Safety precautions when working on fuel supply system
WARNING: This page does not describe the selected car, but rather 14 other vehicles, including the 2005 Volkswagen GTI, 2004 Volkswagen R32, 2004 Volkswagen Jetta, 2004 Volkswagen GTI, and 2003 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:
Observe the following for all installations, especially in 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.
- Fuel system is under pressure! Before opening system, place rags around the connection point. Then release pressure by carefully loosening connection.
- The fuel or fuel lines in fuel system can become very hot (danger of scalding)!
- Wear protective goggles and protective gloves when working on the fuel system!
Always observe the following when removing and installing the sender 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 m3/h can be used.
- Prevent fuel from contacting skin! Wear fuel-resistant gloves!
- For safety reasons, Fuel Pump (FP) -G6- fuse no. 28 must be removed from the fuse holder before opening the fuel system, since the Fuel Pump (FP) can be activated via the door contact switch of the driver's door:
Refer to Electrical Wiring Diagrams, Troubleshooting & Component Locations