an exhaust extractor that is switched on near the fuel tank opening. This will extract the fuel vapors. 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 that 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.