VW Passat & Audi A4 1990-2000

Fuel System Service Precautions


Although diesel fuel is not as flammable as gasoline, whenever working on or around diesel fuel or the fuel delivery system heed the following precautions:

Do NOT allow fuel spray or fuel vapors to come into contact with a heating element or open flame. Do NOT smoke while working on the fuel system.
Always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied.
Always relieve the fuel system pressure prior to disconnecting any fitting or fuel line connection.
To control fuel spray when relieving system pressure, place a shop towel around the fitting prior to loosening to catch the spray. Ensure that all fuel spillage is quickly wiped up and that all fuel soaked rags are deposited into a proper fire safety container.
Always keep a dry chemical (Class B) fire extinguisher near the work area.
Always use a back-up wrench when loosening and tightening fuel line fittings.
Do NOT re-use fuel system gaskets and O-rings, replace with new ones. Do NOT substitute fuel hose where fuel pipe is installed.