Fuel Delivery and Air Induction: Service Precautions

Safety precautions when working on fuel supply system

CAUTION! When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:
Route lines of all types (e.g. for fuel, hydraulic, EVAP canister system, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.
Ensure sufficient clearance to all moving or hot components.

Observe the following when removing and installing the fuel level sensors or fuel pumps (fuel delivery units) from filled or partially filled fuel tanks:

CAUTION! Fuel supply lines are under pressure! Wear protective goggles and protective gloves to avoid damage and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

- Before starting work, switch on exhaust extraction system and place an extraction hose close to the installation opening of fuel tank to extract escaping 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 cubic meters/hour can be used.
- Prevent fuel from contacting skin! Wear fuel-resistant gloves!





- For safety reasons, fuel pump relays -1- (for right side) and -2- (for left side) must be removed from fuse holder of E-box in luggage compartment before opening fuel system, as fuel pump may be activated when opening drivers door.

CAUTION! Do not remove relay from relay plate with metal tools. The terminals could conduct electricity.