WARNING | Risk of injury - fuel system operates under high pressure. |
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| To reduce the pressure in the fuel system, wrap a clean cloth around the connection and carefully loosen the connection. |
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| Vehicles with FSI and TFSI engine: fuel system components on the engine that are fed from the high-pressure pump operate under very high pressure. When working on the engine or injection system, the pressure in the high-pressure section of the system must be reduced to a residual pressure prior to opening → Rep. gr.24. |
| The fuel pump is normally activated when the driver's door is opened. Therefore, unless the battery has been disconnected or the electrical connector for the fuel delivery unit has been unplugged, the fuse for the fuel pump relay or fuel pump control unit must be removed as a safety precaution before opening the fuel system. For identification of fuses, refer to → Current flow diagrams, Electrical fault finding and Fitting locations. |
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| Perform the following steps before starting to work on the fuel supply system: |
WARNING | Mobile phones can cause an explosion risk. |
| Ensure that any mobile phones are well clear of the workbay. |
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Caution | To prevent irreparable damage to the electronic components when disconnecting the battery: |
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| Observe notes on procedure for disconnecting the battery. |
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| Always switch off the ignition before disconnecting the battery. |
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| Briefly open filler cap for fuel tank and close again. |
| Note the following if testers and measuring instruments have to be used during a road test: |
WARNING | Accidents can be caused if the driver is distracted by test equipment while road-testing, or if test equipment is not properly secured. |
| Persons sitting in the front passenger's seat could be injured if the airbag is triggered in an accident. |
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| The use of test equipment while driving causes distraction. |
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| There is an increased risk of injury if test equipment is not secured. |
| Test equipment must always be secured on the rear seat with a strap and operated from the rear seat by a second person. |
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| When removing and installing components from a full or partly full fuel tank, note the following: |
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| Fuel tank must not be full. The amount of fuel which can be left in the fuel tank is indicated in the corresponding procedure description. Drain the tank if necessary. Procedure for vehicles in rest-of-world (front-wheel drive) → Chapter, vehicles in rest-of-world (four-wheel drive) → Chapter, USA vehicles (front-wheel drive) → Chapter, USA vehicles (four-wheel drive) → Chapter. |
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| Before commencing work, switch on exhaust extraction system and place an extraction hose close to the sender opening in the fuel tank to extract escaping petrol fumes. If no exhaust extraction system is available, a radial fan with a displacement of at least 15 m3/h can be used (the fan motor must be clear of the air stream). |
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| Avoid skin contact with fuel. Wear fuel-resistant gloves. |
| When removing and installing the fuel tank, note the following: |
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| Fuel tank must be empty to reduce weight. Drain the tank if necessary. Procedure for vehicles in rest-of-world (front-wheel drive) → Chapter, vehicles in rest-of-world (four-wheel drive) → Chapter, USA vehicles (front-wheel drive) → Chapter, USA vehicles (four-wheel drive) → Chapter. |
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