Diesel Fuel Injection

Safety Precautions

Very hot fuel can burn your skin.

• In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Allow the fuel to cool down before opening any connections otherwise there is a danger of scalding.

• Wear safety gloves

• Wear protective eyewear.

There is a risk of injury because the fuel is under pressure.

• If the battery is not going to be disconnected, then for safety reasons, remove the fuse for the fuel pump control module before opening the fuel system. Otherwise the drivers door contact switch will activate the fuel pump.

• Place a clean cloth around the connection before opening the system. Then release pressure by carefully loosening the connection.

• Wear safety gloves

• Wear protective eyewear.

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.

Secure the scan tool on the rear seat and have a second technician operate it from there.

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

• Always follow the instructions when disconnecting the battery.

• Only disconnect and reconnect wires for the glow plug and fuel injection systems, including test leads, when the ignition is turned off.

• If the engine is to be cranked at starter speed without starting, disconnect the connector from the fuel pressure regulator valve.

• Obtain the code for anti-theft radios before disconnecting the battery.

• Always turn the ignition off before disconnecting or connecting the battery. Failing to do so could damage the diesel direct injection system control module.