Safety Precautions
Note the following when working on the fuel system:
There is a risk of injury because the fuel is under very high pressure.
- Reduce the fuel pressure down to residual pressure before opening high pressure area of the fuel injection system.
- To reduce remaining residual pressure, place a clean cloth around the connector and carefully loosen connector.
-- Procedures before opening high pressure fuel injection system. Refer to General Information .
To prevent personal injury and damage to the injection and ignition system, observe the following:
- The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.
- Only clean engine with ignition switched off.
- If electrical connectors were disconnected and the engine was started, then malfunctions have been stored in the engine control modules.
Danger of causing damage to electrical components when disconnecting the battery.
- Complete the steps for disconnecting the battery.
- Turn off the ignition and disconnect the battery.
-- Disconnect the battery. Refer to Removal and Installation .
Before Opening High Pressure Fuel Injection System
- The injection system is separated into a high-pressure section (maximum approximately 120 bar) and a low-pressure section (approximately 6 bar).
- Before opening high pressure area, fuel pressure must be reduced to a residual pressure of approximately 6 bar. Refer to General Information .
Note the following when working on the cooling system:
Risk of scalding due to hot steam and hot coolant.
- The cooling system is under pressure when the engine is warm.
- Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.
The vehicle could overheat if the cap is installed incorrectly.
- The cap must engage noticeably when sealing.
If it is necessary to use testing and measuring devices on road tests, observe the following:
Distraction and improperly secured test equipment can lead to accidents.
There is a risk that the passenger airbag could deploy in a collision.
- Operating testing and measuring equipment while driving creates a distraction.
- There is an increased risk of injury due to unsecured testing and measuring equipment.
- Always secure testers on the rear seat with a strap and have a second person on the rear seat operate them.
Note the following when working on the exhaust system:
Danger of damaging the decoupling element.
- Decoupling element must not be bent more than 10°.
- Do not load decoupling element on cable.
- Do not damage wire mesh at decoupling element.