Fuel Supply System Safety Precautions

WARNING:

Fuel pressure in high pressure pipe can be up to 120 bar! Always follow the safety precautions when reducing the pressure in the high pressure area.

Reduce the pressure in the high pressure area. Refer to [For transmission(s) 0A4, 09G] [For engine(s) CBTA, CBUA] General, Technical Data or [For transmission(s) 02E] [For engine(s) CDVB] General, Technical Data General Information [For engine(s) CPRA, CPKA] General Information .
The fuel supply line is under pressure. Wear protective eyewear and protective clothing in order to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Remove the hose connection carefully to release the pressure.

CAUTION:

There is a risk of fire due to leaking fuel.

WARNING:

For safety reasons, switch off the current to the fuel pump before opening the fuel system. Otherwise the fuel pump will activated when the driver door is opened.

It is possible to interrupt the current flow by using one of the following possibilities:

Disconnect the battery.

Remove the fuse for the Fuel Pump Control Module -J538- or for the fuel delivery unit.

Remove the fuse for the Fuel Pump -G6-.

Disconnect the connector on the fuel delivery unit flange or on the Fuel Pump Control Module -J538-.

CAUTION:

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

Route all lines in their original locations.
Make sure that all components are easily accessible.

Note the following when removing and installing fuel tank components which are completely or partially filled:

Disable the current to the Transfer Fuel Pump -G6- FUEL SUPPLY SYSTEM SAFETY PRECAUTIONS .
Drain the fuel tank. Refer to FUEL TANK, DRAINING .

WARNING:

Fuel system is under pressure! Wear eye protection and safety gloves in order to avoid injuries and skin contact.

Danger of personal injury to eyes and skin.

Wrap a cloth around the connection before loosening hose connections.

Remove the hose connection carefully to release the pressure.

Complete the following steps before starting work on the fuel supply system:

Before starting work, place the extracting hose on an exhaust extractor that is switched on near the fuel tank opening.
This siphoning hose evacuates 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.
Do not let fuel come in contact with bare 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 engine is running or turning at starting RPM.
The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.

WARNING:

Use only the Used Oil Collection And Extraction Unit SMN372500 (Replaces VAS5190.) when extracting the E 85 - fuel type!

NOTE:

The coupling must audibly engage when locking.

Note the color coding when installing the coupling COUPLINGS, SEPARATING => Coupling Allocation !

Pull on the coupling to make sure it is secure.

Disconnect the couplings. Refer to COUPLINGS, SEPARATING .