Volkswagen Cars 2000-05

Fuel System Service Precautions

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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.
 

Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines.



To avoid the possibility of fire and personal injury, 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 fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts.
 
Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container.
 
Always keep a dry chemical (Class B) fire extinguisher near the work area.
 
Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.
 
Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping.
 
Always replace worn fuel fitting O-rings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.
 

Before servicing the vehicle, make sure to also refer to the precautions in the beginning of this section as well.

 
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