General Repair Information

General Repair Information

CAUTION!
When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (e.g. for fuel, hydraulic, coolant and refrigerant, brake fluid, vacuum) and electrical wiring so that the original path is followed.

• Ensure sufficient clearance to all moving or hot components.

CAUTION!
If mechanical damage is found on exhaust turbocharger, e.g. a destroyed compression wheel, it is not enough to just replace the turbocharger. Perform the following steps to prevent subsequent damage.

• Clean all oil lines.

• Change the engine oil and the oil filter.

• Check the air filter housing, the air filter insert and the intake hoses for contamination.

• Check entire charge air circuit and cooler for contamination.

If contaminants are found in charge air circuit, circuit must be cleaned and cooler replaced if necessary.

• Various hose connections are secured.

• Charge air system must be properly sealed.

• Replace self-locking nuts.

• Hose connections and charge air system hoses must be free of oil and grease before installing. Sealing ring and sealing surfaces must only be lightly oiled with connector couplings => [ Hose Connections with Connection Couplings ] Hose Connections With Connection Couplings.

• Assembly of hose connections with connection couplings => [ Hose Connections with Connection Couplings ] Hose Connections With Connection Couplings

• Install only approved clamps for securing hose connections

• Pliers for spring clamps (VAS 5024 A) or hose clamp pliers (V.A.G 1921) are recommended for installing spring clamps.





• Before screwing on oil supply line, fill turbocharger with engine oil at filler tube.

• After installing turbocharger, let engine idle for approximately 1 minute without increasing engine speed. This ensures adequate oil supply to the turbocharger.

• Note rules of cleanliness => [ Safety Precautions ] Safety Precautions.

• Observe safety precautions => [ Clean Working Conditions ] Clean Working Conditions.