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 (for example: fuel, hydraulic, Evaporative Emission (EVAP) , coolant, refrigerant, brake or vacuum) and electrical wires so that the original path is followed.

• Ensure sufficient clearance to all moving or hot components.

CAUTION!
If mechanical damage is found on the turbocharger, for example, 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 filter.

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

• Check the entire charge air circuit and cooler for contamination.

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

• Various hose connections are secured.

• Charge air system must be properly sealed.

• Replace the self locking nuts.

• Hose connections and charge air system hoses must be free of oil and grease before installing. The sealing ring and sealing surfaces on the connector couplings must only be lightly lubricated. Refer to => [ Hose Connections with Connector Couplings ] Hose Connections with Connector Couplings.

• Connecting the hose connections with connector couplings. Refer to => [ Hose Connections with Connector Couplings ] Hose Connections with Connector Couplings.

• Install only approved clamps for securing hose connections.

• Spring type clip pliers (VAS 5024A) or hose clip pliers (VAG 1921) are recommended for installing spring clamps.

• Before installing the oil supply line, fill the turbocharger with engine oil through the opening for the oil supply line.

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

• Observe the safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.

• Observe the rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.