Fuel System Safety Precautions
Before Opening High Pressure Fuel Injection System
The fuel injection system is divided into a high pressure section (maximum approximately 120 bar (1740 psi)) and a low pressure system (approximately 6 bar (87 psi)).
Before opening high pressure parts, for example removing high pressure pump, fuel rail, fuel injectors, fuel pipes, etc., reduce the fuel pressure in the high pressure area to a residual pressure of approximately 6 bar (87 psi). The procedure for this is as follows.
High Fuel Pressure, Reducing
-- Connect the Vehicle Diagnostic Tester.
-- Start engine and run at idle speed.
-- Select "engine electronics" in On Board Diagnostics (OBD).
-- Select "Measured values".
-- Select "Fuel pressure" from the list.
-- When the engine is at idle, fuel pressure between 30 and 40 bar (435 and 580 psi) is displayed.
-- Pry off the cover -1- on the left of the instrument panel, for example using the Trim Removal Wedge 3409 in direction of -arrow-.
-- While the engine is idling, remove the fuse -in the fuse holder inside the instrument panel on the driver side- from the Fuel Pump Control Module -J538-, refer to appropriate SYSTEM WIRING DIAGRAM.
-- Check fuel pressure.
- The fuel pressure decreases rapidly because the mechanical high pressure pump is no longer supplied with fuel from the Transfer Fuel Pump -G6-.
-- Switch the ignition off as soon as the fuel pressure drops to approximately 8 bar (116 psi).
The fuel pressure must not drop below 6 bar (87 psi, because otherwise the engine will shut off (risk of catalytic converter damage).
The fuel lines will continue to be filled with fuel, but will no longer be under high pressure. To open fuel system, wear protective eyewear and clothing to prevent injuries and contact with skin.
Before opening the high pressure system, place a cloth around the connection.
-- After reducing fuel pressure, place a clean cloth around the connection and open the high pressure system >>immediately<<. Escaping fuel must be absorbed.
Perform the following steps are completing all work:
-- Install the fuse.
-- Erase the Diagnostic Trouble Code (DTC) memory and, using "Guided Fault Finding ", generate the readiness code in the Engine Control Module (ECM) Vehicle Diagnostic Tester.