Product Overview

Summary: This Fuel Injection System Calibrations SOP sets out a safe, consistent method for inspecting, testing and calibrating fuel injection systems on plant, machinery and vehicles. It helps Australian businesses control fire and explosion risks, protect technicians from high‑pressure fuel exposure, and maintain engine performance in line with WHS and environmental obligations.

Fuel injection systems operate under extremely high pressures and involve flammable liquids, specialised test benches and electronic control equipment. Without a structured procedure, calibration work can expose technicians to injection injuries, fuel spills, vapour ignition, and unintended engine start-up, while also leading to poor engine performance and non-compliance with emissions and environmental requirements. This Safe Operating Procedure provides a clear, step-by-step method for preparing the work area, isolating and depressurising systems, performing accurate calibrations, and returning equipment to service safely.

Developed for Australian workshops, depots and field service operations, the SOP integrates WHS risk controls with OEM technical requirements, ensuring that safety and quality are treated as one process rather than separate tasks. It helps businesses demonstrate due diligence under WHS legislation, reduces reliance on informal “tribal knowledge”, and supports consistent technician training across shifts, sites and contractors. By adopting this SOP, organisations can reduce incident rates, protect high-value assets, and deliver reliable, compliant maintenance outcomes for road transport, mining, construction, agriculture and marine fleets.

Key Benefits

• Ensure safe depressurisation, handling and testing of high-pressure fuel systems to prevent injection and burn injuries.
• Reduce the risk of fires, explosions and environmental contamination from fuel leaks and spills during calibration activities.
• Improve engine performance, fuel efficiency and emissions compliance through consistent, accurate calibration practices.
• Standardise workshop procedures across technicians, shifts and sites, strengthening training, supervision and auditability.
• Demonstrate compliance with Australian WHS, hazardous chemicals and environmental requirements for fuel system maintenance.

Who is this for?

• Automotive Technicians
• Diesel Mechanics
• Heavy Vehicle Mechanics
• Plant and Equipment Fitters
• Workshop Supervisors
• Fleet Maintenance Managers
• Service Managers
• WHS Managers
• Workshop Leading Hands
• Marine Mechanics

Hazards Addressed

• High-pressure fuel injection injuries to hands and skin
• Exposure to flammable liquids and vapours (fire and explosion risk)
• Fuel spills leading to slip hazards and environmental contamination
• Unintended engine start-up or movement during testing
• Electrical hazards from diagnostic and test bench equipment
• Noise exposure from engine testing and calibration
• Manual handling strains from removing and refitting heavy fuel system components
• Contact dermatitis or irritation from fuels, solvents and cleaning agents
• Eye injuries from pressurised sprays, splashes or debris

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Standards and Legislative Requirements
• 3.0 Definitions and Abbreviations
• 4.0 Roles and Responsibilities
• 5.0 Competency, Licensing and Training Requirements
• 6.0 Required Tools, Test Equipment and Calibration Instruments
• 7.0 Personal Protective Equipment (PPE) Requirements
• 8.0 Pre-Calibration Planning and Job Safety Analysis
• 9.0 Plant and Vehicle Isolation, Lockout and Tagout
• 10.0 Fuel System Depressurisation and Decontamination
• 11.0 Safe Removal and Handling of Fuel Injection Components
• 12.0 Test Bench Setup and Verification of Calibration Equipment
• 13.0 Step-by-Step Fuel Injection System Calibration Procedure
• 14.0 In-Process Quality Checks and Tolerance Verification
• 15.0 Reinstallation, Recommissioning and Engine Testing
• 16.0 Hazard Identification and Control Measures
• 17.0 Spill Management, Waste Disposal and Environmental Controls
• 18.0 Emergency Procedures for Injection Injury, Fire and Fuel Spills
• 19.0 Housekeeping and Post-Job Inspection
• 20.0 Recordkeeping, Calibration Certificates and Reporting
• 21.0 Review, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and harmonised state and territory WHS Regulations
• Safe Work Australia – Code of Practice: Managing Risks of Hazardous Chemicals in the Workplace
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• AS/NZS 60079.10.1: Explosive atmospheres – Classification of areas – Explosive gas atmospheres
• AS 1940: The storage and handling of flammable and combustible liquids
• AS/NZS 4761: Competencies for working with fuel gas and similar hazards (as applicable to fuel system work)
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161: Occupational protective gloves – Selection, use and maintenance