Safety Precautions When Working on Fuel Supply System

Safety precautions when working on fuel supply system

CAUTION! Follow safety measures for releasing fuel pressure in high pressure area
Fuel supply line is under pressure! Wear protective goggles and protective clothing to prevent injuries and contact with skin. Before removing from hose connection wrap a cloth around the connection. Then release pressure by carefully pulling hose off connection.

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.
To prevent damages to the lines, make sure there is sufficient clearance to all moving or hot components.


To reduce the risk of personal injury and/or damage to the fuel injection and ignition system, always observe the following:

Rabbit/GTI, Eos:





For reasons of safety, if the battery has not been disconnected, Fuse 27 -SD27- must be removed from fuse holder in instrument panel on left side before opening fuel supply system, as the FP is activated by the drivers door contact switch.

Passat:





For reasons of safety, if the battery has not been disconnected, Fuse 34 (on fuse panel D) -SD34- must be removed from fuse holder in instrument panel on right side before opening the fuel supply system, as the FP is activated by the drivers door contact switch.

All vehicles:
Do not touch or disconnect ignition coils with power output stages when engine is running or turning at starting RPM.
The ignition must be switched off before connecting or disconnecting injection and ignition system wiring or tester cables.

Always observe the following when removing and installing the sensor for fuel gauge or the Fuel Pump (FP) from full or partially filled fuel tanks.

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!

If special testing equipment is required during road test, note the following:
Test and measuring instruments must be secured to rear seat and operated by a 2nd person from this location.
If test and measuring instruments are operated from the front passengers seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious injuries when the airbag is triggered.