Safety precautions when working on the fuel supply system: Notes

WARNING: This page is about a different car, the 1999 Volkswagen Jetta, 1996 Volkswagen Passat, and 1996 Volkswagen Jetta. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: When removing and installing the fuel pump or fuel level sensor from a filled or partially filled fuel tank:

BEFORE beginning repairs, the suction pipe of an exhaust extraction system must be located near the fuel tank opening so that escaping fuel vapors can be immediately carried away.
If no exhaust extraction system is available, a radial fan (motor located outside airflow) with volume of at least 15 m3/hr (9 cfm) may be used.
Wear fuel-resistant gloves whenever working with open parts of the fuel system.

Make sure the ignition is switched OFF, when:

Disconnecting fuel injection system wiring
Connecting or disconnecting test equipment leads

BEFORE cranking the engine at starting RPM (such as for compression testing) disable the ignition and fuel injection systems:

Disconnect the ignition coil power output stage.
Disconnect harness connectors from all fuel injectors.
After the work is completed, erase Diagnostic Trouble Code (DTC) memory.

CAUTION: BEFORE disconnecting the battery:

Stop the engine.
Make sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM).
Before disconnecting the battery, determine the correct coding for the anti-theft radio.

Make sure the battery negative ( - ) cable is disconnected, when:

Working on the electrical system
Resistance (spot) welding or electric arc welding anywhere on the vehicle.

When connecting and disconnecting electrical test equipment (LED voltage tester, multimeter, etc.):

Make sure the ignition is switched OFF.
Use correct adapters from the VW1594 connector test kit.