Generic Scan Tool

Safety Precautions

Check for Technical Bulletins that may supersede any information included in this service information.

Failure to follow these instructions may result in personal injury or possible death.

Check the Technical Bulletins for information, cautions and warnings that may supersede or supplement any information included in this service information.

When performing the drive cycle operation, pay strict attention to driving conditions and observe and obey all posted speed limits.

Test equipment must always be secured to the rear seat and operated by a second person. If test and measuring equipment is operated from the passenger seat, the person seated could be injured in the event of an accident involving deployment of the passenger-side airbag.

The fuel system is under pressure! Before opening the fuel system, place rags around the connection area. Then release pressure by carefully loosening the connection.

The engine section of the fuel system, after the high pressure pump, is under extremely high pressure! When working on engine or fuel injection system, fuel pressure must be relieved to residual pressure before opening high pressure components. Refer to the Service Manual for the proper procedure.

If the battery has not been disconnected, the fuel pump fuse must be removed before opening the fuel supply system as the fuel pump may be activated by the driver's door contact switch.

Testing of the EVAP and ORVR systems can result in the escape of explosive fuel vapor. Do not smoke while testing the EVAP system, and make sure the area you are working in is well ventilated.

Observe the following for all procedures, especially in the engine compartment due to lack of room:

• 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.

• Watch for sufficient clearance to all moving or hot components.

• Do not touch or disconnect the Ignition Coils, ignition wires, connecting parts or adapter cables when the ignition is on or the engine is running or turning at starting RPM.

• Only disconnect and reconnect wires for injection and ignition system, including test leads, when the ignition is turned off.

When removing and installing components from full or partially full fuel tanks, observe the following:

• The fuel tank must only be partially full. How much fuel can remain in the fuel tank may be read in the respective work description. Empty the fuel tank if necessary.

• Before starting work, switch on the exhaust extraction system and place an extraction hose close to the installation opening of the 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 m3/h can be used.

• Prevent fuel from contacting the skin! Wear fuel-resistant gloves!

When servicing the engine control module (ECM), it may be necessary to use a heat gun. The heat gun, shear bolts, and parts of the protective housing will become extremely hot. Use extreme caution when working with or handling these parts to avoid personal injury.

Observe operating instructions when working with a heat gun. To prevent damage (burning) to the wiring and harness connections, insulation and the electronic components, perform outlined work steps exactly!

The cooling system is under pressure. To avoid scalding, use caution when opening the cooling system and servicing cooling system components!

The battery must only be disconnected and connected with the ignition switched off. Otherwise, the engine control module (ECM) can be damaged.

The use of nails, paper clips, or another unauthorized materials to back-probe electrical harness connectors is strictly prohibited and may cause damage to the electrical harness connectors, terminal ends or to a component. Use only the manufacturers test lead kit or an equivalent aftermarket test lead kit for back-probing all electrical harness connectors.

Do not use sealants containing silicone. Particles of silicone drawn into the engine, will not be burnt in the engine and will damage the oxygen sensors.

Secure all hose connections with the correct hose clips (the same as original equipment).

If engine is to be cranked without starting, for example as part of a compression test, remove the fuses for the voltage supply of Ignition Coils and the fuel injector.

An electrostatic charge can lead to functional problems of electrical components of the engine, transmission and selector lever mechanism. Touch a grounded object, e.g. a water pipe or a hoist, before working on electrical components.

Do not make direct contact with electrical harness connector terminals.

Use only gold-plated terminals when servicing any component with gold-plated electrical harness connector terminals.